AISIN SEIKI AWGP180E1NHS, AXGP096E1NHS, E1 Series Service Manual
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09D-EDN-1
AISIN GHP
E1 MODEL SERVICE MANUAL
AISIN
AISIN
Gas type
Spec.
Natural Gas
8 TON 15 TON
AXGP096E1NHS AWGP180E1NHS
Introduction
Safety Precautions
The following is an important safety notice you must follow in order to prevent injuries and/or damages that may be caused by incorrect operation in repair, inspection and maintenance of the Gas Heat Pump. Be sure to read these precations carefully and follow the instructions.
Definition of " " and " "
Indicates a potentially hazardous situation that could result in death or serious injury by misuse.
If the items with this symbol shown in this manual are not adhered to, injury or damage to the unit could occur.
Inspection Precautions
[Before starting inspection]
1. Be sure to switch OFF the electric leakage breaker in the outdoor control box.
If not, you could be shocked.
※ If not, you could be injured because the fans may automatically start temporarily to protect the units or maintain performance even if the GHP is stopped.
2. Close the fuel valve.
If not, gas poisoning or gas explosion could occur.
[During inspection]
1. Check for fuel gas leakage. If there is anything unusual such as gas odor, be sure to take proper safety measures.
If not, gas poisoning or gas explosion could occur.
2. Be sure to disconnect the igniter connector before conducting corrective measures against carbon deposit formation on the valve or valve seat.
If not, fire could occur when cranking.
1. Do not touch the engine pulley or compressor belts when the [RUN] switch is ON.
If not, injury could result.
Precautions of Electrical Parts Inspection
[Before starting inspection]
1. Be sure to turn OFF the overcurrent breaker in the junction circuit and the electric leakage breaker in the outdoor control box, and confirm the residual voltage is lower than specified value.
If not, you could be shocked, burned, or injured and the equipment could be damaged.
[Procedure of safety check before starting inspection]
1. Confirm more than 1 minute has elapsed after turning OFF the electrical leakage breaker (to allow residual voltage to self-discharge).
2. Confirm the voltage between the following terminals is lower than 15 V DC with a voltmeter (such as circuit tester).
between the terminal ① (red) and ③ (black) of CN2 on the power PCB, or
between the terminal ① (red) and ③ (black) of CN4 on the DCBL PCB.
High voltage (residual voltage higher than 250 V DC) is still charged in the electrolytic capacitor on the
DCBL PCB at the bottom of the outdoor control box even after turning OFF the electric leakage breaker.
1
Precautions of Usage
Be sure to stop the operation and turn OFF the electric leakage breaker when you do maintenance.
Otherwise, you could be shocked or injured. Even if the GHP is stopped, the fan may automatically start temporary run to protect units or maintain capacity. Be sure to turn OFF the electric leakage breaker when you touch the inside of the outdoor or indoor units.
When more than 13 years or 30,000 running hours have passed since installation of the GHP outdoor unit, serious accident might occur depending on usage profile. In such a case, be sure to consult with GHP dealer.
Outdoor and indoor units can temporarily stop or have insufficient air conditioning performance to protect units or maintain capacity, but the units automatically resume normal operation. In the meantime, fuel gas or electricity consumption may temporarily increase. (For example, during defrosting.)
Leakage of oil or engine coolant could result in malfunction or secondary damage (contamination on household goods). If leakage should occur, consult with the GHP dealer.
Precautions of Installation
Never install the outside unit at the indoor location.
Install the outdoor unit so that its exhaust gas does not flow into the room through the piping, intake/exhaust port or ventilation port leading to the inside of the room. Always discharge the exhaust gas to the open air at a location where the gas will not cause adverse effects on the surrounding area. Do not discharge the exhaust gas into the catch basin or ditch.
If the outdoor unit is installed near the intake/exhaust port to the room, window or ventilation port, it could cause gas poisoning or lack of oxygen.
Never share the same pipe for the exhaust drain for the outdoor unit and the exhaust water drain for the indoor unit.
If exhaust gas flows into the building, it could cause gas poisoning or lack of oxygen.
Arrange the piping so that the exhaust gas in the exhaust drain is released into the atmosphere if : a) The exhaust drain hose of the outdoor unit is connected to the catch basin or ditch with a lid.
b) The exhaust drain water of the outdoor unit is released at the same location as the drain water of the indoor unit.
Otherwise, exhaust gas could flow into the room and cause gas poisoning or lack of oxygen.
2
CONTENTS
Introduction
1. Product Appearance................................................................................ 7
2. Product Specifications ............................................................................. 8
1) Model Name Structure .................................................................................................. 8
2) Configuration.................................................................................................................9
3. Outdoor Unit Specifications ................................................................... 12
4. Outdoor Unit External Dimensions ........................................................ 16
5. Outdoor Unit Internal Structure.............................................................. 18
6. Operating Principle ................................................................................ 24
1) Refrigerant System Diagram....................................................................................... 24
2) Engine Coolant / Fuel Gas / Intake Air and Exhaust Air System Diagrams................ 28
PERIODIC INSPECTION
1. Inspection Items and Intervals............................................................... 38
2. Parts Requiring Periodic Replacement.................................................. 39
3. Procedure and Method of Periodic Inspection....................................... 40
1) Engine Oil Inspection / Refilling .................................................................................. 42
2) Oil Filter Replacement ................................................................................................ 42
3) Spark Plug Replacement ............................................................................................ 43
4) Air Filter Element Replacement .................................................................................. 43
5) Compressor Belt Replacement ................................................................................... 45
6) Exhaust Water Drain Filter Inspection / Refilling......................................................... 46
7) Drain Oil Filter Replacement....................................................................................... 48
8) Engine Coolant Additive Refilling................................................................................ 50
9) Engine Coolant Amount Inspection / Refilling............................................................. 50
10) Engine Coolant Leakage Inspection ........................................................................... 51
11) Engine Oil Leak Inspection ......................................................................................... 51
12) Exhaust Air Leakage Inspection.................................................................................. 51
13) Exhaust Water Drain Hose Inspection ........................................................................ 52
14) Fuel Gas Hose and Fuel Gas Hose Clamp Inspection / Replacement ....................... 52
15) Fuel Gas Leak Inspection ........................................................................................... 53
16) Compressor Inspection ............................................................................................... 54
17) Refrigerant Leakage Inspection .................................................................................. 54
18) Refrigerant and Engine Coolant Line Contact Inspection ........................................... 55
19) Engine Valve Cleaning................................................................................................ 55
20) Engine Valve Clearance Inspection / Adjustment (8 TON only).................................. 56
21) Oil Level Switch Cleaning / Inspection ........................................................................ 57
22) Outdoor Heat Exchanger Compartment Drainage Inspection..................................... 57
23) Accumulator Condensed Water Drainage Inspection ................................................. 58
24) Wiring and Connector Inspection ................................................................................ 58
25) Anchor Bolt Inspection ................................................................................................ 58
26) Engine Startability Inspection...................................................................................... 59
27) Engine Mount Replacement........................................................................................ 59
28) Inspection for Operation Noise.................................................................................... 61
29) Inspection of the Number of Engine and Starter on/off Times .................................... 61
30) Inspection of the Running Hours and Number of on/off Times of the Compressor..... 61
31) Outdoor Heat Exchanger Inspection ........................................................................... 61
3
CONTENTS
32) Indoor Air Filters Inspection ........................................................................................ 61
33) Remote Controller Operation Inspection..................................................................... 62
34) Indoor Unit Temperature Inspection............................................................................ 62
35) Check After Work ........................................................................................................ 62
REPLACEMENT OF MAIN COMPONENTS
1. Before Starting Your Work..................................................................... 63
2. Replacement of Engine Unit.................................................................. 65
3. Replacement of Cylinder Head.............................................................. 97
4. Replacing the Compressor .................................................................. 116
CONTROL
1. System Control Functions ................................................................... 134
1) System Block Diagram.............................................................................................. 134
2. Control Details ..................................................................................... 135
1) Temperature Control Start / Stop.............................................................................. 135
2) Starting the Outdoor Unit
(Starting the Engine and Engaging the Compressor Clutch).................... 135
3) Transition from Start Control to Normal Operation Control....................................... 136
4) Indicated Engine Speed............................................................................................ 136
5) Refrigerant Flow Volume .......................................................................................... 136
6) Defrosting (In Heating Only) ..................................................................................... 140
7) Outdoor Fan.............................................................................................................. 141
8) Oil Bypass Control Valve .......................................................................................... 142
9) Compressor Heater................................................................................................... 142
10) Drain Filter Heater / Drain Hose Heater .................................................................... 142
11) Flow Chart of Backup Operation under Combined Installation
(Conceptual Chart) ................................................................................... 143
3. Function Settings................................................................................. 145
1) Outdoor unit .............................................................................................................. 145
2) Cool/Heat Switching Setting ..................................................................................... 148
4. System Input/Output Specifications..................................................... 150
1) Outdoor Unit Input / Output Specifications................................................................ 150
TROUBLESHOOTING
1. Error Code Description and Possible Cause ....................................... 154
2. Parts Characteristics ........................................................................... 177
3. Failure Phenomenon ........................................................................... 183
1) The System will not Operate..................................................................................... 183
2) Engine will not Start .................................................................................................. 184
3) Engine Starts But Stalls ............................................................................................ 185
4) Engine Coolant Temperature Abnormality................................................................ 186
5) Oil Pressure Abnormality .......................................................................................... 186
6) Over Speed............................................................................................................... 187
7) High Pressure Abnormality in Cooling Operation ..................................................... 187
4
CONTENTS
8) High Pressure Abnormality in Heating Operation ..................................................... 188
9) Refrigerant Low Pressure Abnormality ..................................................................... 189
10) Overheated Refrigerant Discharge Temperature in Cooling Operation .................... 190
11) Overheated Refrigerant Discharge Temperature in Heating Operation.................... 191
12) Communication Failure / Indoor Unit System Failure................................................ 192
13) Gas Heat Pump is Operating but Not Cooling........................................................... 194
14) Gas Heat Pump is Pperating but Not Heating........................................................... 196
4. Procedure for Inspection and Treatment ............................................. 198
1) Check Power Supply System.................................................................................... 198
2) Check Control Unit.................................................................................................... 198
3) Locate Electric Leakage Positions ............................................................................ 198
4) Check Remote Control System................................................................................. 198
5) Inspect Starter........................................................................................................... 199
6) Inspect Starter Transformer ...................................................................................... 199
7) Operation Check of Relay......................................................................................... 200
8) Inspect Fuel Gas Pressure ....................................................................................... 200
9) Inspect Electromagnetic Gas Valve .......................................................................... 200
10) Inspect Spark Plug .................................................................................................... 201
11) Inspect High Voltage Cable....................................................................................... 201
12) Inspect Igniter, etc..................................................................................................... 202
13) Compression Inspection............................................................................................ 203
14) Valve Clearance Inspection / Adjustment ................................................................. 204
15) Treatment for Compression Failure due to Carbon Deposit...................................... 205
16) Inspect Engine Throttle Valve / Fuel Gas Flow Control Valve................................... 210
17) Inspect Air / Fuel Ratio.............................................................................................. 210
18) Check for Contact Failure at the Starter Drive System ............................................. 211
19) Inspect Exhaust Water Drain Heater......................................................................... 211
20) Inspect Engine Oil Pan Heater.................................................................................. 212
21) Check Ignition Timing................................................................................................ 213
22) Check Engine Coolant Circulation ............................................................................ 214
23) Check Engine Coolant Amount or Leakage Location ............................................... 214
24) Inspect Engine Coolant Pump................................................................................... 215
25) Inspect Thermostat ................................................................................................... 216
26) Check Engine Coolant Heat Dissipation Condition (in cooling)................................. 216
27) Inspect Outdoor Fan Motor ....................................................................................... 217
28) Inspect Engine Coolant Temperature Sensor ........................................................... 218
29) Inspect Radiator Cap ................................................................................................ 218
30) Check Engine Oil Amount ......................................................................................... 218
31) Check Engine Oil Leakage........................................................................................ 219
32) Check Engine Oil Consumption Amount................................................................... 219
33) Inspect Oil Pressure.................................................................................................. 220
34) Inspect Engine Oil Pressure Switch .......................................................................... 220
35) Technical Data When Replacing the Refrigerant System Parts................................ 221
36) Inspect Refrigerant Pressure (Inspect Refrigerant Amount) ..................................... 222
37) Inspection Check Valve (Refrigerant Pressure Increase) ......................................... 222
38) Inspect Refrigerant High Pressure Switch................................................................. 222
39) Inspect Refrigerant High Pressure Sensor................................................................ 223
40) Inspect Hot Gas Bypass Valve.................................................................................. 223
41) Inspect Indoor Fan Motor .......................................................................................... 224
42) Inspect for Blockage in the Indoor Electronic Expansion Valve ................................ 224
43) Check Environmental Conditions (Low Intake Air Temperature) .............................. 224
44) Inspect Strainer ......................................................................................................... 224
45) Inspection Check Valve (Refrigerant Pressure Drop) ............................................... 224
5
CONTENTS
46) Inspect Refrigerant Low Pressure Sensor................................................................. 224
47) Inspect Sub Heat Exchanger Liquid Flow Control Valve........................................... 225
48) Inspect Outdoor Heat Exchanger Liquid Flow Control Valve .................................... 226
49) Inspect Reversing Valve ........................................................................................... 227
50) Check for Readings of the Compressor Discharge Pipe Temperature Sensor......... 227
51) Check for Readings of the Outside Air Temperature Sensor .................................... 228
52) Check for Readings of the Engine Exhaust Air Temperature Sensor ....................... 228
53) Check for Readings of the Outdoor Temperature Sensors ....................................... 229
54) Inspect Subcooling Valve.......................................................................................... 230
55) Check Operation Condition ....................................................................................... 231
56) Check for Readings of the Indoor Temperature Sensors.......................................... 231
57) Check Indoor Air Intake Status ................................................................................. 231
58) Check Drain Water.................................................................................................... 232
59) Inspect Drain Pump................................................................................................... 232
60) Inspect Drain Float Switch ........................................................................................ 232
61) Inspect Compressor Clutch....................................................................................... 232
5. Board Maintenance Functions............................................................. 233
1) Outline of the Maintenance Function ........................................................................ 233
2) Code List for Each Mode .......................................................................................... 235
3) Running Hours Display Mode ................................................................................... 239
4) Monitor Mode ............................................................................................................ 245
5) Command Mode ....................................................................................................... 246
6) Check Mode.............................................................................................................. 247
7) Operational Procedure / Display Contents................................................................ 248
6. Protection Devices............................................................................... 299
7. Standard Operation Data..................................................................... 305
8. Wiring Diagram of the Outdoor Unit .................................................... 306
TECHNICAL DATA FOR REPAIR
1. Engine System .................................................................................... 310
2. Refrigerant System.............................................................................. 312
3. Engine Coolant System ....................................................................... 314
4. Thermistor Characteristics................................................................... 315
6
Introduction
1. Product Appearance
8 TON
Multi zone type
Outdoor unit ※
Introduction
15 TON
Combination Multi type
Outdoor unit ※
AISIN
AISIN
※ Refer to "Outdoor Unit Model Name Structure" for outdoor unit model name.
7
Introduction
2. Product Specifications
1)
Model Name Structure
[ Outdoor Unit Model Name Structure ]
Code
Model name
(Example) a
A b
X c
G
Model code list
Code
a
Item
Brand b c d e f g h
Type
Outdoor unit
Refrigerant type
Capacity
Model change suffix
Minor change suffix
Special specification categories
d
P e
096 f
E g
1
Symbol and description
A
X
: AISIN brand
: Multi zone type
W : Combination Multi type
G : Outdoor unit
P : R410A
096 : 96,000 BTU/h (8 TON)
180 : 180,000 BTU/h (15 TON)
A, B, … (sequential alphabet is appended)
1, 2, … (sequential number is appended)
NHS : Natural Gas, For USA
h
NHS
8
Introduction
2)
Configuration
8 TON
Power supply
Single-phase 230 or 208V
Power supply
Single-phase 230 or 208V
Outdoor unit
Over-
current breaker
Electric leakage breaker
}
Over-
current breaker
Electric leakage breaker
}
Signal wire
It’s indicates the breaker on the power distribution board of building or facility.
Refrigerant line
D class grounding
Exhaust water drain pipe
Indoor unit Indoor unit Indoor unit
Remote controller
Exhaust water drain pipe
(VP30)
Remote controller
Exhaust water drain pipe
(VP30)
Remote controller
Exhaust water drain pipe
(VP30)
Opening for fuel gas pipe R3/4
Exhaust water drain hose
Opening for refrigerant vapor line
Opening for refrigerant liquid line
Opening for signal wires inlet
Opening for power supply wires inlet
Condensed water drain port
Connecting position of piping / wiring (Outdoot unit back side)
9
Introduction
15 TON
[ Stand-alone installation ]
Power supply
Single-phase 230 or 208V
Power supply
Single-phase 230 or 208V
Outdoor unit
Over-
current breaker
Electric leakage breaker
}
Over-
current breaker
Electric leakage breaker
}
Signal wire
It’s indicates the breaker on the power distribution board of building or facility.
Refrigerant line
D class grounding
Exhaust water drain pipe
Indoor unit Indoor unit Indoor unit
Exhaust water drain pipe
Remote controller
(VP30)
Remote controller
Exhaust water drain pipe
(VP30)
Remote controller
Exhaust water drain pipe
(VP30)
Opening for fuel gas pipe R3/4
Opening for signal wires inlet
Opening for power supply wires inlet
Opening for refrigerant vapor line(brazing connection)
Opening for refrigerant liquid line(brazing connection)
Condensed water drain port
Exhaust water drain hose
Connecting position of piping / wiring (Outdoot unit back side)
10
Introduction
[ Combined installation ]
Power supply
Single-phase 230 or 208V
Power supply
Single-phase 230 or 208V
Power supply
Single-phase 230 or 208V
Outdoor unit
Over-
current breaker
Electric leakage breaker
Outdoor unit
Electric leakage breaker
Over-
current breaker
Electric leakage breaker
It’s indicates the breaker on the power distribution board of building or facility.
Refrigerant line
Signal wire
Combination Multi communication wires
D class grounding
Exhaust water drain pipe
D class grounding
Exhaust water drain pipe
Indoor unit Indoor unit Indoor unit
Remote controller
Exhaust water drain pipe
(VP30)
Exhaust water drain pipe
(VP30)
Remote controller
Remote controller
Exhaust water drain pipe
(VP30)
Exhaust water drain hose
Opening for fuel gas pipe R3/4
Opening for signal wires inlet
Opening for power supply wires inlet
Opening for refrigerant vapor line(brazing connection)
Opening for refrigerant liquid line(brazing connection)
Condensed water drain port
Connecting position of piping / wiring (Outdoot unit back side)
11
Introduction
3. Outdoor Unit Specifications
[8 Ton Fuel gas type : Natural Gas]
Model
Type
Rated cooling
Capacity
Rated heating
Height
External dimensions
Width
Depth
Mass
Exterior color (Munsell No.)
Power supply
Starting current
BTU/h (Ton) inch (mm) lbs (kg)
V
A
Power consumption kW
Electric characteristics
Operating current A
Power factor %
Engine
Fuel gas consumption
Engine coolant
BTU/h
Type
Displacement
Rated output
Starting system
Speed range
L kW rpm
Lubricant
Pump
Type
Amount
Exhaust port position
Type
Amount
Concentration
Freezing temperature
Motor output
Type gal (L) gal (L)
Vol %
℉ ( ℃ ) kW
(60 Hz)
AXGP096E1NHS
8 Ton Multi zone type
96,000 (8)
103,000 (8.6)
81.8 (2077)
55.1 (1400)
34.6 (880)
1,340 (608)
DIC546 1/2
Single-phase 230 or 208
20
Cooling
Heating
Cooling
Heating
1.12
0.9
4.7
3.7
Cooling
Heating
Cooling
Heating
68
68
73,000
79,500
Water-cooled straight 4-cycle OHV
0.952
10.0
AC/DC conversion DC starter
Cooling
Heating
800 ~ 1700
800 ~ 3000
AISIN Gas Engine Oil L-10000G
7.93 (30)
On the top
AISIN Coolant S
3.96 (15)
50
-4 (-20)
DC brushless canned pump
0.12
12
Introduction
Type x number of unit
Displacement inch
3
/rev
(cm
3
/rev)
Scroll type x 2 units
5.26 x 2 (86.2 x 2)
Compressor
Speed range rpm
Cooling
Heating
NL10
1.06 (4)
1 Poly V-belt
R410A
25.4 (11.5)
Slit fin
Multi-tube heat exchanger
Louver fin
Front / Back
On the top
Plate heat exchanger (Refrigerant heating)
Refrigerant reverse cycle
Propeller fan x 2
9,710 (275)
Brushless DC motor (8P)
686 x 2
3/8 (9.5)
7/8 (22.2)
NTP 3/4
3-1/8 (80)
5/8 (15)
840 ~ 1785
840 ~ 3150
Refrigerant
Heat exchanger
Fan
Specified refrigerant oil
Amount of refrigerant oil
Power transmission system gal (L)
Type
Amount
Outdoor heat exchanger lbs (kg)
Exhaust air heat exchanger
Engine radiator
Air intake
Air discharge
Exhaust heat recovery system
Defrosting system
Type x number of unit
Rated air volume cfm (m
3
/min)
Motor
Refrigerant line
Type
Rated output
Liquid line
Vapor line
W inch (mm)
Piping size
Permissible piping length
Permissible height difference between indoor and outdoor units
Fuel gas pipe
Exhaust port
Exhaust air drain pipe
Equivalent length /
Actual length
Outdoor unit installed above indoor units
Outdoor unit installed below indoor units
Permissible vertical distance among indoor units
Connectable indoor units inch (mm) ft (m)
Number of units
623/541 (190/165)
164 (50)
131 (40)
49 (15)
1 ~ 16
NOTE 1) Capacity and electric characteristics values were measured in accordance with AISIN standard under
JIS-B8627 condition.
NOTE 2) The noise level is measured in an anechoic room conforming to JIS standard. Actual noise level may be louder than the measured value due to ambient noise and/or reverberation.
13
Introduction
[15 Ton Fuel gas type : Natural Gas]
Model
Type
Rated cooling
Capacity
Rated heating
Height
External dimensions
Width
Depth
Mass
Exterior color (Munsell No.)
Power supply
Starting current
Power consumption
Electric characteristics
Operating current
BTU/h (Ton) inch (mm) lbs (kg)
V
A kW
A
% Power factor
Engine
Fuel gas consumption
Type
Displacement
Rated output
Starting system
Speed range
Engine coolant
BTU/h
L kW rpm
Lubricant
Pump
Type
Exhaust port position
Type
Amount
Concentration
Freezing temperature
Type
Motor output gal (L)
Vol %
℉ ( ℃ ) kW
AWGP180E1NHS
(60 Hz)
15 TON combination Multi type
180,000 (15)
205,000 (17)
81.8 (2077)
65.4 (1660)
34.6 (880)
1,670 (758)
DIC546 1/2
Single-phase 230 or 208
20
Cooling
Heating
Cooling
Heating
1.32
1.24
5.5
5.2
Cooling
Heating
Cooling
Heating
67
67
186,000
179,000
Water-cooled straight 4-cycle OHV
1.998
15.7
AC/DC conversion DC starter
Cooling
Heating
600 ~ 2000
600 ~ 2125
AISIN Gas Engine Oil L-10000G
On the top
AISIN Coolant S
6.87 (26)
50
-4 (-20)
DC brushless canned pump
0.13
14
Introduction
Type x number of unit
Displacement inch
(cm
3
3
/rev
/rev)
Scroll type x 2 units
5.26 x 2 (86 x 2)
Compressor
Speed range rpm
Cooling
Heating
NL10
1.06 (4)
1 Poly V-belt
R410A
25.4 (11.5)
Slit fin
Multi-tube heat exchanger
Louver fin
Front / Back / Side
On the top
Plate heat exchanger (Refrigerant heating)
Refrigerant reverse cycle
Propeller fan x 2
13,700 (388)
Brushless DC motor (8P)
600 × 2
5/8 (15.9)
1-1/8 (28.6)
NTP 3/4
3-7/8 (100)
5/8 (15)
1170 ~ 3900
1170 ~ 3802
Refrigerant
Heat exchanger
Fan
Specified refrigerant oil
Amount of refrigerant oil
Power transmission system gal (L)
Type
Amount
Outdoor heat exchanger lbs (kg)
Exhaust air heat exchanger
Engine radiator
Air intake
Air discharge
Exhaust heat recovery system
Defrosting system
Type x number of unit
Rated air volume cfm (m
3
/min)
Motor
Refrigerant line
Type
Rated output
Liquid line
Vapor line
W inch (mm)
Piping size
Permissible piping length
Permissible height difference between indoor and outdoor units
Fuel gas pipe
Exhaust port
Exhaust air drain pipe
Equivalent length /
Actual length
Outdoor unit installed above indoor units
Outdoor unit installed below indoor units
Permissible vertical distance among indoor units
Connectable indoor units inch (mm) ft (m)
Number of units
623/541 (190/165)
164 (50)
131 (40)
49 (15)
2 ~ 33
NOTE 1) Capacity and electric characteristics values were measured in accordance with AISIN standard under
JIS-B8627 condition.
NOTE 2) The noise level is measured in an anechoic room conforming to JIS standard. Actual noise level may be louder than the measured value due to ambient noise and/or reverberation.
15
Introduction
4. Outdoor Unit External Dimensions
8 TON
16
15 TON
Introduction
17
Introduction
5. Outdoor Unit Internal Structure
8 TON
FRONT
Thermostats
Ignition coils (3 pieces)
Engine coolant temperature sensor
Engine oil pressure switch
Electromagnetic compressor capacity valve 2
Engine
Engine oil pan heater
(unit with drain heater kit only)
Compressor 2
Compressor 1
Electromagnetic compressor capacity valve 1
Ccompressor heater
REAR
Reserve tank
Engine coolant pump
Exhaust water drain filter
Fuel gas flow control valve
Gas mixer
Engine throttle valve
Air filters
Engine speed sensor
Spark plugs (3 pieces)
Deodorizing catalyst
(unit with deodorant kit only)
Exhaust air heat exchanger
Sub oil reservoir
Electromagnetic gas valves
Iintake silencer
Oil level switch
Gas regulator
Exhaust water drain heater
(unit with drain heater kit only)
Figure 1 Engine and related parts
18
PANEL SIDE
Subcooling valve
Strainer (for vapor)
Introduction
Sub heat exchanger liquid flow control valve
Outdoor heat exchanger liquid flow control valve
Outdoor liquid pipe temperature sensor
Dryer filter
Stop valve (for vapor)
Electromagnetic compressor capacity valve 1
Stop valve (for liquid)
Refrigerant line connection port (for vapor)
Refrigerant line connection port (for liquid)
Strainer (for liquid)
Accumulator
Accumulator outlet temperature sensor
Oil separator
ENGINE SIDE
Outdoor heat exchanger liquid temperature sensor
Sub heat exchanger liquid temperature sensor
Subcooling heat exchanger
(double pipe)
Outdoor heat exchanger vapor temperature sensor
Hot gas bypass valve
Sub heat exchanger Reversing valve
Refrigerant low pressure sensor
Oil bypass control valve
Compressor discharge pipe temperature sensor 1
Refrigerant high pressure sensor 1
Refrigerant high pressure switch 1
Compressor 1
Compressor intake temperature sensor
Compressor 2
(with clutch)
Compressor discharge pipe temperature sensor 2 Electromagnetic compressor capacity valve 2
Figure 2 Refrigerant system
19
Introduction
Communication I/F PCB
Electric leakage breaker
Power supply PCB
Reactor
Exhaust port
Outdoor heat exchanger (rear)
ENLARGE
Transformer 1
Figure 3 In control box
Diode
Radiator cap
Main PCB
EMC PCB
Cold district PCB
(unit with drain heater kit only)
Igniter
DCBL PCB
Capacitor
Outdoor fans
Engine compartment temperature sensor
(attached to the 1F top panel)
Fan motors
Outdoor heat exchanger
(front)
Outside air temperature sensor
Figure 4 2F
20
Introduction
15 TON
FRONT
Thermostats
Engine oil pressure sensor
Igniter
Sspark plugs (4 pieces)
Ignition coils (4 pieces)
Engine coolant temperature sensor
Engine
Engine speed sensors
Gas regulator
Electromagnetic gas valves
Exhaust water drain heater
(unit with drain heater kit only)
Compressor heater
REAR
Engine coolant pump
Oil level switch
Fuel gas flow control valve
Exhaust water drain filter
Engine oil pan heater
(unit with drain heater kit only)
Engine throttle valve
Gas mixer
Air filters
Exhaust muffler
Intake silencer
Sub oil reservoir
Exhaust air heat exchanger
Deodorizing catalyst
(unit with deodorant kit only)
Figure 1 Engine and related parts
21
Introduction
SIDE PANEL SIDE Sub heat exchanger liquid flow control valve
Subcooling valve
Strainer (for vapor)
Outdoor heat exchanger liquid flow control valve
Dryer filter
Stop valve (for vapor)
Outdoor liquid pipe temperature sensor
Electromagnetic compressor capacity valve 1
Refrigerant high pressure switch 1 Stop valve (for liquid)
Refrigerant line connection port (for vapor)
Refrigerant line connection port (for liquid)
Strainer (for liquid) Oil separator
Accumulator
Accumulator outlet temperature sensor
Subcooling heat exchanger (double pipe)
ENGINE SIDE
Outdoor heat exchanger liquid temperature sensor
Outdoor heat exchanger vapor
Sub heat exchanger liquid temperature sensor temperature sensor
Hot gas bypass valve
Sub heat exchanger
Refrigerant low pressure sensor
Reversing valve
Oil bypass control valve
Compressor discharge pipe temperature sensor 1
Refrigerant high pressure sensor 1
Compressor 1
Refrigerant high pressure switch 2
Compressor 2
(with clutch)
Compressor discharge pipe temperature sensor 2
Compressor intake temperature sensor
Electromagnetic compressor capacity valve 2
Figure 2 Refrigerant system
22
Communication I/F PCB
Electric leakage breaker
Power supply PCB
Capacitor
ENLARGE
Reactor
Transformer 1 Diode
Figure 3 In control box
Outdoor heat exchanger (rear)
Exhaust port
Transformer 2
Introduction
Main PCB
EMC PCB
Cold district PCB
(unit with drain heater kit only)
DCBL PCB
Outdoor fans
Radiator cap
Fan motors
Outdoor heat exchanger
(front)
Outside air temperature sensor
Reserve tank
Figure 4 2F
23
Engine compartment temperature sensor
(attached to the 1F top panel)
Introduction
6. Operating Principle
1)
Refrigerant System Diagram
1. Cooling
Refrigerant (R410A) coming out of the compressors flows into the outdoor heat exchanger after passing through the oil separator and the reversing valve. Then heat is dissipated by the outside air, the refrigerant condenses into a liquid, eventually entering an overcooled status in the subcooling heat exchanger.
The overcooled refrigerant then flows through the pipe to the indoor electronic expansion valve where the refrigerant reduces its pressure.
Then the refrigerant flows into the indoor heat exchanger where it is evaporated by absorbing the indoor heat and continues through the reversing valve and the accumulator before returning to the compressors.
8 TON shows the refrigerant flow direction
Outdoor heat exchanger
THO
THG
Fusible plug
Sub heat exchanger
THL Check valve for liquid pipe
Fusible plug
Outdoor heat exchanger liquid flow control valve
Strainer (for liquid)
Sub heat exchanger liquid flow control valve SOT
Reversing valve
PSH1
HLSW1
Hot gas bypass valve
High pressure service port
Dryer filter
Oil bypass control valve
Supercooling heat exchanger
Buffer
Electromagnetic compressor capacity valve 1
Oil separator
Electromagnetic compressor capacity valve 2
C/P T2 C/P T1
C/P2 C/P1
P
S
L
Strainer
(for vapor)
AOT
Accumulator
Strainer
(for liquid)
Supercooling valve
ILT
Strainer (for liquid)
Strainer (for vapor)
Stop valve (for liquid)
Stop valve (for vapor)
Low pressure service port C/P S
The compressor capacity control valve bypasses the refrigerant to reduce the refrigerant amount in the refrigerant system during low-load operation.
C/P : Compressor
Electronic expansion valve
Indoor heat exchanger liquid pipe temperature sensor
Intake air temperature sensor
Indoor heat exchanger
Indoor heat exchanger vapor pipe temperature sensor
AOT
C/P S
C/P T1
C/P T2
Accumulator outlet temperature sensor
Compressor intake temperature sensor
Compressor discharge pipe temperature sensor 1
Compressor discharge pipe temperature sensor 2
HLSW1 Refrigerant high pressure switch 1
ILT Outdoor liquid pipe temperature sensor
PSH1
PSL
SOT
THG
THL
THO
Refrigerant high pressure sensor 1
Refrigerant low pressure sensor
Sub heat exchanger liquid temperature sensor
Outdoor heat exchanger vapor temperature sensor
Outdoor heat exchanger liquid temperature sensor
Outside air temperature sensor
24
Introduction
15 TON shows the refrigerant flow direction
Outdoor heat exchanger
THO
THL
Sub heat exchanger
THG
Fusible plug
Reversing valve
High pressure service port
Hot gas bypass valve
Check valve
High pressure service port
PSH1
Dryer filter
Oil bypass control valve
Buffer
Electromagnetic compressor capacity valve 1
Oil separator
Electromagnetic compressor capacity valve 2
C/P T2 C/P T1
AOT
SOT
Check valve for liquid pipe
Outdoor heat exchanger liquid flow control valve
Strainer (for liquid)
Sub heat exchanger liquid flow control valve
Fusible plug
Supercooling heat exchanger
Strainer
(for liquid)
Supercooling valve
C/P2 C/P1
P
S
L
Accumulator
Strainer
(for vapor)
HLSW2
HLSW1
C/P S
The compressor capacity control valve bypasses the refrigerant to reduce the refrigerant amount in the refrigerant system during low-load operation.
Low pressure service port
C/P : Compressor
ILT
Strainer (for liquid)
Stop valve (for liquid)
Strainer (for vapor) Stop valve (for vapor)
Electronic expansion valve
Indoor heat exchanger liquid pipe temperature sensor
Intake air temperature sensor
Indoor heat exchanger
Indoor heat exchanger vapor pipe temperature sensor
AOT
C/P S
C/P T1
C/P T2
HLSW1
HLSW2
ILT
Accumulator outlet temperature sensor
Compressor intake temperature sensor
Compressor discharge pipe temperature sensor 1
Compressor discharge pipe temperature sensor 2
Refrigerant high pressure switch 1
Refrigerant high pressure switch 2
Outdoor liquid pipe temperature sensor
PSH1
PSL
SOT
THG
THL
THO
Refrigerant high pressure sensor 1
Refrigerant low pressure sensor
Sub heat exchanger liquid temperature sensor
Outdoor heat exchanger vapor temperature sensor
Outdoor heat exchanger liquid temperature sensor
Outside air temperature sensor
25
Introduction
2. Heating
The refrigerant (R410A) coming out of the compressors flows into the indoor heat exchanger after passing through the oil separator and the reversing valve. Dissipating heat to the room, the refrigerant condenses into a liquid in the indoor heat exchanger.
After that, the refrigerant reduces its pressure at the indoor electronic expansion valve. The refrigerant then passes through the subcooling heat exchanger and flows to two destinations: the outdoor heat exchanger through the outdoor heat exchanger liquid flow control valve, and the sub heat exchanger through the sub heat exchanger liquid flow control valve. These two valves further reduce refrigerant pressure. At the outdoor heat exchanger the refrigerant evaporates by absorbing heat from the outside air, while at the sub heat exchanger it evaporates by absorbing heat from the engine exhaust. The refrigerant from the outdoor heat exchanger flows through the reversing valve and is mixed with the refrigerant from the sub heat exchanger before flowing into the accumulator and returning to the compressors.
8 TON shows the refrigerant flow direction
Outdoor heat exchanger
THO
THG
Fusible plug
Sub heat exchanger
THL
SOT
Check valve for liquid pipe
Fusible plug
Outdoor heat exchanger liquid flow control valve
Strainer (for liquid)
Sub heat exchanger liquid flow control valve
Reversing valve
PSH1
HLSW1
Hot gas bypass valve
High pressure service port
Dryer filter
Oil bypass control valve
Supercooling heat exchanger
Buffer
Electromagnetic compressor capacity valve 1
Oil separator
Electromagnetic compressor capacity valve 2
C/P T2 C/P T1
C/P2 C/P1
P
S
L
Strainer
(for vapor)
AOT
Accumulator
Strainer
(for liquid)
Supercooling valve
ILT
Strainer (for liquid)
Strainer (for vapor)
Stop valve (for liquid)
Stop valve (for vapor)
Low pressure service port C/P S
The compressor capacity control valve bypasses the refrigerant to reduce the refrigerant amount in the refrigerant system during low-load operation.
C/P : Compressor
Electronic expansion valve
Indoor heat exchanger liquid pipe temperature sensor
Intake air temperature sensor
Indoor heat exchanger
Indoor heat exchanger vapor pipe temperature sensor
AOT
C/P S
C/P T1
C/P T2
Accumulator outlet temperature sensor
Compressor intake temperature sensor
Compressor discharge pipe temperature sensor 1
Compressor discharge pipe temperature sensor 2
HLSW1 Refrigerant high pressure switch 1
ILT Outdoor liquid pipe temperature sensor
26
PSH1
PSL
SOT
THG
THL
THO
Refrigerant high pressure sensor 1
Refrigerant low pressure sensor
Sub heat exchanger liquid temperature sensor
Outdoor heat exchanger vapor temperature sensor
Outdoor heat exchanger liquid temperature sensor
Outside air temperature sensor
Introduction
15 TON shows the refrigerant flow direction
Outdoor heat exchanger
THG
Fusible plug
THL
Sub heat exchanger
Check valve for liquid pipe
Outdoor heat exchanger liquid flow control valve
Strainer (for liquid)
Sub heat exchanger liquid flow control valve
Reversing valve
High pressure service port
Hot gas bypass valve
Check valve
High pressure service port
PSH1
Dryer filter
Oil bypass control valve
Buffer
Electromagnetic compressor capacity valve 1
Oil separator
Electromagnetic compressor capacity valve 2
C/P T2 C/P T1
AOT
Buffer
C/P2
Buffer
C/P1
P
S
L
Accumulator
Strainer
(for vapor)
HLSW2
HLSW1
C/P S
The compressor capacity control valve bypasses the refrigerant to reduce the refrigerant amount in the refrigerant system during low-load operation.
Low pressure service port
C/P : Compressor
Fusible plug
Supercooling heat exchanger
Strainer
(for liquid)
Supercooling valve
ILT
Strainer (for liquid)
Stop valve (for liquid)
Strainer (for vapor) Stop valve (for vapor)
Electronic expansion valve
Indoor heat exchanger liquid pipe temperature sensor
Intake air temperature sensor
Indoor heat exchanger
Indoor heat exchanger vapor pipe temperature sensor
AOT
C/P S
C/P T1
C/P T2
HLSW1
HLSW2
ILT
Accumulator outlet temperature sensor
Compressor intake temperature sensor
Compressor discharge pipe temperature sensor 1
Compressor discharge pipe temperature sensor 2
Refrigerant high pressure switch 1
Refrigerant high pressure switch 2
Outdoor liquid pipe temperature sensor
PSH1
PSL
SOT
THG
THL
THO
Refrigerant high pressure sensor 1
Refrigerant low pressure sensor
Sub heat exchanger liquid temperature sensor
Outdoor heat exchanger vapor temperature sensor
Outdoor heat exchanger liquid temperature sensor
Outside air temperature sensor
27
Introduction
2)
Engine Coolant / Fuel Gas / Intake Air and Exhaust Air System Diagrams
1. 8 TON
Engine coolant · · · a) When the engine coolant temperature is 140 ℉ (60 ℃ ) or lower
Engine coolant sent from the engine coolant pump ( ① ) is heated throuth the exhaust air heat exchanger ( ② ) and the engine ( ⑧ ). The heated engine coolant returns to the engine coolant pump ( ① ) by making a shortcut via the thermostat ( ④ , ③ ).
shows the coolant flow direction
① : Engine coolant pump ⑦ : Engine coolant reserve tank ⑬ : Engine coolant temperature sensor
② : Exhaust air heat exchanger ⑧ : Engine ⑭ : Radiator cap
③ : Thermostat (140 ℉ (60 ℃ ) ⑨ : Gas mixer
④ : Thermostat (158 ℉ (70 ℃ ) ⑩ : Gas regulator
⑮
⑯
: Exhaust air pipe
: Exhaust water drain filter
⑤ : Sub heat exchanger
⑥ : Radiator
⑪ : Electromagnetic gas valve
⑫ : Air filter
⑰ : Exhaust water drain hose
⑱ : Sub oil reservoir
28
Introduction
Engine coolant · · · b) When the engine coolant temperature is 140 ℉ (60 ℃ ) or higher and lower than 158 ℉ (70 ℃ )
Engine coolant flows into the sub heat exchanger ( ⑤ ) and heats refrigerant to increase heating efficiency in heating operation. In low-temperature cooling, engine coolant enhances evaporation efficiency.
shows the coolant flow direction
① : Engine coolant pump ⑦ : Engine coolant reserve tank ⑬ : Engine coolant temperature sensor
② : Exhaust air heat exchanger ⑧ : Engine ⑭ : Radiator cap
③ : Thermostat (140 ℉ (60 ℃ ) ⑨ : Gas mixer
④ : Thermostat (158 ℉ (70 ℃ ) ⑩ : Gas regulator
⑮
⑯
: Exhaust air pipe
: Exhaust water drain filter
⑤ : Sub heat exchanger
⑥ : Radiator
⑪ : Electromagnetic gas valve ⑰ : Exhaust water drain hose
⑫ : Air filter ⑱ : Sub oil reservoir
29
Introduction
Engine coolant · · · c) When the engine coolant temperature is 158 ℉ (70 ℃ ) or higher
Engine coolant flows into the radiator ( ⑥ ) via the thermostat ( ④ ) to dissipate heat, and returns to the engine coolant pump ( ① ).
shows the coolant flow direction
① : Engine coolant pump ⑦ : Engine coolant reserve tank ⑬ : Engine coolant temperature sensor
② : Exhaust air heat exchanger ⑧ : Engine ⑭ : Radiator cap
③ : Thermostat (140 ℉ (60 ℃ ) ⑨ : Gas mixer
④ : Thermostat (158 ℉ (70 ℃ ) ⑩ : Gas regulator
⑮
⑯
: Exhaust air pipe
: Exhaust water drain filter
⑤ : Sub heat exchanger
⑥ : Radiator
⑪ : Electromagnetic gas valve
⑫ : Air filter
⑰ : Exhaust water drain hose
⑱ : Sub oil reservoir
30
Introduction
Fuel gas · · · Fuel gas flowing through the series of electromagnetic gas valves ( ⑪ ) is depressurized down to atmospheric pressure by the gas regulator ( ⑩ ) and supplied to the gas mixer ( ⑨ ).
The high-pressure portion of the fuel system is separated from the engine compartment to assure safety.
shows the fuel gas flow direction
① : Engine coolant pump ⑦ : Engine coolant reserve tank ⑬ : Engine coolant temperature sensor
② : Exhaust air heat exchanger ⑧ : Engine ⑭ : Radiator cap
③ : Thermostat (140 ℉ (60 ℃ ) ⑨ : Gas mixer
④ : Thermostat (158 ℉ (70 ℃ ) ⑩ : Gas regulator
⑮
⑯
: Exhaust air pipe
: Exhaust water drain filter
⑤ : Sub heat exchanger
⑥ : Radiator
⑪ : Electromagnetic gas valve
⑫ : Air filter
⑰ : Exhaust water drain hose
⑱ : Sub oil reservoir
31
Introduction
Intake Air and
Exhaust Air · · ·
Intake air enters the gas mixer ( ⑨ ) through the air filter ( ⑫ ) to be mixed with the fuel. The air/fuel mixture then flows into the engine ( ⑧ ) cylinder.
Exhaust air dissipates heat at the exhaust air heat exchanger ( ② ), and is emitted into the atmosphere through an exhaust air pipe ( ⑮ ).
Condensed water produced by exhaust air heat dissipation is neutralized at the exhaust water drain filter ( ⑯ ), and discharged from the unit through the exhaust water drain hose ( ⑰ ).
shows the intake air flow direction shows the exhaust air flow direction shows the condensed water flow direction
① : Engine coolant pump ⑦ : Engine coolant reserve tank ⑬ : Engine coolant temperature sensor
② : Exhaust air heat exchanger ⑧ : Engine ⑭ : Radiator cap
③ : Thermostat (140 ℉ (60 ℃ ) ⑨ : Gas mixer
④ : Thermostat (158 ℉ (70 ℃ ) ⑩ : Gas regulator
⑮
⑯
: Exhaust air pipe
: Exhaust water drain filter
⑤ : Sub heat exchanger
⑥ : Radiator
⑪ : Electromagnetic gas valve
⑫ : Air filter
⑰ : Exhaust water drain hose
⑱ : Sub oil reservoir
32
Introduction
2. 15 TON
Engine coolant · · · a) When the engine coolant temperature is 140 ℉ (60 ℃ ) or lower
Engine coolant sent from the engine coolant pump ( ① ) is heated throuth the exhaust air heat exchanger ( ② ) and the engine ( ⑧ ). The heated engine coolant returns to the engine coolant pump ( ① ) by making a shortcut via the thermostat ( ④ , ③ ).
shows the coolant flow direction
① : Engine coolant pump ⑧ : Engine
② : Exhaust air heat exchanger ⑨ : Gas mixer
③ : Thermostat (140 ℉ (60 ℃ ) ⑩ : Gas regulator
④ : Thermostat (158 ℉ (70 ℃ ) ⑪ : Electromagnetic gas valve
⑤ : Sub heat exchanger
⑥ : Radiator
⑫
⑬
: Air filter
: Engine coolant temperature sensor
⑦ : Engine coolant reserve tank ⑭ : Radiator cap
⑮ : Exhaust muffler
⑯ : Exhaust water drain filter
⑰ : Exhaust water drain hose
⑱ : Exhaust water drain trapper
⑲ : Sub oil reservoir
33
Introduction
Engine coolant · · · b) When the engine coolant temperature is 140 ℉ (60 ℃ ) or higher and lower than 158 ℉ (70 ℃ )
Engine coolant flows into the sub heat exchanger ( ⑤ ) and heats refrigerant to increase heating efficiency in heating operation. In low-temperature cooling, engine coolant enhances evaporation efficiency.
shows the coolant flow direction
① : Engine coolant pump ⑧ : Engine
② : Exhaust air heat exchanger ⑨ : Gas mixer
③ : Thermostat (140 ℉ (60 ℃ ) ⑩ : Gas regulator
④ : Thermostat (158 ℉ (70 ℃ ) ⑪ : Electromagnetic gas valve
⑤ : Sub heat exchanger
⑥ : Radiator
⑫
⑬
: Air filter
: Engine coolant temperature sensor
⑦ : Engine coolant reserve tank ⑭ : Radiator cap
⑮ : Exhaust muffler
⑯ : Exhaust water drain filter
⑰ : Exhaust water drain hose
⑱ : Exhaust water drain trapper
⑲ : Sub oil reservoir
34
Introduction
Engine coolant · · · c) When the engine coolant temperature is 158 ℉ (70 ℃ ) or higher
Engine coolant flows into the radiator ( ⑥ ) via the thermostat ( ④ ) to dissipate heat, and returns to the engine coolant pump ( ① ).
shows the coolant flow direction
① : Engine coolant pump ⑧ : Engine
② : Exhaust air heat exchanger ⑨ : Gas mixer
③ : Thermostat (140 ℉ (60 ℃ ) ⑩ : Gas regulator
④ : Thermostat (158 ℉ (70 ℃ ) ⑪ : Electromagnetic gas valve
⑤ : Sub heat exchanger
⑥ : Radiator
⑫
⑬
: Air filter
: Engine coolant temperature sensor
⑦ : Engine coolant reserve tank ⑭ : Radiator cap
⑮ : Exhaust muffler
⑯ : Exhaust water drain filter
⑰ : Exhaust water drain hose
⑱ : Exhaust water drain trapper
⑲ : Sub oil reservoir
35
Introduction
Fuel gas · · · Fuel gas flowing through the series of electromagnetic gas valves ( ⑪ ) is depressurized down to atmospheric pressure by the gas regulator ( ⑩ ) and supplied to the gas mixer ( ⑨ ).
The high-pressure portion of the fuel system is separated from the engine compartment to assure safety.
shows the fuel gas flow direction
① : Engine coolant pump ⑧ : Engine
② : Exhaust air heat exchanger ⑨ : Gas mixer
③ : Thermostat (140 ℉ (60 ℃ ) ⑩ : Gas regulator
④ : Thermostat (158 ℉ (70 ℃ ) ⑪ : Electromagnetic gas valve
⑤ : Sub heat exchanger
⑥ : Radiator
⑫
⑬
: Air filter
: Engine coolant temperature sensor
⑦ : Engine coolant reserve tank ⑭ : Radiator cap
⑮ : Exhaust muffler
⑯ : Exhaust water drain filter
⑰ : Exhaust water drain hose
⑱ : Exhaust water drain trapper
⑲ : Sub oil reservoir
36
Introduction
Intake Air and
Exhaust Air · · ·
Intake air enters the gas mixer ( ⑨ ) through the air filter ( ⑫ ) to be mixed with the fuel. The air/fuel mixture then flows into the engine ( ⑧ ) cylinder.
Exhaust air dissipates heat at the exhaust air heat exchanger ( ② ), and is emitted into the atmosphere through an exhaust air pipe ( ⑮ ) and an exhaust water drain trapper ( ⑱ ).
Condensed water produced by exhaust air heat dissipation is neutralized at the exhaust water drain filter ( ⑯ ), and discharged from the unit through the exhaust water drain hose ( ⑰ ).
shows the intake air flow direction shows the exhaust air flow direction shows the condensed water flow direction
① : Engine coolant pump ⑧ : Engine
② : Exhaust air heat exchanger ⑨ : Gas mixer
③ : Thermostat (140 ℉ (60 ℃ ) ⑩ : Gas regulator
④ : Thermostat (158 ℉ (70 ℃ ) ⑪ : Electromagnetic gas valve
⑤ : Sub heat exchanger
⑥ : Radiator
⑫
⑬
: Air filter
: Engine coolant temperature sensor
⑦ : Engine coolant reserve tank ⑭ : Radiator cap
⑮ : Exhaust muffler
⑯ : Exhaust water drain filter
⑰ : Exhaust water drain hose
⑱ : Exhaust water drain trapper
⑲ : Sub oil reservoir
37
No.
28
29
30
31
24
25
26
27
32
33
20
21
22
23
16
17
18
19
12
13
14
15
10
11
8
9
6
7
4
5
1
2
3
PERIODIC INSPECTION
PERIODIC INSPECTION
1. Inspection Items and Intervals
Periodic maintenance and inspection as well as replacement of the parts are required for long-term use of the
Gas Heat Pump (GHP) air conditioner.The table below lists the maintenance and inspection items and replacement parts when the yearly operation hours of a GHP are 3,333 or more hours.
For a GHP, operated for less than 3,333 hours in a year, perform maintenance/inspection and parts replacement in intervals of 3 years of operation.
Item
Engine Oil Inspection / Refilling
Oil Filter Inspection / Replacement
Spark Plug Replacement
Air Filter Element Replacement
Compressor Belt Replacement
Exhaust Water Drain Filter Inspection / Refilling
Drain Oil Filter Replacement
Engine Coolant Additive Refilling
Engine Coolant Amount Inspection / Refilling
Engine Coolant Leakage Inspection
Engine Oil Leak Inspection
Exhaust Air Leakage Inspection
Exhaust Water Drain Hose Inspection
Fuel Gas Hose Inspection / Replacement
Fuel Gas Hose Clamp Inspection / Replacement
Fuel Gas Leak Inspection
Compressor Inspection
Refrigerant Leakage Inspection
Refrigerant and Engine Coolant Line Contact Inspection
Engine Valve Cleaning
Engine Valve Clearance Inspection / Adjustment (8 TON only)
Oil Level Switch Cleaning / Inspection
Outdoor Heat Exchanger Compartment Drainage Inspection
Accumulator Condensed Water Drainage Inspection
Wiring and Connector Inspection
Anchor Bolt Inspection
Engine Startability Inspection
Engine Mount Replacement (8 TON only)
Inspection for Operation Noise
Inspection of the Number of Engine and Starter on/off Times
Inspection of the Running Hours and Number of on/off Times of the Compressor
Outdoor Heat Exchanger Inspection
Indoor Air Filters Inspection
△ ※
-
△ ※
△
△
△
△
△
△
△
△
△ ※
△
▲ ※
△
△
△
△
△
●
△
△
△ ※
△ ※
△ ※
△ ※
△
Maintenance interval :
(running hours)
10,000 h
3 years
20,000 h
6 years
△
●
△
●
●
●
●
△
●
●
●
△
●
△
△
△ ※
△ ※
△ ※
△ ※
●
△ ※
●
△ ※
△
△
△
△
△
●
△
△
△ ※
△
▲ ※
△
△
△
△
△
38
PERIODIC INSPECTION
34
35
Remote Controller Operation Inspection
Indoor Unit Temperature Inspection
△
△ ※
△
△ ※
1. Perform periodic inspection in accordance with the table above, every 3 years or every 10,000 hours, whichever comes first. (Use the genuine parts specified by AISIN for replacement, refill, engine oil, engine coolant, engine coolant additive, and valve cleaner.)
2. Symbols: ● : Replacement, ▲ : Cleaning, △ : Inspection (adjustment, refilling). ※Symbol : inspection to be carried out while the GHP is operating.
3. For the items requiring only "inspection ( △ )", it is necessary to replace the part if a problem is found in inspection.
4. When refilling engine coolant additive, supply the specified amount to the reserve tank. Refill the engine coolant of specified concentration for the shortfall. The specified concentration is 50~60 vol% (engine coolant: 0.55, water:
0.45). If an optical densitometer is used to measure the concentration, reading of 40~48 % of the densitometer corresponds to the specified concentration.
5. Refill the engine oil only the consumed amount.
6. Refill the exhaust water drain filter only the consumed amount.
7. Tell your customers to consult the dealer regarding inspection in the 7th year and after.
2. Parts Requiring Periodic Replacement
Part name
AISIN Gas Engine Oil L-10000G (2.6 gal (10 L) can)
Oil filter
Spark plugs
Air filter elements
Compressor belts
Exhaust water drain filter (2.2 lbs (1 kg) container)
Exhaust water drain filter gasket
Drain oil filter No. 1
Drain oil filter No. 2
Engine coolant additive (16.9 fl oz. (500 mL) container)
Engine coolant
Valve cleaner
Fuel gas hose (gas mixer side)
Fuel gas hose (regulator side)
Fuel gas hose clamp
Engine mount (8 TON only)
Quantity
4
2
1
1
1
1
1
1
1
1
1
1
4
2
2
1
Replacement /
Use intervals
Every 3 years or
10,000 hours
20,000 hours or
6 years
※ "Quantity" column shows the maximum number of the parts to be used for E model.
※ See parts catalog for parts NO.
39
PERIODIC INSPECTION
3. Procedure and Method of Periodic Inspection
Before starting your work
Indicates a potentially hazardous situation that could result in death or serious injury.
Indicates a potentially hazardous situation that may result in injury as well as damage to properties.
Preparation 1
Remove the outside panels of the outdoor unit.
8 TON
Front : 2, Rear : 3, Left side : 1
15 TON
Front : 2, Rear : 3, Left side : 1
Preparation 2
After confirming the GHP unit stops, turn OFF the electric leakage breaker in the control box at the front left side of the outdoor unit. Then check the LED segments are off.
Turn OFF the breaker on the power distribution board, close the fuel gas valve, then start inspection.
Segments light
Turn OFF the electric leakage breaker Segments are off
Before starting inspection, be sure to confirm more than 1 minute has elapsed after turning OFF the breaker on the power distribution board and electrical leakage breaker in the control box
(to allow residual voltage to self-discharge).
If you do not turn OFF the electric leakage breakers, or if you start working before 1 minute has passed from turning OFF the breakers, you could be shocked or injured by unexpected starting of the engine.
40
Necessary tools
Tools
Torque wrench
12 mm socket head
6 mm hexagon wrench
Phillips-head screwdriver
Oil filter wrench
Plug wrench
Engine coolant jug
Hook
Ratchet socket wrench
14 mm socket head
14 mm wrench
Diagonal cutting pliers
Oil jug
Wire brush
Gas leak detector liquid
150 mm Extension bar
6 mm hexagon socket head
30 mm open-end wrench or adjustable wrench
Mechanical belt tension gauge
Sonic belt tension gauge
Feeler gauge
Metal ruler
Paint marker (white)
Wooden block
Jack
Saucers
Rag
Bucket
Purpose
Tightening with required torque
Replacing the oil filter
Removing the spark plug
Removing the fuel gas hose
Cutting the bundling bands
Cleaning the electrodes of the spark plug
Checking the fuel gas leakage / removing the fuel gas hose
Measuring the belt tension
Adjusting the engine valve clearance
Exhaust water drain filter refilling
Replacing the engine mount
Containing removed bolts
Preventing blot and cleaning around the unit
Containing exhaust drain water
Belt tension gauge
Mechanical
Sonic
Measures belt tension with spring tension
Measures belt tension by detecting sound wave generated by the belt
Setting for sonic belt tension gauge
Compressor belts
8 TON Setting items
Unit mass
Number of ribs
Span 212 mm
17 g / rib·m
8 pieces
PERIODIC INSPECTION
15 TON
242 mm
41
PERIODIC INSPECTION
1)
Engine Oil Inspection / Refilling
1. Check the oil level with an oil level gauge on the sub oil reservoir.
NOTE) When the outdoor unit is running or just has stopped, wait for 5 minutes before you check the engine oil amount.
2. Refill new engine oil until the oil level reaches the specified level.
NOTE) Wait until the pressure is equalized (for 5 minutes or more), and check the engine oil level again with an oil level gauge.
Refilling amount per scale of the oil level gauge
8 TON Approx. 0.5 gal (2 L)
15 TON Approx. 0.6 gal (2.3 L)
8 TON
15 TON
Refilling interval
Specified amount (sub oil reservoir)
B level -3/8 ~ 0 inch (-10 ~ 0 mm)
A level -3/8 ~ 0 inch (-10 ~ 0 mm)
Every 3 years (10,000 hours)
2)
Oil Filter Replacement
1. Remove the oil filter with an oil filter wrench.
NOTE)
Cover the other parts with rag or other covering material to protect them from oil spills.
Wipe out all the engine oil adhering on the bottom plate or side surface of the oil pan.
Drain the engine oil left in the removed oil filter into a waste oil can.
Make sure that the O ring on the oil filter is not left on the engine side.
Oil filter wrench
Oil filter
2. Clean the oil filter mounting surface with rag.
Oil filter
Oil level gauge
Sub oil reservoir
Rag
7.9 gal (30 L)
8.5 gal (32 L)
42
Mounting surface
3. Tighten the oil filter by hand until the gasket comes into contact with the bracket.
4. Further tighten the filter by 3/4 turns with the oil filter wrench.
NOTE) Even if the oil filter says "Tighten hard with your hands", be sure not to tighten it by 3/4 or more turns with an oil filter wrench. There is a possibility that it will not come off.
Replacement interval Every 3 years (10,000 hours)
Oil filter
Bracket
3)
Spark Plug Replacement
1. Pull the caps to remove the cables.
NOTE) Do not pull the cable.
PERIODIC INSPECTION
Cap
2. Remove the spark plugs with a plug wrench.
3. Tighten the new spark plug by hand.
4. Further tighten the spark plug with a torque wrench.
Tightening torque 15 ~ 22 lb·ft (20 ~ 30 N·m)
5. Fit the cap onto the plug until it makes a clicking sound.
Replacement interval Every 3 years (10,000 hours)
4)
Air Filter Element Replacement
1. Move a clamp to remove the air intake hose.
Plug wrench
Air intake hose
Clamp
43
Air filter
PERIODIC INSPECTION
2. Unscrew 6 nuts to remove the cap.
Nuts (6 pieces)
3. Remove the air filter element.
4. Clean the dust inside the cap and the case.
5. Set the new air filter element so the deeper side is placed in the case.
Aair filter elements
Cap
6. Mount the cap so a pipe hole comes slighly to the front, then tighten the cap with 6 nuts.
Tightening torque 3.7 ± 1.1 lb·ft (5 ± 1.5 N·m)
REAR
Cap
Case
Nuts (6 pieces)
FRONT
7. Attach the air intake hose, and fix the hose with a clamp.
NOTE) Be sure to check if the clamp is attached securely.
Air intake hose
Pipe hole
Air filter
Clamp
Replacement interval Every 3 years (10,000 hours)
44
PERIODIC INSPECTION
5)
Compressor Belt Replacement
1. [ 15 TON only ]
Unscrew 5 bolts to remove the front side stay.
Outdoor unit capacity
8 TON
15 TON
Stay
Without
With
2. Loosen a locknut and an adjustment bolt adequately.
3. Loosen 4 bolts in the front of the outdoor unit, and remove the compressor belt.
4. Install the new belt and lightly tighten 4 bolts.
5. Adjust the belt tension with the adjustment bolt.
Bolts
Stay
Bolts (5 pieces)
Compressor belt
Adjustment bolt
Locknut
Belt tension adjustment standard (Replacement)
Belt tension ※
Outdoor unit capacity
Sonic Mechanical (Reference value)
8 TON
15 TON
225 ~ 270 lbf (1,000 ~ 1,200 N)
301 ~ 346 lbf (1,340 ~ 1,540 N)
155 lbf (690 N)
202 lbf (900 N)
Outdoor unit capacity
Belt tension adjustment standard (Inspection)
Belt tension ※
Sonic Mechanical (Reference value)
8 TON
15 TON
180 ~ 216 lbf (800 ~ 960 N)
241 ~ 277 lbf (1,070 ~ 1,230 N)
124 lbf (550 N)
162 lbf (720 N)
※ Measure the belt tension with a sonic belt tension gauge. Tension values for a mechanical belt tension gauge on the chart are reference values.
6. After adjusting the belt tension, tighten the locknut to fix the compressor.
Tightening torque 7.4 ~ 11.1 lb·ft (10 ~ 15 N·m) Bolts
7. Tighten up 4 bolts.
Tightening torque 31.0 lb·ft (42.0 N·m)
8. Run the engine for 10~20 minutes and measure to adjust the belt tension again.
Replacement interval Every 3 years (10,000 hours)
Locknut
45
PERIODIC INSPECTION
6)
Exhaust Water Drain Filter Inspection / Refilling
1. [ Unit with drain heater kit only ]
Move 2 clamps in the rear of the outdoor unit, and remove the 2 exhaust water drain hose.
2. [ 8 TON only ]
1) Unscrew 2 bolts to remove the stay.
2) Move 3 hose clamps to pull the SUS pipe and the
3 exhaust water drain hoses.
Exhaust water drain hoses
Clamps
Bolts
Stay
Clamps
3. [ 15 TON only ]
Move a lower clamp to remove the exhaust water drain hose.
Clamp
4. [ 15 TON only ]
Unscrew 2 nuts to remove the stay.
Nuts
46
PERIODIC INSPECTION
5. [ 15 TON only ]
Unscrew 2 bolts to remove the oil tray.
Bolts
6. Unscrew a bolt (2 bolts for 8 TON) to remove the exhaust water drain filter box.
NOTE) Do not tilt the box when removing it, because the box contains exhaust drain water.
7. After removing the box, pour the exhaust drain water into the bucket.
NOTE) Be sure to dispose of exhaust drain water in the bucket as industrial waste.
8. Unscrew all bolts to open the lid.
Number of bolts
8 TON
15 TON
18 pieces
19 pieces
Bolt
If the outdoor unit has drain heater kit, be careful not to damage the exhaust water drain heater or its wiring.
9. Using the metal scale, put a mark on the depth of
3/8 inch (1 cm) below the upper surface of the box.
10. Flatten out the filter stone at the bottom of the box and tamp it down. Fill the box with stones until the marked position.
Filter stone
Metal scale
Bolts
Mark
Time for refilling Every 3 years (10,000 hours)
47
PERIODIC INSPECTION
7)
Drain Oil Filter Replacement
?Do this work following " Exhaust Water Drain Filter Inspection / Refilling ".
1. Remove the drain oil filter No.1 (for separation), No.2
(for absorption) and the gasket.
2. Clean the inside of the box. Clean the portion holding the drain oil filters in particular.
3. Replace the new drain oil filter No.1 (for separation),
No.2 (for absorption) and the new gasket.
NOTE)
Filter No.1 (separation)
Insert the oil filter No.1 (for separation) keeping the arrow on the filter side up and point to the oil filter No.
2 (for absorption) to the box.
Filter No.1
Gasket
Filter No.2 (for absorption) : 8 TON
Insert the oil filter No. 2 (for absorption) keeping the cutout side top of the box.
Cutout
Filter No.2
Filter No.2 (for absorption) : 15 TON
Insert the oil filter No. 2 (for absorption) keeping the upper cutout facing outside of the box.
※ All the filters provided are already oriented to the same direction to be inserted as it is. Be sure not to replace it.
Upper cutout
Outside of the box
Lower cutout
4. Tighten all bolts to install the lid.
8 TON
15 TON
Number of bolts
18 pieces
19 pieces
Tightening torque 2.2 ± 0.7 lb·ft (3.0 ± 0.9 N·m)
5. Install the box on the outdoor unit. Tighten the bolt
(2 bolts for 8 TON).
8 TON
15 TON
Tightening torque
14.8 lb·ft (20.0 N·m)
8.9 ± 2.7 lb·ft (12.0 ± 3.6 N·m)
Bolts
Inside of the box
Bolts
48
6. [ 15 TON only ]
Mount the oil tray and tighten 2 bolts.
Tightening torque 2.2 ± 0.7 lb·ft (3.0 ± 0.9 N·m)
7. [ 15 TON only ]
Mount the stay and tighten 2 nuts.
Tightening torque 8.9 ± 2.7 lb·ft (12.0 ± 3.6 N·m)
8. [ 15 TON only ]
Connect the exhaust water drain hose and fix with the lower clamp.
Clamp
PERIODIC INSPECTION
Bolts
Nuts
9. [ 8 TON only ]
Connect the SUS pipe and 3 exhaust water drain hoses, and fix with 3 clamps.
Clamps
10. [ 8 TON only ]
Mount the stay and tighten 2 bolts.
Tightening torque 3.7 ± 1.1 lb·ft (5.0 ± 1.5 N·m)
Stay
11. [ Unit with drain heater kit only ]
Connect the 2 exhaust water drain hoses from the rear of the outdoor unit, and fix with 2 clamps.
Replacement interval Every 3 years (10,000 hours)
Exhaust water drain hoses
49
Bolts
Clamps
PERIODIC INSPECTION
8)
Engine Coolant Additive Refilling
1. Remove the radiator cap to put the specified amount of engine coolant additive.
NOTE)
If the engine coolant reaches full level before completing refilling, drain the engine coolant from the drain plug on the engine block and refill the remaining engine coolant additive.
Pour the drained engine coolant into the reserve tank.
8 TON
15 TON
Specified amount
10.1 ~ 11.8 fl oz. (300 ~ 350 cm 3 )
15.6 ~ 17.2 fl oz. (460 ~ 510 cm 3 )
For engine coolant additive, be sure to use the AISIN
Coolant product.
Refilling interval Every 3 years (10,000 hours)
9)
Engine Coolant Amount Inspection / Refilling
1. Check the engine coolant level in the reserve tank.
2. If the engine coolant level is lower than the reference line, refill the engine coolant until the engine coolant level reaches the reference line.
When refilling engine coolant, be sure to use AISIN
Coolant S.
When refilling engine coolant, be sure to mix with the following balance 50~60 vol% (coolant: 0.55, water:
0.45).
Refilling interval Every 3 years (10,000 hours)
Radiator cap
Drain plug
Reference line
50
PERIODIC INSPECTION
10)
Engine Coolant Leakage Inspection
1. Check the engine coolant hoses for cracks or deterioration.
2. Check if the clamp is attached securely.
3. Check the engine coolant hoses and connections for leakage.
NOTE) Be sure to check in the heat exchanger compartment.
4. Check the radiator cap for leakage.
Inspection interval Every 3 years (10,000 hours)
11)
Engine Oil Leak Inspection
1. Check the engine block and the gasket for oil leakage.
2. Check if the clamp is attached securely.
3. Check the engine oil hoses and hose connections for leakage.
4. Check the sub oil reservoir for oil leakage.
Inspection interval Every 3 years (10,000 hours)
Sub oil reservoir
12)
Exhaust Air Leakage Inspection
1. Check the exhaust air hoses for disconnection or cracks.
2. Check if the clamp is attached securely.
3. Check the exhaust air hoses and hose connecting points for exhaust air leakage.
NOTE) Be sure to check in the heat exchanger compartment.
Exhaust muffler
Connecting points
Inspection interval Every 3 years (10,000 hours)
Exhaust air heat exchanger
Radiator cap
51
PERIODIC INSPECTION
13)
Exhaust Water Drain Hose Inspection
1. Check the exhaust water drain hoses for disconnection.
2. Check if the clamp is attached securely.
3. Check the exhaust water drain hoses and hose connecting points for exhaust drain water leakage.
NOTE) Be sure to check in the heat exchanger compartment.
4. Check the exhaust water drain hoses for crush or clogging. Also check if the exhaust water drains normally.
Exhaust water drain hoses
Inspection interval Every 3 years (10,000 hours)
Exhaust water drain hoses
14)
Fuel Gas Hose and Fuel Gas Hose Clamp Inspection / Replacement
Replacement
1. Move 4 clamps.
Gas mixer
Clamp
Clamps
Clamp
Regulator
52
2. Remove the 2 fuel gas hoses.
1) Insert the hook between the fuel gas pipe and fuel gas hose. Apply the gas leak detector liquid so that the liquid gets through the clearance between the fuel gas pipe and fuel gas hose.
Fuel gas hose
PERIODIC INSPECTION
Hook
Fuel gas pipe
2) Apply the soapy water sliding the hook by 90°from the insert point so that the gas leak detector liquid gets through at least 4 locations. Then, pull out the hook.
NOTE) Be careful not to damage the fuel gas pipe and fuel gas hose.
3. Connect the 2 fuel gas hoses.
4. Fix the hoses with new clamps.
Replacement interval 6 years (20,000 hours)
Inspection
1. Check the fuel gas hose for cracks or deterioration.
2. Check the fuel gas hose for contact with other parts.
3. Check the clamp for corrosion.
15)
Fuel Gas Leak Inspection
1. Check the fuel gas pipe for corrosion.
2. Check if the clamp is attached securely.
3. Check the fuel system parts and connecting points for fuel gas leakage with gas leak detector liquid.
Gas mixer
Regulator
Electromagnetic gas valves
53
PERIODIC INSPECTION
If there is any problem such as fuel gas leakage or fuel gas odor during inspection, be sure to fix the problem.
If there is dirt or leaf soil around the fuel system parts, be sure to clean up around the fuel system parts.
Inspection interval Every 3 years (10,000 hours)
Opening for fuel gas pipe
16)
Compressor Inspection
1. When the GHP is stopped, turn the compressor shaft by hand and check that it turns smoothly.
2. Check the compressor unit for refrigerant or refrigerant oil leakage.
3. Touch the compressor heater with your hand to check if it is warm.
NOTE) Depending on the ambient temperature, compressor heater may not be electrified.
Inspection interval Every 3 years (10,000 hours)
Compressor heater
Compressor
17)
Refrigerant Leakage Inspection
1. Check the refrigerant line and refrigerant line connecting points for refrigerant leakage.
Portions prone to leakage
Line connecting points Flexible tubes
2. Check and record the values in the right table with the monitor mode in the board maintenance functions during operation.
Operating condition
Operate all indoor units with maximum load
Inspection interval Every 3 years (10,000 hours)
Code No.
41
40
11
-
Items to be checked
Refrigerant low pressure
Refrigerant high pressure 1
Actual engine speed
Number of connected compressor units
54
PERIODIC INSPECTION
18)
Refrigerant and Engine Coolant Line Contact Inspection
1. Check the refrigerant line and engine coolant line for contact with other parts.
[Refrigerant line] [Engine coolant line]
Inspection interval Every 3 years (10,000 hours)
19)
Engine Valve Cleaning
1. Run the outdoor unit.
2. Move a clamp above the gas mixer.
Clamp
Gas mixer
3. Lift the air intake hose a little bit off the gas mixer, insert the nozzle of a valve cleaner, and supply about
1/2 can of valve cleaner.
NOTE) Supply the valve cleaner intermittently taking care so that there is no engine stall or over speed.
4. Pull out the nozzle of the valve cleaner, and connect the air intake hose.
5. Keep the engine running until no more white smoke is emitted from the exhaust port. Then stop the engine.
6. Fix the air intake hose with a clamp.
Take extra care during engine valve cleaning. There are possibilities that your fingers or clothing could be caught by the crank pulley or other rotating parts.
Do not apply the valve cleaner to the hot portion in cleaning the engine valves. Fire could occur.
Cleaning interval Every 3 years (10,000 hours)
55
Air intake hose Valve cleaner
Clamp
Gas mixer
PERIODIC INSPECTION
20)
Engine Valve Clearance Inspection / Adjustment (8 TON only)
[ 8 TON only ]
1. Close the fuel gas valve.
2. Hold and pull the caps to remove the cables
(3 places).
NOTE) Do not pull the cable.
3. Remove 3 spark plugs with plug wrench.
4. Remove the cylinder head cover.
1) Unscrew a bolt to remove the blow-by hose.
2) Unscrew 3 nuts to remove the cylinder head cover.
5. Wipe out the oil on the contact surface between the removed cover and cylinder head.
Nuts
Caps
Spark plugs
Cylinder head cover
Blow-by hose
6. Turn the crank pulley by hand, and align the top dead center mark on the crank pulley with the top dead center mark on the engine block.
Bolt
Top dead center marks
FRONT side
7. Check that the intake rocker arm of No. 1 cylinder does not move when the crank pulley is turned approximately 60 ˚ clockwise and counterclockwise.
(Set No. 1 cylinder to the top dead center.)
NOTE) If the intake rocker arm of No. 1 cylinder moves, turn the crank pulley by another 1 revolution so that the top dead center marks align with each other again.
8. At the top dead center, adjust the intake valve clearance on No. 1 and No. 3 cylinders and exhaust valve clearance on No. 1 and No. 2 cylinders by loosening the adjustment nuts as shown in the illustration.
9. Turn the crank pulley by 1 revolution by hand so that the top dead center marks align with each other again.
10. Adjust the intake valve clearance on No. 2 cylinder and exhaust valve clearance on No. 3 cylinder by loosening the adjustment nuts as shown in the illustration.
Standard value
0.014 ± 0.002 inch(0.35 ± 0.05 mm)
0.010 ± 0.002 inch(0.25 ± 0.05 mm)
Rear side
Front side
No.3 exhaust
No.3 intake
No.2 exhaust
No.2 intake
No.1 exhaust
No.1 intake
Front side
Adjustment nuts
When the engine is hot.
When the engine is cold.
56
PERIODIC INSPECTION
11. Install the cylinder head cover and spark plugs with the reverse procedure for the removal.
NOTE)
Do not use a feeler gauge with a blade thickness of 0.008 inch (0.2 mm) or more. When adjusting a clearance of 0.008 inch (0.2 mm) or more, use two blades of feeler gauge.
Do not use a feeler gauge with bent or rusty blades.
When adjusting a valve clearance (while warm), set the target in the range from 0.013 inch (0.33 mm) ~ 0.015
inch (0.38 mm) (allows the insertion of a 0.013 inch (0.33 mm) blade but not a 0.015 inch (0.38 mm) blade).
Adjusting interval Every 3 years (10,000 hours)
21)
Oil Level Switch Cleaning / Inspection
Inspection
1. Check the continuity of the oil level switch by moving the oil level detecting float up and down with your finger.
When the float is up
When the float is down
There is no continuity
There is continuity
2. Check the shaft for accumulation of foreign object or damage.
Inspection interval Every 3 years (10,000 hours)
Switch
Float
Cleaning
1. Move the oil level detecting float up and down with your finger, and wipe out the foreign object accumulating on the shaft with rag.
Shaft
Float
22)
Outdoor Heat Exchanger Compartment Drainage Inspection
1. Check if the rainwater in the outdoor heat exchanger compartment drains to the outside of the unit through the drain hose.
Drain hose
57
PERIODIC INSPECTION
2. Check the inside of the outdoor heat exchanger compartment for dirt such as fallen leaves.
Outdoor heat exchanger compartment
If there is dirt or leaf soil in the outdoor heat exchanger compartment, clean up the outdoor heat exchanger compartment.
Inspection interval Every 3 years (10,000 hours)
23)
Accumulator Condensed Water Drainage Inspection
1. Check if the condensed water on the surface of the accumulator drains to the outside of the unit from the refrigerant pan.
2. Check the inside of the refrigerant pan for dirt.
If there is dirt or leaf soil in the refrigerant pan, clean up the refrigerant pan.
Inspection interval Every 3 years (10,000 hours)
24)
Wiring and Connector Inspection
1. Check the wirings for contacting rotating parts or being pinched by other parts.
2. Check if the wirings are securely fixed by the clamps.
3. Check the connectors for disconnection or looseness.
Inspection interval Every 3 years (10,000 hours)
25)
Anchor Bolt Inspection
1. Check if the outdoor unit is firmly secured by anchor bolts.
Inspection interval Every 3 years (10,000 hours)
58
Anchor bolt
Foundation
Refrigerant pan
26)
Engine Startability Inspection
1. Crank the engine to check if the engine starts within 3 sets.
Inspection interval Every 3 years (10,000 hours)
27)
Engine Mount Replacement
[ 8 TON only ]
1. Check engine mount replacement location.
PERIODIC INSPECTION
Engine mount
(front side)
2. Place the jack from the rear at the location shown right.
3. Set the wooden block on the jack.
4. Then jack up until the engine is lifted about 0.2 inch
(5 mm).
NOTE)
Be sure to jack up until the engine is lifted.
Be careful not to crush the harnesses on the base panel.
Wooden block
Engine mount (rear side)
Jack
5. Unscrew 4 bolts of rear side engine bracket.
Rear side
59
Bolts
(4 pieces)
PERIODIC INSPECTION
6. Unscrew 2 bolts to remove the rear side engine mount.
7. Set the new engine mount with spacer to the base plate and tighten with 2 bolts.
Tightening torque 31.0 lb·ft (42.0 N·m)
Rear side
Engine mount
8. Mount the rear side engine bracket and tighten
4 bolts.
Tightening torque 14.8 lb·ft (20.0 N·m)
Rear side
Bolts
Bolts
(4 pieces)
9. Unscrew 4 bolts of front side engine bracket.
Front side
Bolts
(4 pieces)
10. Unscrew 2 bolts to remove the front side engine mount.
11. Set the new engine mount with spacer to the base plate and tighten with 2 bolts.
Tightening torque 31.0 lb·ft (42.0 N·m)
Front side
Bolts
Engine mount
60
12. Mount the front side engine bracket and tighten
4 bolts.
Tightening torque 14.8 lb·ft (20.0 N·m)
13. Check the bolts are tightened with the specified tightening torque.
14. Lower the jack slowly. Remove the wooden block and jack.
Front side
Replacement interval 6 years (20,000 hours)
PERIODIC INSPECTION
Bolts
(4 pieces)
28)
Inspection for Operation Noise
1. Check if the outdoor unit generates abnormal noise or vibration during operation.
2. In particular, check for rattling noise and chattering noise from the cylinder head, or interference noise from around the engine rotating parts .
Inspection interval Every 3 years (10,000 hours)
29)
Inspection of the Number of Engine and Starter on/off Times
1. Check and record the values in the right table with the monitor mode in the board maintenance functions.
Code No.
68
69
Inspection interval Every 3 years (10,000 hours)
Items to be checked
Number of starter on/off times
Number of engine on/off times
30)
Inspection of the Running Hours and Number of on/off Times of the Compressor
1. Check and record the values in the right table with the monitor mode in the board maintenance functions.
Inspection interval Every 3 years (10,000 hours)
Code No.
62
63
6A
6b
Items to be checked
Compressor 1 running hours
Compressor 2 running hours
Number of compressor 1 on/off times
Number of compressor 2 on/off times
31)
Outdoor Heat Exchanger Inspection
1. Check if the fins of the outdoor heat exchanger are extremely dirty.
NOTE) Cleaning of the outdoor heat exchanger requires additional charge.
Inspection interval Every 3 years (10,000 hours)
32)
Indoor Air Filters Inspection
1. Check if the indoor air filters are extremely dirty.
NOTE)
Ask your customers to clean the indoor air filters.
Cleaning of the indoor air filters requires additional charge.
Inspection interval Every 3 years (10,000 hours)
61
PERIODIC INSPECTION
33)
Remote Controller Operation Inspection
1. Check if the system works properly by operating the system with the remote controller.
Inspection interval Every 3 years (10,000 hours)
34)
Indoor Unit Temperature Inspection
1. Operate all the indoor units, and measure discharge and intake air temperature for each indoor unit.
Inspection interval Every 3 years (10,000 hours)
35)
Check After Work
Check the following items
Check that all bolts are properly tightened.
Check that the compressor belt tension is correct. ( Refer to P45, [Compressor Belt Replacement] )
Check that there is no contact between the wiring harnesses or brackets and other parts.
Check that the bundling bands and fixing clamps are properly fastened.
Clean up around the unit.
After completion of the work
1) Turn the breaker on the power distribution board ON, and open the fuel gas valve.
2) The electric leakage breaker is in the control box at the front left side of the outdoor unit. Turn the electric leakage breaker ON.
3) Conduct a test run, and check that there is no problem. Then install all the outside panels of the outdoor unit.
NOTE) After all warking, be sure to reset periodical inspection by using the [periodical inspection (code No. 7b)] of the board maintenance function or a maintenance checker.
Check the display of [engine running hours (code No. 60)] is the same as [last periodical inspection time
(code No. 61)]. And then, check that periodical inspection reset is completed.
62
REPLACEMENT OF MAIN COMPONENTS
REPLACEMENT OF MAIN COMPONENTS
1. Before Starting Your Work
Indicates a potentially hazardous situation that could result in death or serious injury.
Indicates a potentially hazardous situation that may result in injury as well as damage to properties.
Preparation 1
Remove the outside panels of the outdoor unit.
8 TON
Front : 2, Left side : 1, Rear : 3
15 TON
Front : 2, Front small panel: 1, Rear : 3
AISIN
AISIN
Preparation 2
After confirming the GHP unit stops, turn OFF the electric leakage breaker in the control box at the front left side of the outdoor unit. Then check the LED segments are off.
Turn OFF the breaker on the power distribution board, close the fuel gas valve, then start inspection.
Segments light
Turn OFF the electric leakage breaker
Segments are off
Before starting inspection, be sure to confirm more than 1 minute has elapsed after turning OFF the breaker on the power distribution board and electrical leakage breaker in the control box
(to allow residual voltage to self-discharge).
If you do not turn OFF the electric leakage breakers, or if you start working before 1 minute has passed from turning OFF the breakers, you could be shocked or injured by unexpected starting of the engine.
63
REPLACEMENT OF MAIN COMPONENTS
Necessary tools
Tools
Torque wrench
Hose clipper
Wooden block
Thickness: approximately 1-1/2 inch (40 mm), length: 24 inch (600 mm) or longer, 2 pieces
Thickness: approximately 3 inch (80 mm), length: 24 inch (600 mm) or longer, 1 piece
Thickness: approximately 2 inch (55 mm), length: 24 inch (600 mm) or longer, 1 piece
Thickness: approximately 4-1/2 inch (115 mm), length: 24 inch (600 mm) or longer, 2 pieces
Gasket remover
Scraper
Phillips-head screwdriver
Oil filter wrench
Plug wrench
Hook
Cylinder head replacement tool (SST)
(09270-71010: Toyota Part No.)
Diagonal cutting pliers
Vacuum pump
Scale
Purpose
Tightening with required torque
Clipping hoses
Engine Replacement (8 TON)
Engine Replacement (15 TON)
Replacing the oil filter
Replacing the spark plug
Removing the fuel gas hose
Replacing the cylinder head
Gas leak detector liquid
Manifold gauge
Mechanical belt tension gauge
Sonic belt tension gauge
Digital thermometer
Table approximately 4 inch (100 mm) high
Saucers
Rag
Cutting the bundling bands
Replacing the compressor
Replacing the compressor
Checking the fuel gas leakage / removing the fuel gas hose
Replacing the compressor
Measuring the belt tension
Measuring the belt tension
Replacing the compressor
Replacing the compressor
Containing removed bolts
Preventing blot and cleaning around the unit
Belt tension gauge
Mechanical
Sonic
Measures belt tension with spring tension
Measures belt tension by detecting sound wave generated by the belt
Setting for sonic belt tension gauge
Compressor belts
8 TON Setting items
Unit mass
Number of ribs
Span 212 mm
17 g / rib·m
8 pieces
15 TON
242 mm
64
REPLACEMENT OF MAIN COMPONENTS
2. Replacement of Engine Unit
[Necessary items]
Parts
Part name
Set, Engine ASSY
AISIN Coolant S
AISIN Gas Engine Oil L-10000G
Bolt, Washer Base Head Hexagon (8 TON only)
Part No.
See parts catalog
Quantity
1
1
4
6
[ 8 TON ]
[Removal]
1. Drain engine oil.
1) Clamp the oil hose with 2 hose clippers at both sides of joint.
2) Remove the joint and loosen one hose clipper at a time to drain engine oil in the engine and sub oil reservoir.
3) Install the joint as before, and remove both hose clippers.
4) Disconnect the 3 oil hoses from the engine.
NOTE) Be careful because oil will drip from the oil hoses when you remove the hoses.
2. Drain engine coolant.
1) Clamp the engine coolant hoses at the outlet and inlet ports of the radiator (2 places) with 2 hose clippers.
Oil hoses
Sub oil reservoir
Clamping positions Oil hose
Clamping positions
Joint
2) Open the radiator cap.
3) Clamp the engine coolant hoses at the outlet and inlet ports of the engine coolant pump (2 places) with 2 hose clippers.
4) Disconnect the hose at engine coolant pump inlet side and remove the hose clip. Drain the engine coolant.
5) Clamp the hose again with a hose clipper when the engine coolant drains away.
6) Disconnect the hose at engine coolant pump outlet side and remove the hose clip in the same way.
Drain the engine coolant.
7) Clamp the hose again with a hose clipper when the engine coolant drains away.
65
Radiator cap
Clamping positions
Pump inlet side
REPLACEMENT OF MAIN COMPONENTS
3. Remove the engine coolant pump.
1) Unscrew 2 bolts to remove the cover.
Bolts
2) Unscrew 2 bolts to remove the engine coolant pump.
4. Loosen the drain plug cap, and drain engine coolant from the engine.
NOTE) It makes draining easier to insert a hose with approximately 1/4 inch (7 mm) inner diameter into the drain plug.
Drain plug
Bolts
5. Remove the under engine parts.
1) Unscrew 2 bolts to remove the 2 oil stays.
2) Unscrew 2 bolts to remove the cover. Remove the oil level switch.
3) Unscrew 2 bolts to remove the stay.
Stay
66
Bolts
Bolts
Cover
Bolts
6. Remove the 2 engine coolant hoses from the engine.
7. Remove the breather hose from the exhaust air heat exchanger.
REPLACEMENT OF MAIN COMPONENTS
Engine coolant hoses
Breather hose
8. Unscrew a bolt connecting the thermostat to the outdoor unit, and separate the thermostat.
Bolt
9. Disconnect each wire harness.
1) Disconnect 2 wire harnesses from the starter.
2) Disconnect a connector from the engine speed sensor.
Thermostat
Engine speed sensor
3) Disconnect 2 relay connectors of the gas mixer wire harness.
4) Disconnect a relay connector of engine oil pressure switch wire harness.
5) Disconnect connectors from the ignition coils
(3 places).
6) Disconnect a relay connector of the engine coolant temperature sensor wire harness.
Ignition coils
Starter
Gas mixer
Engine oil pressure switch
Engine coolant temperature sensor
67
REPLACEMENT OF MAIN COMPONENTS
10. Remove the exhaust air heat exchanger.
1) Unscrew 2 nuts ans 2 bolts to remove the exhaust pipe.
NOTE) The outdoor unit has the deodorizing catalyst instead of the exhaust pipe if the deodorant kit is installed.
Bolts Exhaust pipe
2) Disconnect the exhaust hose from the exhaust air heat exchanger.
Nuts
3) Remove 2 bolts.
4) Remove 2 nuts.
Exhaust air heat exchanger Exhaust hose
Bolts
Nuts
5) Unscrew 2 nuts to remove the exhaust air heat exchanger.
Nuts
Exhaust air heat exchanger
68
11. Remove the compressor belt.
1) Loosen a locknut and an adjustment bolt adequately.
2) Loosen 4 bolts in the front of the outdoor unit, and remove the compressor belt.
REPLACEMENT OF MAIN COMPONENTS compressor belt
12. Disconnect the air intake hose and the fuel gas hose from the engine.
Bolts
Fuel gas hose
Locknut Adjustment bolt
Air intake hose
13. Remove the exhaust water drain filter box.
1) Unscrew 2 bolts to remove the stay.
2) Disconnect the 3 exhaust water drain hoses from the box.
3) Unscrew 2 bolts to remove the box.
Bolts
NOTE) Disconnect the connector of the exhaust water drain filter if the drain heater kit is installed.
Exhaust water drain hoses
Heater
69
Bolts
REPLACEMENT OF MAIN COMPONENTS
14. Dismount the engine.
1) Place a wooden block (thickness: approximately
3 inch (80 mm), length: 24 inch (600 mm) or longer) under the compressor bracket.
2) Place 2 wooden blocks (thickness: approximately
1-1/2 inch (40 mm), length: 24 inch (600 mm) or longer) under the oil pan.
Bracket
Oil pan
3) Unscrew 5 bolts to remove the bracket (front side).
Wooden blocks (Thickness : 1-1/2inch)
Wooden block (Thickness : 3inch)
Front side Bolts (5 pieces)
4) Unscrew 4 bolts to remove the bracket (rear side).
Bolts (4 pieces) Rear side
5) Unscrew 11 connecting bolts between the compressor bracket and engine (2 of the bolts are installed from the engine side), and separate the compressor bracket from the engine.
Bolts
70
Bolts (installed from the engine side)
Bolts
6) Double-check if the hoses or wire harnesses are disconnected from the engine. If connected, disconnect the hoses or wire harnesses.
7) Unscrew 6 bolts (both sides) to remove the engine brackets (both sides). Dismount the engine.
NOTE) When placing the engine on the floor, place wooden blocks, rag or other appropriate material on the floor and put the engine on it carefully so that the pipes on the bottom of the oil pan will not be damaged.
REPLACEMENT OF MAIN COMPONENTS
Bolts
Bolts (4 pieces)
15. Remove the surrounding parts of engine.
1) Unscrew 2 bolts (2 places) to remove the stays
(2 places).
Bolts
Bolts
2) Unscrew 5 bolts to remove the crank pulley.
3) Unscrew 6 bolts to remove the flywheel.
4) Unscrew 2 bolts to remove the starter.
Starter
Bolts
5) Unscrew 7 bolts to remove the bracket.
Pulley
Bolts
(5 pieces)
Bolts
(6 pieces)
Flywheel
Bolts
Bracket
71
REPLACEMENT OF MAIN COMPONENTS
6) Unscrew a bolt to remove the blow-by hose.
7) Unscrew 2 bolts to remove the gas mixer.
Bolt
Blow-by hose
Gas mixer
Bolts
8) Unscrew 6 nuts to remove the exhaust manifold.
Nuts (6 pieces)
72
REPLACEMENT OF MAIN COMPONENTS
[Reassembling]
1. Unscrew 6 bolts from the new engine to remove the flywheel.
NOTE) Once removed, the bolts can not be reused.
Put on the shelf these bolts.
Bolts (6 pieces)
2. Mount the surrounding parts on the new engine.
1) Mount the exhaust manifold and tighten 6 nuts.
NOTE) Replace the gasket before mounting the exhaust manifold.
Tightening torque 14.8 lb·ft (20.0 N·m)
Nuts (6 pieces)
2) Mount the gas mixer and tighten 2 bolts.
NOTE) Replace the gasket before installing the gas mixer.
Tightening torque 14.8 lb·ft (20.0 N·m)
Gas mixer
Bolts
3) Mount the blow-by hose and tighten the bolt.
Tightening torque 6.3 lb·ft (8.5 N·m)
Blow-by hose
Bolt
73
REPLACEMENT OF MAIN COMPONENTS
4) Mount the bracket and tighten 7 bolts.
Tightening torque 31.0 lb·ft (42.0 N·m)
Bolts
Bracket
5) Mount the starter and tighten 2 bolts.
Tightening torque 31.0 lb·ft (42.0 N·m)
6) Mount the flywheel and tighten new 6 bolts.
NOTE) Use new bolts.
Tightening torque
29.6 ~ 35.5 lb·ft
(40 ~ 48 N·m)
7) Mount the crank pulley and tighten 5 bolts.
Tightening torque 23.7 lb·ft (32.0 N·m)
8) Mount the stays (2 places) and tighten 2 bolts
(2 places).
Tightening torque 14.8 lb·ft (20.0 N·m)
Starter
Bolts
Pulley
Bolts
(5 pieces)
Bolts
(6 pieces)
Flywheel
Bolts
Bolts
3. Reassemble the engine.
1) Place a wooden block (thickness: approximately
3 inch (80 mm), length: 24 inch (600 mm) or longer) under the compressor bracket.
2) Place 2 wooden blocks (thickness: approximately
1-1/2 inch (40 mm), length: 24 inch (600 mm) or longer) where the engine is placed.
3) Place the new engine on the wooden blocks.
Bracket
Oil pan
Wooden blocks (Thickness : 1-1/2inch)
Wooden block (Thickness : 3inch)
74
4) Mount the brackets (both sides) and tighten 4 bolts.
Tightening torque 14.8 lb·ft (20.0 N·m)
REPLACEMENT OF MAIN COMPONENTS
5) Fix the engine by tightening 2 bolts of engine mount
(both sides).
Tightening torque 31.0 lb·ft (42.0 N·m)
Bolts (4 pieces)
Bracket
6) Mount 3 compressor brackets to the engine and tighten 11 connecting bolts (2 of the bolts are installed from the engine side).
Tightening torque 31.0 lb·ft (42.0 N·m)
Bolts
Bolts
Engine mount
Bolts
7) Mount the rear side bracket and tighten 4 bolts in the order shown right.
①④ Tightening torque
②③ Tightening torque
14.8 lb·ft (20.0 N·m)
31.0 lb·ft (42.0 N·m)
Bolts (installed from the engine side)
④
①
②
③
Rear side
75
REPLACEMENT OF MAIN COMPONENTS
8) Mount the front side bracket and tighten 5 bolts in the order shown right.
①② Tightening torque
③~⑤ Tightening torque
14.8 lb·ft (20.0 N·m)
31.0 lb·ft (42.0 N·m)
9) Remove the 3 wooden blocks under the compressor bracket and oil pan.
Front side
②
③
④
⑤
①
4. Reassemble the exhaust water drain filter box.
1) Mount the box and tighten 2 bolts.
Tightening torque 14.8 lb·ft (20.0 N·m)
2) Connect the 3 exhaust water drain hoses to the box.
3) Mount the stay and tighten 2 bolts.
Tightening torque
3.7 ± 1.1 lb·ft
(5.0 ± 1.5 N·m)
Bolts
Exhaust water drain hoses
Bolts
NOTE) Connect the connector of the exhaust water drain filter if the drain heater kit is installed.
Heater
5. Connect the air intake hose and the fuel gas hose to the engine.
Fuel gas hose Air intake hose
76
6. Mount the compressor belt.
1) Attach the compressor belt.
2) Lightly tighten 4 mounting bolts of front side compressor.
3) Adjust the belt tension with the adjustment bolt.
REPLACEMENT OF MAIN COMPONENTS
Compressor belt
Bolts
31.0 lb·ft (42.0 N·m)
Adjustment bolt
Belt tension ※
Belt tension adjustment standard (Replacement) Belt tension adjustment standard (Inspection)
Sonic
225 ~ 270 lbf (1,000 ~ 1,200 N)
Mechanical
(Reference value)
155 lbf (690 N)
Sonic
180 ~ 216 lbf (800 ~ 960 N)
Mechanical
(Reference value)
124 lbf (550 N)
※ Measure the belt tension with a sonic belt tension gauge. Tension values for a mechanical belt tension gauge on the chart are reference values.
4) After adjusting the belt tension, tighten the locknut to fix the compressor.
Tightening torque
7.4 ~ 11.1 lb·ft
(10 ~ 15 N·m)
Bolts
5) Tighten up 4 bolts.
Tightening torque
Locknut
Nuts Exhaust air heat exchanger
7. Reassemble the exhaust air heat exchanger.
1) Attach the exhaust air heat exchanger to the engine temporarily. Then tighten 2 nuts to fix the stay.
NOTE) Replace the gasket before mounting the exhaust air heat exchanger.
Tightening torque 14.8 lb·ft (20.0 N·m)
77
REPLACEMENT OF MAIN COMPONENTS
2) Fix the exhaust air heat exchanger and stay by tightening 2 nuts.
Tightening torque 14.8 lb·ft (20.0 N·m)
Nuts
3) Fix the exhaust air heat exchanger and stay by tightening 2 bolts.
Tightening torque 14.8 lb·ft (20.0 N·m)
4) Connect the exhaust hose to the exhaust air heat exchanger.
Bolts
5) Mount the exhaust pipe. Tighten it with 2 nuts and
2 bolts.
NOTE)
Replace the gasket before mounting the exhaust pipe.
The outdoor unit has the deodorizing catalyst instead of the exhaust pipe if the deodorant kit is installed.
Tightening torque 14.8 lb·ft (20.0 N·m)
8. Install each wire harness
1) Connect the 2 wire harnesses to the starter.
2) Connect the connector to the engine speed sensor.
Exhaust air heat exchanger
Bolts
Exhaust pipe
Exhaust hose
Nuts
78
Engine speed sensor
Starter
REPLACEMENT OF MAIN COMPONENTS
3) Connect the 2 relay connectors of the gas mixer wire harnesses.
4) Connect the relay connector of engine oil pressure switch wire harness.
5) Connect the connectors (3 places) to the 4 ignition coils.
6) Connect the relay connector of the engine coolant temperature sensor wire harness.
Ignition coils
Gas mixer
9. Mount the thermostat and fix it to the outdoor unit by tightening a bolt.
Tightening torque
8.9 ± 2.7 lb·ft
(12.0 ± 3.6 N·m)
Engine oil pressure switch
Engine coolant temperature sensor
Bolt
Thermostat
10. Connect the breather hose to the exhaust air heat exchanger.
11. Connect the 2 engine coolant hoses to the engine.
Engine coolant hose Breather hose
12. Mount the engine mount parts.
1) Put the cover over the oil level switch, and tighten
2 bolts.
Tightening torque
2.2 ± 0.7 lb·ft
(3.0 ± 0.9 N·m)
2) Mount the stay and tighten 2 bolts.
Tightening torque
8.9 ± 2.7 lb·ft
(12.0 ± 3.6 N·m)
Stay
Bolts Bolts Cover
79
REPLACEMENT OF MAIN COMPONENTS
3) Mount 2 oil trays and tighten 2 bolts.
Tightening torque
2.2 ± 0.7 lb·ft
(3.0 ± 0.9 N·m)
13. Mount the engine coolant pump.
1) Mount the engine coolant pump and tighten 2 bolts.
Tightening torque
3.7 ± 1.1 lb·ft
(5.0 ± 1.5 N·m)
2) Mount the cover and tighten 2 bolts.
Tightening torque
3.7 ± 1.1 lb·ft
(5.0 ± 1.5 N·m)
Bolts
3) Connect the 2 engine coolant hoses at the outlet and inlet ports of the engine coolant pump to the engine coolant pump.
Bolts
Engine coolant hoses
Bolts
14. Connect the 3 oil hoses to the engine.
15. Check that all the hoses are securely fixed.
16. Remove all the hose clippers clamping the hoses.
Oil hoses
Sub oil reservoir
Oil hose
80
17. Refill the engine coolant.
1) Open the radiator cap, and fill the radiator with the engine coolant to the full capacity.
Engine coolant concentration
(volumetric concentration)
50 ~ 60 vol%
(engine coolant: 0.55, water: 0.45).
2) Check the engine coolant level in the reserve tank, and refill the engine coolant until the engine coolant reaches the reference line.
REPLACEMENT OF MAIN COMPONENTS
Radiator cap
Reference line
18. Supply the specified amount of fresh engine oil through the oil filler port of the sub oil reservoir.
Specified amount 7.9 gal (30 L)
Oil level gauge
Sub oil reservoir
19. Double-check the amount of engine coolant and engine oil.
1) Run the engine coolant pump using check mode "engine coolant refill mode (code No. OA)" of the board maintenance functions.
2) Check the engine coolant level in the radiator. If the level is low, refill the engine coolant until the engine coolant level reaches the full level.
3) Repeat items 1) and 2) until the engine coolant level in the radiator does not lower any more, and close the cap.
4) Check the engine coolant level in the reserve tank, and refill the engine coolant until the engine coolant reaches the reference line.
5) Run the engine and check that the engine runs without problems such as leakage of oil or engine coolant.
6) Check the fuel system parts and connecting points for fuel gas leakage with gas leak detector liquid.
7) Run the engine 10 ~ 20 minutes and measure the belt tension again. If the belt tension is out of standard range, repeat adjust.
8) Stop the engine and measure the level of the oil in the sub oil reservoir with a engine oil level gauge at least
5 minutes after stopping the engine.
Specified amount B level -3/8 ~ 0 inch (-10 ~ 0 mm)
81
REPLACEMENT OF MAIN COMPONENTS
[ 15 TON ]
[Removal]
1. Drain engine oil.
1) Clamp the oil hose with 2 hose clippers at both sides of joint.
2) Disconnect the joint and drain oil from the engine and the sub oil reservoir.
3) Disconnect the 3 oil hoses from the engine.
NOTE) Be careful because oil will drip from the oil hoses when you remove the hoses.
Oil hoses
Sub oil reservoir
Clamping positions
Joint
Oil hose
2. Drain engine coolant.
1) Clamp the engine coolant hoses at the outlet and inlet ports of the radiator (2 places) with 2 hose clippers.
Clamping positions
2) Open the radiator cap.
Radiator cap
3) Clamp the oil hose with 2 hose clippers at both sides of joint.
4) Remove the joint, and loosen one hose clipper at a time to drain engine coolant of both sides.
Engine coolant pump
Pump outlet side
Joint
Clamping positions
82
3. Remove the engine coolant pump.
1) Disconnect the engine coolant hose at the engine coolant pump inlet side.
2) Unscrew 2 bolts to remove the cover.
REPLACEMENT OF MAIN COMPONENTS
Pump inlet side
Bolts
3) Unscrew 2 bolts to remove the engine coolant pump.
4. Remove the under engine parts.
1) Unscrew 2 bolts to remove the cover. Remove the oil level switch.
Bolts
2) Unscrew 6 bolts to remove the 2 oil stays.
Bolts
Bolts
3) Unscrew 2 nuts to remove the stay.
Bolts
Nuts
83
REPLACEMENT OF MAIN COMPONENTS
5. Loosen the drain plug cap, and drain engine coolant from the engine.
NOTE) It makes draining easier to insert a hose with approximately 1/4 inch (7 mm) inner diameter into the drain plug.
Drain plug
6. Remove the 2 engine coolant hoses and the breather hose from the exhaust air heat exchanger.
Breather hose
Exhaust air heat exchanger
Engine coolant hoses
7. Unscrew a bolt connecting the thermostat to the outdoor unit, and separate the thermostat.
Bolt
8. Disconnect each wire harness.
1) Disconnect 2 wire harnesses from the starter.
2) Disconnect 2 relay connectors of the gas mixer wire harness.
3) Disconnect 2 connectors from the engine speed sensor.
4) Disconnect a relay connector of engine oil pressure switch wire harness.
5) Disconnect a relay connector for the igniter.
6) Disconnect a relay connector of the engine coolant temperature sensor wire harness.
Igniter
Thermostat
Gas mixer
Engine coolant t e m p e r a t u r e sensor
84
Starter
Engine speed sensors
Engine oil pressure switch
9. Remove the muffler.
1) Unscrew 2 nuts.
2) Disconnect the 2 pipes at the outlet and inlet ports of muffler and remove the muffler.
REPLACEMENT OF MAIN COMPONENTS
Muffler Nuts
Pipes
10. Remove the exhaust air heat exchanger.
1) Unscrew 2 bolts and 2 nuts to remove the exhaust pipe.
NOTE) The outdoor unit has the deodorizing catalyst instead of the exhaust pipe if the deodorant kit is installed.
Nuts
Exhaust pipe
2) Unscrew 2 bolts and 2 nuts to remove the exhaust air heat exchanger.
Exhaust air heat exchanger
Bolts
Bolts
Nuts
11. Remove the compressor belt.
1) Unscrew 5 bolts to remove the front side stay.
85
Front side
Bolts (5 pieces)
REPLACEMENT OF MAIN COMPONENTS
2) Loosen a locknut and an adjustment bolt adequately.
3) Loosen 4 bolts in the front of the outdoor unit, and remove the compressor belt.
Bolts
Compressor belt
12. Disconnect the air intake hose and the fuel gas hose from the engine.
Fuel gas hose
Locknut
Adjustment bolt
Air intake hose
13. Remove the exhaust water drain filter box.
1) Disconnect the 3 exhaust water drain hoses from the box.
Exhaust water drain hoses
2) Unscrew a bolt to remove the box.
NOTE) Do not tilt the box when removing it, because the box contains exhaust drain water.
NOTE) Disconnect the connector of the exhaust water drain filter if the drain heater kit is installed.
Bolt
Heater
Box
86
14. Dismount the engine.
1) Place a wooden block (thickness: approximately
2 inch (55 mm), length: 24 inch (600 mm) or longer) under the compressor bracket.
2) Place 2 wooden blocks (thickness: approximately
4-1/2 inch (115 mm), length: 24 inch (600 mm) or longer) under the oil pan.
REPLACEMENT OF MAIN COMPONENTS
Bracket
Oil pan
3) Unscrew 5 bolts to remove the bracket (both sides).
Wooden blocks (Thickness:4-1/2inch)
Wooden block (Thickness : 2inch)
Bolts
4) Unscrew 11 connecting bolts between the compressor bracket and engine (2 of the bolts are installed from the engine side), and separate the compressor bracket from the engine.
Bolts
Bolts
Bolts (installed from the engine side)
5) Check if the hoses or wire harnesses are disconnected from the engine. If connected, disconnect the hoses or wire harnesses.
6) Unscrew 2 bolts of engine mount bracket (both sides).
Bolts
Bracket
87
REPLACEMENT OF MAIN COMPONENTS
7) Unscrew 2 bolts to remove the bracket (front side).
Bolts Front side
8) Unscrew 4 bolts to remove the bracket (rear side).
Dismount the engine.
NOTE) When placing the engine on the floor, place wooden blocks, rag or other appropriate material on the floor and put the engine on it carefully so that the pipes on the bottom of the oil pan will not be damaged.
15. Remove the surrounding parts of engine.
1) Unscrew 6 bolts to remove the flywheel.
2) Unscrew 2 bolts to remove the starter.
Bolts
(6 pieces)
Rear side Bolts (4 pieces)
Bolts
Flywheel
Starter
3) Unscrew 4 bolts to remove the bracket.
Bolts
Bracket
4) Disconnect the blow-by hose.
5) Unscrew a bolt and 2 nuts to remove the gas mixer.
Blow-by hose
Nuts
Bolt
Gas mixer
88
[Reassembling]
1. Mount the surrounding parts on the new engine.
1) Mount the gas mixer. Tighten it with a bolt and
2 nuts.
NOTE) Replace the gasket before installing the gas mixer.
Tightening torque 14.8 lb·ft (20.0 N·m)
2) Connect the blow-by hose.
REPLACEMENT OF MAIN COMPONENTS
Blow-by hose
Nuts
Bolt
Gas mixer
3) Mount the bracket and tighten 4 bolts.
Tightening torque 52.5 lb·ft (71.0 N·m)
Bolts
Bracket
4) Mount the starter and tighten 2 bolts.
Tightening torque 31.0 lb·ft (42.0 N·m)
Bolts
5) Mount the flywheel and tighten 6 bolts.
Tightening torque
57.7 ~ 65.1 lb·ft
(78 ~ 88 N·m)
Bolts
(6 pieces)
Flywheel
Starter
89
REPLACEMENT OF MAIN COMPONENTS
2. Reassemble the engine.
1) Place a wooden block (thickness: approximately
2 inch (55 mm), length: 24 inch (600 mm) or longer) under the compressor bracket.
2) Place 2 wooden blocks (thickness: approximately
4-1/2 inch (115 mm), length: 24 inch (600 mm) or longer) where the engine is placed.
3) Place the new engine on the wooden blocks.
Bracket Oil pan
4) Mount the rear side bracket and tighten 4 bolts.
Tightening torque 31.0 lb·ft (42.0 N·m)
Wooden blocks (Thickness : 4-1/2inch)
Wooden block (Thickness : 2inch)
Rear side Bolts (4 pieces)
5) Tighten 2 bolts of engine mount bracket.
Tightening torque 31.0 lb·ft (42.0 N·m)
6) Mount the front side bracket and tighten 2 bolts.
Tightening torque 31.0 lb·ft (42.0 N·m)
Bracket
Front side
Bolts
Rear side
Bolts
90
7) Tighten 2 bolts of engine mount bracket.
Tightening torque 31.0 lb·ft (42.0 N·m)
REPLACEMENT OF MAIN COMPONENTS
Front side
8) Mount 3 compressor brackets to the engine and tighten 11 connecting bolts (2 of the bolts are installed from the engine side).
Tightening torque 31.0 lb·ft (42.0 N·m)
Bolts
Bolts
Bracket
Bolts
9) Mount the brackets (both sides) and tighten 5 bolts
(both sides) in the order shown right.
Tightening torque 31.0 lb·ft (42.0 N·m)
10) Remove the 3 wooden blocks under the compressor bracket and oil pan.
Bolts (installed from the engine side)
②
③
①
④
⑤
3. Reassemble the exhaust water drain filter box.
1) Mount the box and tighten 1 bolts.
NOTE) Do not tilt the box when installing it, because the box contains exhaust drain water.
Tightening torque
8.9 ± 2.7 lb·ft
(12.0 ± 3.6 N·m)
NOTE) Connect the connector of the exhaust water drain filter if the drain heater kit is installed.
Bolt
Heater
91
REPLACEMENT OF MAIN COMPONENTS
2) Connect the 3 exhaust water drain hoses to the box.
Box
Exhaust water drain hose
4. Connect the air intake hose and the fuel gas hose to the engine.
Fuel gas hose
Air intake hose
5. Mount the compressor belt.
1) Attach the compressor belt.
2) Lightly tighten 4 mounting bolts of front side compressor.
3) Adjust the belt tension with the adjustment bolt.
Bolts
Compressor belt
Adjustment bolt
Belt tension ※
Belt tension adjustment standard (Replacement) Belt tension adjustment standard (Inspection)
Sonic
301 ~ 346 lbf (1,340 ~ 1,540 N)
Mechanical
(Reference value)
202 lbf (900 N)
Sonic
241 ~ 277 lbf (1,070 ~ 1,230 N)
Mechanical
(Reference value)
162 lbf (720 N)
※ Measure the belt tension with a sonic belt tension gauge. Tension values for a mechanical belt tension gauge on the chart are reference values.
4) After adjusting the belt tension, tighten the locknut to fix the compressor.
Tightening torque
7.4 ~ 11.1 lb·ft
(10 ~ 15 N·m)
Bolts
5) Tighten up 4 bolts.
Tightening torque 31.0 lb·ft (42.0 N·m)
Locknut
92
6. Mount the front side stay and tighten 5 bolts.
Tightening torque
31.0 ± 6.2 lb·ft
(42.0 ± 8.4 N·m)
REPLACEMENT OF MAIN COMPONENTS
7. Reassemble the exhaust air heat exchanger.
1) Mount the bracket and tighten 2 nuts.
Tightening torque 31.0 lb·ft (42.0 N·m)
2) Mount the stay and tighten 2 bolts.
Tightening torque 31.0 lb·ft (42.0 N·m)
Exhaust air heat exchanger
Front side
Bolts
Bolts (5 pieces)
Nuts
3) Mount the exhaust pipe. Tighten it with 2 nuts and
2 bolts.
NOTE)
Replace the gasket before mounting the exhaust pipe.
The outdoor unit has the deodorizing catalyst instead of the exhaust pipe if the deodorant kit is installed.
Tightening torque 14.8 lb·ft (20.0 N·m)
Nuts
Exhaust pipe
Muffler
Nuts
Bolts
8. Mount the muffler.
1) Mount the muffler to the stay and tighten 2 nuts lightly.
Tightening torque
8.9 ± 2.7 lb·ft
(12.0 ± 3.6 N·m)
2) Tighten 2 nuts firmly.
Tightening torque
8.9 ± 2.7 lb·ft
(12.0 ± 3.6 N·m)
NOTE) Be sure to tighten 2 nuts lightly and firmly.
93
REPLACEMENT OF MAIN COMPONENTS
3) Connect the 2 pipes at the outlet and inlet ports of muffler, and install the muffler.
Muffler
Pipes
9. Install each wire harness
1) Connect the 2 wire harnesses to the starter.
2) Connect the 2 relay connectors of the gas mixer wire harnesses.
3) Connect the 2 connectors to the engine speed sensor.
4) Connect the relay connector of engine oil pressure switch wire harness.
5) Connect the connector of the igniter.
6) Connect the relay connector of the engine coolant temperature sensor wire harness.
Igniter Gas mixer
Engine coolant t e mp e r a t u r e sensor
10. Mount the thermostat and fix it to the outdoor unit by tightening a bolt.
Tightening torque
8.9 ± 2.7 lb·ft
(12.0 ± 3.6 N·m)
Starter
Engine speed sensors
Engine oil pressure switch
Bolt
11. Connect the 2 engine coolant hoses and the breather hose to the exhaust air heat exchanger.
Thermostat
Breather hose Exhaust air heat exchanger
94
Engine coolant hoses
12. Mount the engine mount parts.
1) Mount the stay and tighten 2 nuts.
Tightening torque
8.9 ± 2.7 lb·ft
(12.0 ± 3.6 N·m)
REPLACEMENT OF MAIN COMPONENTS
Nuts
2) Mount 2 oil trays and tighten 6 bolts.
Tightening torque for oil tray ①
Tightening torque for oil tray ②
2.2 ± 0.7 lb·ft
(3.0 ± 0.9 N·m)
3.7 ± 1.1 lb·ft
(5.0 ± 1.5 N·m)
Bolts
Oil tray ①
Bolts
Ooil tray ②
3) Put the cover over the oil level switch, and tighten
2 bolts.
Tightening torque
1.6 ± 0.5 lb·ft
(2.2 ± 0.7 N·m)
Bolts
13. Mount the engine coolant pump.
1) Mount the engine coolant pump and tighten 2 bolts.
Tightening torque
3.7 ± 1.1 lb·ft (5.0 ± 1.5
N·m)
2) Connect the 2 engine coolant hoses at the outlet and inlet sides of the engine coolant pump to the engine coolant pump.
3) Mount the cover and tighten 2 bolts.
Tightening torque 3.7 ± 1.1 lb·ft (5.0 ± 1.5 N·m)
Bolts
Engine coolant hoses
Bolts
95
REPLACEMENT OF MAIN COMPONENTS
14. Connect the 3 oil hoses to the engine.
15. Check that all the hoses are securely fixed.
16. Remove all the hose clippers clamping the hoses.
Oil hoses
17. Refill the engine coolant.
1) Open the radiator cap, and fill the radiator with the engine coolant to the full capacity.
Engine coolant concentration (volumetric concentration)
50 ~ 60 vol%
(engine coolant: 0.55,
water: 0.45).
2) Check the engine coolant level in the reserve tank, and refill the engine coolant until the engine coolant reaches the reference line.
Sub oil reservoir
Radiator cap
Reference line
18. Refill the engine oil.
1) Check that all oil hoses are connected.
2) Supply the specified amount of fresh engine oil through the oil filler port of the sub oil reservoir.
Specified amount 8.45 gal (32 L)
Oil level gauge
Oil filler port
19. Double-check the amount of engine coolant and engine oil.
1) Run the engine coolant pump using check mode "engine coolant refill mode (code No. OA)" of the board maintenance functions.
2) Check the engine coolant level in the radiator. If the level is low, refill the engine coolant until the engine coolant level reaches the full level.
3) Repeat items 1) and 2) until the engine coolant level in the radiator does not lower any more, and close the cap.
4) Check the engine coolant level in the reserve tank, and refill the engine coolant until the engine coolant reaches the reference line.
5) Run the engine and check that the engine runs without problems such as leakage of oil or engine coolant.
6) Check the fuel system parts and connecting points for fuel gas leakage with gas leak detector liquid.
7) Run the engine 10 ~ 20 minutes and measure the belt tension again. If the belt tension is out of standard range, repeat adjust.
8) Stop the engine and measure the level of the oil in the sub oil reservoir with a engine oil level gauge at least
5 minutes after stopping the engine.
Specified amount A level -3/8 ~ 0 inch (-10 ~ 0 mm)
96
REPLACEMENT OF MAIN COMPONENTS
3. Replacement of Cylinder Head
[Necessary items]
Parts
Part name
Set, Cylinder Head ASSY
AISIN Coolant S
AISIN Gas Engine Oil L-10000G
[ 8 TON ]
[Removal]
1. Drain engine coolant.
1) Clamp the engine coolant hoses at the outlet and inlet ports of the radiator (2 places) with 2 hose clippers.
Part No.
See parts catalog
Clamping positions
Quantity
1
1
Small amount
2) Open the radiator cap.
3) Loosen the drain plug cap, and drain engine coolant from the engine.
Drain plug
Radiator cap
4) Remove the 2 engine coolant hoses from the engine.
Engine coolant hoses
97
REPLACEMENT OF MAIN COMPONENTS
2. Disconnect each wire harness.
1) Disconnect 2 relay connectors of the gas mixer wire harness.
2) Disconnect connectors from the ignition coils
(3 places).
3) Disconnect a relay connector of the engine coolant temperature sensor wire harness.
Ignition coils
Gas mixer
3. Pull the caps to remove the cables. (3 places)
4. Remove the spark plugs with a plug wrench.
(3 places)
Engine coolant temperature sensor
Caps (3 places)
Spark plugs
(3 places)
5. Remove the surrounding parts of exhaust air heat exchanger.
1) Unscrew 2 nuts and 2 bolts to remove the exhaust pipe.
NOTE) The outdoor unit has the deodorizing catalyst instead of the exhaust pipe if the deodorant kit is installed.
Bolts
Exhaust pipe
2) Unscrew 4 nuts to remove the stay.
Nuts
Nuts
6. Disconnect the air intake hose and the oil hose from the engine.
Air intake hose
Oil hose
98
7. Remove the surrounding parts of cylinder head.
1) Unscrew a bolt to remove the blow-by hose.
REPLACEMENT OF MAIN COMPONENTS
Bolt
2) Unscrew 6 bolts to remove the intake manifold.
Bolts (6 pieces)
3) Unscrew the 3 bolts (3 places) and remove the
3 ignition coils.
Bolts
4) Unscrew 4 bolts to remove the 2 stays.
Bolts
5) Loosen 3 nuts to remove the cylinder head cover.
Bolts
Nuts
99
REPLACEMENT OF MAIN COMPONENTS
8. Remove the cylinder head.
1) Loosen 3 nuts to remove the rocker shaft ASSY
NOTE) The valve stem caps stick to the rocker shaft
ASSY with engine oil. Take care not to drop the valve stem caps into the engine.
2) Remove 6 valve stem caps.
3) Remove 6 push rods.
NOTE) Place the push rods in the order they are removed.
Nuts
Valve stem cap
Push rods
Rocker shaft
4) Remove 3 stud bolts.
5) Loosen 14 bolts evenly in the order shown right in several rounds, and remove the cylinder head.
NOTE) Take care not to damage the mounting surface of the cylinder head.
Valve
Stud bolts
9. Remove the surrounding parts from the cylinder head.
1) Unscrew 2 bolts to remove the water inlet bracket.
2) Unscrew 2 bolts to remove the water outlet bracket.
Water outlet bracket
Bolts
3) Unscrew 6 nuts to remove the exhaust manifold.
Bolts
Nuts (6 pieces)
Water inlet bracket
4) Remove 6 stud bolts.
Stud bolts (6 pieces)
100
REPLACEMENT OF MAIN COMPONENTS
[Reassembling]
1. Remove completely the gasket or dirt sticking to the sealing surface such as the cylinder block upper surface, water inlet bracketor water outlet bracket with a scraper or a gasket remover.
NOTE)
Make sure that dust does not enter the oil inlet, engine coolant inlet or bolt hole.
Never use a gasket remover on anything other than metallic portions.
If there is water or oil spill in a bolt hole, remove it with rag.
(If not, the spill may ooze when a bolt is tightened, which may cause a sealing failure.)
2. Install the surrounding parts to the new cylinder head.
1) Mount 6 stud bolts.
Stud bolts (6 pieces)
2) Mount the exhaust manifold and tighten 6 nuts.
NOTE) Replace the gasket before mounting the exhaust manifold.
Tightening torque 14.8 lb·ft (20.0 N·m)
3) Mount the water inlet bracket with 2 bolts.
4) Mount the water outlet bracket with 2 bolts.
NOTE) Replace the gasket before mounting the water inlet bracket and water outlet bracket.
Nuts (6 pieces)
Water outlet bracket
Bolts
Water inlet bracket
3. Reassemble the cylinder head.
1) Mount a new gasket on the cylinder block carefully in the correct direction.
Bolts
2) Apply engine oil to the 14 bolts to tighten the bolts evenly in the order shown right in several rounds.
Tightening torque 25.1 lb·ft (34 N·m)
3) Mount 3 stud bolts.
Stud bolts
FRONT side
101
REPLACEMENT OF MAIN COMPONENTS
4) Apply engine oil to the both ends of the 6 push rods, and install them in the order of removal.
5) Mount the 6 valve stem caps on the valve.
6) Mount the rocker shaft so that the adjustment screws come into the cup of the push rods, and tighten 3 nuts.
NOTE) Take care not to drop the valve stem cap into the engine.
Tightening torque 14.8 lb·ft (20.0 N·m)
Valve stem cap
Valve
Nuts
4. Pour engine oil on the rocker arm portion evenly.
Rocker shaft
5. Mount the surrounding parts on the cylinder head.
1) Attach the cylinder head cover with 3 nuts.
NOTE) Wipe off the oil on the sealing surface before mounting the cylinder head.
Nuts
2) Mount the 2 stays with 4 bolts.
3) Mount the 3 ignition coils with 3 bolts (3 places).
Bolts
Bolts
Push rods
Cylinder head cover
Bolts
102
4) Mount the intake manifold with 6 bolts.
NOTE) Replace the gasket before mounting the intake manifold.
REPLACEMENT OF MAIN COMPONENTS
Bolts (6 pieces)
5) Mount the blow-by hose and tighten the bolt.
Tightening torque 6.3 lb·ft (8.5 N·m)
6. Connect the air intake hose and the oil hose to the engine.
Bolts
Air intake hose
Oil hose
7. Mount the surrounding parts of exhaust air heat exchanger.
1) Mount the stay and tighten 4 nuts.
Tightening torque 14.8 lb·ft (20.0 N·m)
2) Mount the exhaust pipe. Tighten it with 2 nuts and
2 bolts.
NOTE)
Replace the gasket before mounting the exhaust pipe.
The outdoor unit has the deodorizing catalyst instead of the exhaust pipe if the deodorant kit is installed.
Tightening torque 14.8 lb·ft (20.0 N·m)
Bolts Exhaust pipe
103
Nuts
Nuts
REPLACEMENT OF MAIN COMPONENTS
8. Install each wire harness
1) Connect the 2 relay connectors of the gas mixer wire harness.
2) Connect the 3 connectors to the ignition coils.
3) Connect the relay connector of the engine coolant temperature sensor wire harness.
Ignition coils Gas mixer
9. Connect the engine coolant hose.
1) Connect the 2 engine coolant hoses to the engine.
Engine coolant temperature sensor
Engine coolant hoses
10. Adjust the valve clearance.
Clearance adjustment value
When the engine is cold.
0.010 ± 0.002 inch
(0.25 ± 0.05 mm)
When the engine is hot.
0.014 ± 0.002 inch
(0.35 ± 0.05 mm)
NOTE) Refer to P56, [Engine Valve Clearance Inspection / Adjustment (8 TON only)] for detailed procedure.
11. Mount the spark plugs with a plug wrench. (3 places)
12. Connect the high voltage cables. (3 places)
Front side
Adjustment nuts
Caps
(3 places)
Spark plugs
(3 places)
13. Refill the engine coolant.
1) Check that all the hoses are securely fixed.
2) Remove all the hose clippers clamping the hoses.
3) Open the radiator cap, and fill the radiator with the engine coolant to the full capacity.
Engine coolant concentration (volumetric concentration) 50 ~ 60 vol% (engine coolant: 0.55, water: 0.45).
104
REPLACEMENT OF MAIN COMPONENTS
4) Check the engine coolant level in the reserve tank, and refill the engine coolant until the engine coolant reaches the reference line.
5) Run the engine coolant pump using check mode
"engine coolant refill mode (code No. OA)" of the board maintenance functions.
6) Check the engine coolant level in the radiator. If the level is low, refill the engine coolant until the engine
Reference line
Reserve tank coolant level reaches the full level.
7) Repeat items 5) and 6) until the engine coolant level in the radiator does not lower any more, and close the cap.
8) Check the engine coolant level in the reserve tank, and refill the engine coolant until the engine coolant reaches the reference line.
14. Using a compression gauge, check that fuel gas is compressed to the specified pressure.
Specified compression value
Compression limit
203 psi (1.4 MPa) or higher
160 psi (1.1 MPa)
15. Run the engine and check that the engine runs without problems such as leakage of oil or engine coolant.
105
REPLACEMENT OF MAIN COMPONENTS
[ 15 TON ]
[Removal]
1. Drain engine coolant.
1) Clamp the engine coolant hoses at the outlet and inlet ports of the radiator (2 places) with 2 hose clippers.
Clamping positions
2) Loosen the drain plug cap, and drain engine coolant from the engine.
Drain plug
3) Clamp the oil hose with 2 hose clippers at both sides of joint.
4) Remove the joint, and loosen one hose clipper at a time to drain engine coolant of both sides.
5) Install the joint as before, and remove both hose clippers.
Clamping positions
2. Remove the 3 engine coolant hoses from the engine.
Joint
Pump outlet side
Engine coolant pump
Engine coolant hoses
106
3. Remove the muffler.
1) Unscrew 2 nuts.
2) Disconnect the 2 pipes at the outlet and inlet ports of muffler and remove the muffler.
REPLACEMENT OF MAIN COMPONENTS
Muffler Nuts
4. Remove the exhaust air heat exchanger.
1) Unscrew 2 bolts and 2 nuts to remove the exhaust pipe.
NOTE) The outdoor unit has the deodorizing catalyst instead of the exhaust pipe if the deodorant kit is installed.
Nuts
Pipes
2) Unscrew 2 bolts and 2 nuts to remove the exhaust air heat exchanger.
Bolts
Exhaust pipe Bolts
5. Disconnect each wire harness.
1) Disconnect a relay connector of the engine coolant temperature sensor wire harness.
2) Disconnect 2 relay connectors of the gas mixer wire harness.
3) Disconnect a relay connector for the igniter wire harness.
Igniter
Nuts
Gas mixer
Engine coolant temperature sensor
107
REPLACEMENT OF MAIN COMPONENTS
6. Disconnect the air intake hose, the fuel gas hose and the oil hose from the engine.
Fuel gas hose
Oil hose
Air intake hose
7. Disconnect the blow-by hose.
Blow-by hose
8. Pull the caps to remove the cables (4 places).
9. Remove the spark plugs with a plug wrench.
(4 places)
Spark plugs
(4 places)
Caps
(4 places)
10. Remove the surrounding parts of cylinder head.
1) Unscrew 2 bolts and 2 nuts. Remove the igniter and
4 ignition coils with the bracket.
Bracket
Nuts
108
Bolts
2) Unscrew 6 bolts and 2 nuts to remove the exhaust manifold.
REPLACEMENT OF MAIN COMPONENTS
Bolts (6 pieces)
3) Unscrew 3 bolts and 2 nuts to remove the oil return pipe.
Bolts
Nuts
Nuts
4) Unscrew a bolt to remove the front side engine hanger.
5) Unscrew 2 bolts to remove the rear side engine hanger.
Rear side
Bolts
6) Unscrew 2 bolts to remove the water outlet bracket.
Bolts
Front side
Bolt
109
REPLACEMENT OF MAIN COMPONENTS
7) Unscrew 3 bolts to remove the cylinder head cover.
Cylinder head cover
Bolts
11. Remove the cylinder head.
1) Loosen the bolts and nuts evenly in several rounds in the order shown right, and remove the rocker shaft assembly.
2) Remove the push rods.
NOTE) Place the push rods in the order they are removed.
3) Loosen 13 bolts evenly in the order shown right in several rounds, and remove the cylinder head.
NOTE) Take care not to damage the mounting surface of the cylinder head.
FRONT side
110
REPLACEMENT OF MAIN COMPONENTS
[Reassembling]
1. Remove completely the old gasket or dirt sticking to the cylinder block upper surface and sealing surface of the exhaust manifold and other parts with a scraper or a gasket remover.
NOTE)
Make sure that dust does not enter the oil inlet, engine coolant inlet or bolt hole.
Never use a gasket remover on anything other than metallic portions.
If there is water or oil spill in a bolt hole, remove it with rag. (If not, the spill may ooze when a bolt is tightened, which may cause a sealing failure.)
2. Reassemble the new cylinder head.
1) Mount a new gasket on the cylinder block carefully in the correct direction.
FRONT side
2) Apply engine oil to the 13 bolts to tighten the bolts evenly in the order shown right in several rounds.
Tightening torque
M12 (Large)
M8 (Small)
65.1 lb·ft (88.2 N·m)
14.0 lb·ft (19.0 N·m)
FRONT side
3) Apply engine oil to the both ends of the push rods, and install the push rods in the order of removal.
NOTE)
Position the push rods as shown right using an
SST.
Insert the push rods surely into the sheet portion of the valve lifters.
Push rod
SST
Push rod
4) Mount the rocker shaft assembly by tightening the bolts and nuts in the order shown right.
NOTE) Tighten bolts and nuts so that the push rods do not separate from the rocker arm.
Tightening torque 17.3 lb·ft (23.5 N·m)
3. Pour engine oil on the rocker arm portion evenly.
111
REPLACEMENT OF MAIN COMPONENTS
4. Mount the surrounding parts on the cylinder head.
1) Attach the cylinder head cover with 3 bolts.
Cylinder head cover
Bolts
2) Mount the water outlet bracket with 2 bolts.
NOTE) Replace the gasket before mounting the water outlet bracket.
Bolts
3) Mount the front side engine hanger with a bolt.
4) Mount the rear side engine hanger with 2 bolts.
Rear side
Bolts
5) Mount the oil return pipe with 3 bolts and 2 nuts.
Bolts
Nuts
Front side
Bolt
6) Mount the exhaust manifold with 6 bolts and 2 nuts.
NOTE) Replace the gasket before mounting the exhaust manifold.
112
Nuts
Bolts (6 pieces)
REPLACEMENT OF MAIN COMPONENTS
7) Mount the igniter and 4 ignition coils with the bracket by 2 bolts and 2 nuts.
Bracket
Nuts
Bolts
5. Mount the 4 high voltage cables.
6. Mount the spark plugs with a plug wrench. (4 places)
Spark plugs
(4 places)
Caps
(4 places)
7. Connect the blow-by hose.
Blow-by hose
8. Connect the air intake hose, the fuel gas hose and the oil hose to the engine.
Fuel gas hose
Oil hose
Air intake hose
113
REPLACEMENT OF MAIN COMPONENTS
9. Reassemble the exhaust air heat exchanger.
1) Mount the exhaust air heat exchanger. Tighten it with 2 nuts and 2 bolts.
Tightening torque
Bolts
Nuts
31.0 lb·ft (42.0 N·m)
Bolts
Nuts
2) Mount the exhaust pipe. Tighten it with 2 nuts and
2 bolts.
NOTE)
Replace the gasket before mounting the exhaust pipe.
The outdoor unit has the deodorizing catalyst instead of the exhaust pipe if the deodorant kit is installed.
Tightening torque
Bolts
Nuts
14.8 lb·ft (20.0 N·m)
10. Install each wire harness
1) Connect the relay connector of the engine coolant temperature sensor wire harness.
2) Connect the 2 relay connectors of the gas mixer wire harness.
3) Connect the relay connector of igniter wire harness.
Nuts
Exhaust pipe
Bolts
Gas mixer
Igniter
Engine coolant t e m p e r a t u r e sensor
11. Connect the 3 engine coolant hoses to the engine.
Engine coolant hoses
114
12. Mount the muffler.
1) Mount the muffler to the stay and tighten 2 nuts lightly.
Tightening torque 8.9 lb·ft (12.0 N·m)
2) Tighten 2 nuts firmly.
Tightening torque 8.9 lb·ft (12.0 N·m)
NOTE) Be sure to tighten 2 nuts lightly and firmly.
3) Connect the 2 pipes at the outlet and inlet ports of muffler, and install the muffler.
REPLACEMENT OF MAIN COMPONENTS
Nuts
Muffler
Pipes
13. Refill the engine coolant.
1) Check that all the hoses are securely fixed.
2) Remove all the hose clippers clamping the hoses.
3) Open the radiator cap, and fill the radiator with the engine coolant to the full capacity.
Radiator cap
Engine coolant concentration (volumetric concentration) 50~60 vol% (engine coolant: 0.55, water: 0.45).
4) Check the engine coolant level in the reserve tank, and refill the engine coolant until the engine coolant reaches the reference line.
5) Run the engine coolant pump using check mode
"engine coolant refill mode (code No. OA)" of the board maintenance functions.
6) Check the engine coolant level in the radiator. If the level is low, refill the engine coolant until the engine
Reference line coolant level reaches the full level.
7) Repeat items 5) and 6) until the engine coolant level in the radiator does not lower any more, and close the cap.
8) Check the engine coolant level in the reserve tank, and refill the engine coolant until the engine coolant reaches the reference line.
14. Using a compression gauge, check that fuel gas is compressed to the specified pressure.
Compression limit
Specified compression value
160 psi (1.1 MPa)
203 psi (1.4 MPa) or higher
15. Run the engine and check that the engine runs without problems such as leakage of oil or engine coolant.
115
REPLACEMENT OF MAIN COMPONENTS
4. Replacing the Compressor
[Necessary items]
Parts
Part name
Compressor (supply kit)
Dryer filter
Refrigerant oil (NL10)
Part No.
See parts catalog
Quantity
1 / compressor 1 unit
1
As required
[ 8 TON ]
●
Replace only the compressor that needs replacement although this section shows how to replace 2 compressors at the same time.
[Removal]
1. Perform refrigerant recovery. (Refer to the following diagram.)
Recovery from the outdoor and indoor units at the same time: Recover the refrigerant from the outdoor unit stop valves (liquid and vapor).
Recovery only from the outdoor unit: Recover the refrigerant from the outdoor unit service ports (high pressure and low pressure).
116
NOTE) If the liquid refrigerant accumulates in the accumulator during recovery, warm and vaporize the liquid refrigerant with a heat gun and recover all refrigerant.
REPLACEMENT OF MAIN COMPONENTS
2. Perform the following work while recovering the refrigerant.
1) Remove a clamp fixing the engine coolant pump wire harness to the cover.
2) Remove 2 clamps fixing the engine coolant pump wire harness to the engine coolant pump inlet side hose.
3) Move the engine coolant pump inlet side hose above the oil filter.
Accumulator
Oil filter
Inlet side hose
4) Cut off the bundling bands fixing the compressor heater, compressor clutch (for only No.2 compressor), and electromagnetic compressor capacity valve wire harness.
NOTE) Take care not to damage or cut the wire harnesses when cutting the bundling bands.
NOTE) Confirm the current condition of the wire harnesses so that you can put the wire harnesses back to the original condition with the bundling bands when mounting the compressor.
5) Disconnect the connectors of compressor heater, the clutch (No.2 compressor only) and the electromagnetic compressor capacity valve.
(Do not remove the heater at this time.)
6) Unscrew a bolt and remove the grounding wire.
Harness
Clamps
Compressor heater
Cover
Bolt
Grounding wire
117
REPLACEMENT OF MAIN COMPONENTS
7) Unscrew 2 bolts and move the exhaust water drain filter not to cause an obstrustion.
8) Loosen a locknut and an adjustment bolt adequately.
9) Take out 4 bolts.
NOTE) When removing the mounting bolts, catch the
2 stays (plate-shaped) with your hand so that they do not fall on the bottom plate.
10) Move No. 1 compressor inward, and remove the compressor belt.
No. 1
Bolts
Lock nut Adjustment bolt
Bolts
(4 pieces)
Compressor belt
Stays
3. Check that no refrigerant is left in the main unit, and perform the following work.
1) Turn the compressor pulley (clutch plate as for No.
2 compressor) a few turns by hand.
2) Loosen each 2 bolts of intake (upper side) and discharge ports.
3) Disconnect the oil tube from the compressor unit.
4) Dismount the compressor from the bracket.
NOTE) Take care not to damage the flanges (contact surfaces of the o-rings) of the intake and discharge ports.
Discharge port
Intake port
4. Place the removed compressor on the table approximately 4 inch (100 mm) high, and perform the following work.
1) Unscrew each 2 bolts of compressor capacity electromagnetic valve port and intake port.
2) Unscrew 2 bolts to remove the electromagnetic compressor capacity valve with the stay.
3) Remove the compressor heater from the compressor.
Intake port
Compressor capacity electromagnetic valve port
Bolts
Pulley
Oil tube
Compressor heater
Stay
118
REPLACEMENT OF MAIN COMPONENTS
[Reassembling]
1. Remove the port cover of the new compressor.
Supply the specified amount of refrigeration oil through the intake and discharge ports.
Refrigeration oil name
Specified amount to be supplied
NL10
Intake side 1.7 fl oz. (50 cm
3
)
Discharge side 5 fl oz. (150 cm
3
)
Electromagnetic compressor capacity valve ports
Discharge ports
NOTE) If the refrigerant oil adheres on the surface of the compressor main unit, wipe out all the oil.
2. Mount the new o-rings to the intake and compressor capacity electromagnetic valve ports grooves.
NOTE) Apply refrigeration oil to the o-ring, and install it so that it is not damaged.
Port
Intake side
Electromagnetic compressor capacity valve side
Intake ports
No. 1 (Without clutch)
Inner diameter
Ф 1-1/8 inch ( Ф 29.8 mm)
Ф 5/8 inch ( Ф 17.4 mm)
Ф
Ф
Wire diameter
3/32 inch (
3/32 inch (
Ф
Ф
No. 2 (With clutch)
2.3 mm)
2.3 mm)
3. Mount the compressor heater on the compressor.
NOTE) Mount the compressor heater paying attention to the direction and position of the heater and heater wire harness referring to the right figure.
Compressor heater mounting direction
Wire harness Port side
Spring Pulley side
Compressor heater
Heater wire harness
4. Mount the compressor capacity electromagnetic valve.
1) Mount the stay and tighten 2 bolts.
Tightening torque 6.3 lb·ft (8.5 N·m)
2) Tighten each 2 bolts of compressor capacity electromagnetic valve port and intake (lower side) port.
NOTE) When mounting each port, pay attention so that the o-rings will not be caught.
Tightening torque
8.9 ~ 13.3 lb·ft
(12 ~ 18 N·m)
Intake port
Compressor capacity e l e c t r o m a g n e t i c valve port
Bolts
Stay
119
REPLACEMENT OF MAIN COMPONENTS
5. Check that the steel plate and the bracket under the compressor main unit are in the correct position
(see right).
NOTE) Mount the steel plate so that the bent portion faces down.
Bent portion
6. Mount the compressor on the compressor bracket.
1) To prevent pinching or hooking, move the wire harnesses of the compressor discharge pipe temperature sensor and refrigerant high pressure switch above the discharge pipe (No. 1 compressor) or between the discharge pipe and intake pipe (No. 2 compressor).
2) Connect the oil tube to the compressor. Mount the
No. 2 compressor and No. 1 compressor on the compressor bracket in order.
NOTE) Insert the oil tube until it hits a dead end.
NOTE) Take care so that the flanges (o-ring contact surfaces) of each port are not damaged.
3) Hold the 2 stays (plate-shaped) at No. 2 compressor side under the bracket with your hand paying attention to the direction.Holding the stays, tighten
4 bolts firmly of No. 2 compressor.
Stay mounting position
Rounded corner Bracket side
Sharp corner Base plate side
Bracket side
Stay
Tightening torque 31.0 lb·ft (42 N·m)
4) Attach the compressor belt to the compressor.
Bracket
No.2
Iron plate
Discharge port
Intake port
No.1
Bolts (4 pieces)
Stays
Compressor belt
Oil tube
No.2
Bolts
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REPLACEMENT OF MAIN COMPONENTS
5) Hold the 2 stays (plate-shaped) at No. 1 compressor side under the bracket with your hand paying attention to the direction.Holding the stays, tighten
4 bolts lightly so that the No. 1 compressor moves.
Stay mounting position
Rounded corner Bracket side
Sharp corner Base plate side
Bracket side
No.1
Bolts (4 pieces)
Stay
Stays
7. Mount the intake and discharge ports.
1) Mount the new o-rings to the intake (upper side) and discharge ports grooves.
NOTE) Apply refrigeration oil to the o-ring, and install it so that it is not damaged.
Port
Intake side
Discharge side
Inner diameter
Ф 1-1/8 inch
( Ф 29.8 mm)
Ф 7/8 inch
( Ф 21.6 mm)
Wire diameter
Ф 3/32 inch
( Ф 2.3 mm)
Ф 3/32 inch
( Ф 2.3 mm)
2) Tighten each 2 bolts of intake and discharge ports.
NOTE) When mounting each port, pay attention so that the o-rings will not be caught.
Tightening torque
8.9 ~ 13.3 lb·ft
(12 ~ 18 N·m)
8. Replace the old dryer filter with a new one.
1) Loosen 2 flare nuts with double open-end wrench, and move the nuts upward and downward.
2) Unscrew a bolt to remove the clamp. Remove the dryer filter.
3) Set a new dryer filter carefully in the correct direction.
4) Mount the clamp of dryer filter and tighten a bolt.
Tightening torque
2.2 ± 0.7 lb·ft
(3.0 ± 0.9 N·m)
5) Tighten 2 flare nuts with double wrench.
NOTE) Remove the foreign objects at the flare portion of flare nuts. Apply the refrigerant oil to nuts to tighten the nuts.
Tightening torque
18.4 ± 3.7 lb·ft
(25.0 ± 5.0 N·m)
Bolt
Clamp
Discharge port
Flare nut
Flare nut
Intake port
Dryer filter
121
REPLACEMENT OF MAIN COMPONENTS
9. Perform the following work while vacuuming (operating the vacuum pump for 1 hour or longer after the pressure drops to -14.65 psi (-101 kPa, -755 mmHg) or lower).
1) Move the No. 1 compressor until the compressor belt is tight, and tighten 4 bolts lightly.
Compressor belt
Bolts
NOTE) After mounting the compressor, tighten bolts lightly before giving the tension to the compressor belt, and check that the compressor is in the correct position.
Compressor belt
2) Slide the No. 1 compressor by turning the adjustment bolt to give tension to the compressor belt.
Adjust the belt tension to the standard value, and tighten 4 bolts firmly.
Tightening torque 31.0 lb·ft (42 N·m)
Compressor belt
Belt tension ※
Belt tension adjustment standard (Replacement)
Sonic
225 ~ 270 lbf (1,000 ~ 1,200 N)
Mechanical
(Reference value)
155 lbf (690 N)
Bolts
Adjustment bolt
Belt tension ※
Belt tension adjustment standard (Inspection)
Sonic
180 ~ 216 lbf (800 ~ 960 N)
Mechanical
(Reference value)
124 lbf (550 N)
Locknut
※ Measure the belt tension with a sonic belt tension gauge. Tension values for a mechanical belt tension gauge on the chart are reference values.
122
NOTE) Make sure that misalignment between the edge line of the crank pulley groove and the edge line of the compressor pulley groove is
1/8 inch (3 mm) or less when measured on the crankshaft axis.
3) Tighten a locknut of the adjustment bolt.
Tightening torque
7.4 ~ 11.1 lb·ft
(10 ~ 15 N·m)
REPLACEMENT OF MAIN COMPONENTS
3/8 inch or less
Crank pulley
Compressor pulley
4) Tighten 2 bolts to mount the exhaust water drain filter box.
Tightening torque 14.8 lb·ft (20.0 N·m)
Bolts
Compressor heater
5) Mount the grounding wire with a bolt.
6) Connect the connectors of the compressor heaters, the clutch (No. 2 compressor only) and the electromagnetic compressor capacity valve.
7) Fix the wire harnesses to their original positions with bundling bands.
Bolt
Grounding wire
Inlet side hose
8) Install the engine coolant pump inlet side hose as before. Fix the engine coolant pump wire harness to the engine coolant pump inlet side hose and the cover with 3 clamps.
9) Refill the refrigerant oil as required.
Clamps
Cover
123
REPLACEMENT OF MAIN COMPONENTS
10. After finishing vacuuming, refill the specified amount of refrigerant.
Standard amount of refrigerant 25.4 lbs (11.5 kg)
Calculate additional refrigerant refilling amount using the formula indicated below :
Refilling amount (lbs)
= (l
1
x 0.237) + (l
2
x 0.168) + (l
3
x 0.114) + (l
4
x 0.074) + (l
5
x 0.036) + (l
6
x 0.015)
Refilling amount (kg)
= (l
1
x 0.353) + (l
2
x 0.250) + (l
3
x 0.170) + (l
4
x 0.110) + (l
5
x 0.054) + (l
6
x 0.022) l
1
=Liquid piping Ф 7/8 inch total length (ft) l
2
=Liquid piping Ф 3/4 inch total length (ft) l
3
=Liquid piping Ф 5/8 inch total length (ft) l
4
=Liquid piping Ф 1/2 inch total length (ft) l
5
=Liquid piping Ф 3/8 inch total length (ft) l
6
=Liquid piping Ф 1/4 inch total length (ft) l
1
=Liquid piping Ф 22.22 mm total length (m) l
2
=Liquid piping Ф 19.05 mm total length (m) l
3
=Liquid piping Ф 15.88 mm total length (m) l
4
=Liquid piping Ф 12.70 mm total length (m) l
5
=Liquid piping Ф 9.52 mm total length (m) l
6
=Liquid piping Ф 6.35 mm total length (m)
NOTE) When more than one indoor unit is connected, add 2.2 lbs (1 kg) more refrigerant to the above-mentioned formula.
[When more than one indoor unit is connected]
Refilling amount (lbs)
= (l
1
x 0.237) + (l
2
x 0.168) + (l
3
x 0.114) + (l
4
x 0.074) + (l
5
x 0.036) + (l
6
x 0.015) + 2.2
Refilling amount (kg)
= (l
1
x 0.353) + (l
2
x 0.250) + (l
3
x 0.170) + (l
4
x 0.110) + (l
5
x 0.054) + (l
6
x 0.022) + 1.0
11. After refilling, run the engine 10 ~ 20 minutes and measure the belt tension again. If the belt tension is out of standard range, repeat adjust.
Belt tension ※
Belt tension adjustment standard (Replacement) Belt tension adjustment standard (Inspection)
Sonic
225 ~ 270 lbf (1,000 ~ 1,200 N)
Mechanical
(Reference value)
155 lbf (690 N)
Sonic
180 ~ 216 lbf (800 ~ 960 N)
Mechanical
(Reference value)
124 lbf (550 N)
※ Measure the belt tension with a sonic belt tension gauge. Tension values for a mechanical belt tension gauge on the chart are reference values.
12. Check the operating status by measuring high and low pressure and temperature of the refrigerant.
( Refer to P305 and after, [Standard Operation Data] for the standard value)
NOTE) After operation check, check that the service port cap and other parts are securely tightened.
124
REPLACEMENT OF MAIN COMPONENTS
[ 15 TON ]
●
Replace only the compressor that needs replacement although this section shows how to replace 2 compressors at the same time.
[Removal]
1. Perform refrigerant recovery. (Refer to the following diagram.)
Recovery from the outdoor and indoor units at the same time: Recover the refrigerant from the outdoor unit stop valves (liquid and vapor).
Recovery only from the outdoor unit: Recover the refrigerant from the outdoor unit service ports (high pressure and low pressure).
NOTE) Use the high pressure service port at the reversing valve side for refrigerant recovery. If you use the high pressure service port at the oil separator side, refrigerant recovery may be insufficient because of the check valve.
NOTE) If the liquid refrigerant accumulates in the accumulator during recovery, warm and vaporize the liquid refrigerant with a heat gun and recover all refrigerant.
125
Accumulator
REPLACEMENT OF MAIN COMPONENTS
2. Perform the following work while recovering the refrigerant.
1) Unscrew 15 bolts to remove the 3 stays.
NOTE) Unscrew bolts holding the stays with your hand to prevent the stays from falling.
Stays
Bolts
2) Cut off the bundling bands fixing the compressor heater, compressor clutch (for only No.2 compressor), and electromagnetic compressor capacity valve wire harness.
NOTE) Take care not to damage or cut the wire harnesses when cutting the bundling bands.
NOTE) Confirm the current condition of the wire harnesses so that you can put the wire harnesses back to the original condition with the bundling bands when mounting the compressor.
3) Disconnect the connectors of compressor heater, the clutch (No.2 compressor only) and the electromagnetic compressor capacity valve.
(Do not remove the heater at this time.)
4) Unscrew a bolt and remove the grounding wire.
5) Loosen a locknut and an adjustment bolt adequately.
Bolts
Compressor heater
Bolt
Grounding wire
6) Take out 4 bolts.
NOTE) When removing the mounting bolts, catch the
2 stays (plate-shaped) with your hand so that they do not fall on the bottom plate.
7) Move No. 1 compressor inward, and remove the compressor belt.
No.1
A d j u s t m e n t bolt
Locknut
Compressor belt
Bolts (4 pieces)
Stays
126
REPLACEMENT OF MAIN COMPONENTS
3. Check that no refrigerant is left in the main unit, and perform the following work.
1) Turn the compressor pulley (clutch plate as for No.
2 compressor) a few turns by hand.
2) Loosen each 2 bolts of intake (upper side) and discharge ports.
3) Disconnect the oil tube between the oil tank and compressor at the oil tank side. (Do not disconnect the oil tube from the compressor at this time.)
4) Dismount the compressor from the bracket.
NOTE) Take care so that the flanges (o-ring contact surfaces) of each port are not damaged.
Discharge port Intake port
Pulley
4. Place the removed compressor on the table approximately 4 inch (100 mm) high, and perform the following work.
1) Disconnect the oil tube from the compressor.
2) Unscrew each 2 bolts of electromagnetic compressor capacity valve and intake ports.
3) Unscrew 2 bolts to remove the electromagnetic compressor capacity valve with the stay.
4) Remove the compressor heater from the compressor.
Intake port
Electromagnetic compressor capacity port
Bolts
Compressor heater
Stay
127
REPLACEMENT OF MAIN COMPONENTS
[Reassembling]
1. Remove the port cover of the new compressor.
Supply the specified amount of refrigeration oil through the intake and discharge ports.
Refrigeration oil name
Specified amount to be supplied
NL10
Intake side 1.7 ft oz. (50 cm 3 )
Discharge side 5 ft oz. (150 cm 3 )
Electromagnetic compressor capacity valve ports Discharge ports
NOTE) If the refrigerant oil adheres on the surface of the compressor main unit, wipe out all the oil.
2. Mount the new o-rings to the intake and electromagnetic compressor capacity valve ports grooves.
NOTE) Apply refrigeration oil to the o-ring, and install it so that it is not damaged.
Port
Intake side
Electromagnetic compressor capacity valve side
Intake ports
No. 1 (Without clutch)
Inner diameter
Ф 1-1/8 inch ( Ф 29.8 mm)
Ф 5/8 inch ( Ф 17.4 mm)
Ф
Ф
Wire diameter
3/32 inch (
3/32 inch (
No. 2 (With clutch)
Ф
Ф
2.3 mm)
2.3 mm)
3. Mount the compressor heater on the compressor.
NOTE) Mount the compressor heater paying attention to the direction and position of the heater and heater wire harness referring to the right figure.
Compressor heater mounting direction
Wire harness Port side
Spring Pulley side
Compressor heater
Heater wire harness
4. Mount the electromagnetic compressor capacity valve on the compressor.
1) Mount the stay and tighten 2 bolts.
Tightening torque 6.3 lb·ft (8.5 N·m)
Intake port
2) Tighten each bolts of electromagnetic compressor capacity valve and intake (lower side) ports.
NOTE) When mounting each port, pay attention so that the o-rings will not be caught.
Tightening torque
8.9 ~ 13.3 lb·ft
(12 ~ 18 N·m)
E l e c t r o m a g n e t i c compressor capacity port
Bolts
Stay
5. Connect the oil tube to the compressor.
NOTE) Insert the oil tube until it hits a dead end.
128
6. Check that the steel plate and the bracket under the compressor main unit are in the correct position (see right).
NOTE) Mount the steel plate so that the bent portion faces down.
REPLACEMENT OF MAIN COMPONENTS
Bracket
Bent portion
7. Mount the compressor on the compressor bracket.
1) To prevent pinching or hooking, move the wire harnesses of the compressor discharge pipe temperature sensor and refrigerant high pressure switch above the discharge pipe (No. 1 compressor) or between the discharge pipe and intake pipe (No. 2 compressor).
2) Mount the No. 2 compressor and No. 1 compressor on the compressor bracket in order.
NOTE) Take care so that the flanges (o-ring contact surfaces) of each port are not damaged.
No.2
No.1
Steel plate
Discharge port
3) Hold the 2 stays (plate-shaped) at No. 2 compressor side under the bracket with your hand paying attention to the direction. Holding the stays, tighten
4 compressor mounting bolts firmly of No. 2 compressor.
Stay mounting direction
Rounded corner Bracket side
Sharp corner Base plate side
Bracket side
Stay
Bolts (4 pieces)
Intake port
No.2
Tightening torque 31.0 lb·ft (42 N·m)
Stays
4) Attach the compressor belt to the compressor.
Compressor belts
129
REPLACEMENT OF MAIN COMPONENTS
5) Hold the 2 stays (plate-shaped) at No. 1 compressor side under the bracket with your hand paying attention to the direction. Holding the stays, tighten
4 bolts lightly so that the No. 1 compressor moves.
Stay mounting direction
Rounded corner Bracket side
Sharp corner Base plate side
Bracket side
Stay
No.1
Bolts (4 pieces)
Stays
8. Mount the intake and discharge ports.
1) Mount the new o-rings to the intake (upper side) and discharge ports grooves.
NOTE) Apply refrigeration oil to the o-ring, and install it so that it is not damaged.
Port
Intake side
Discharge side
Inner diameter
Ф 1-1/8 inch
( Ф 29.8 mm)
Ф 7/8 inch
( Ф 21.6 mm)
Wire diameter
Ф 3/32 inch
( Ф 2.3 mm)
Ф 3/32 inch
( Ф 2.3 mm)
2) Tighten each 2 bolts of intake and discharge ports.
NOTE) When mounting each port, pay attention so that the o-rings will not be caught.
Tightening torque
8.9 ~ 13.3 lb·ft
(12 ~ 18 N·m)
9. Replace the old dryer filter with a new one.
1) Loosen 2 flare nuts with double open-end wrench, and move the nuts upward and downward.
2) Unscrew a bolt to remove the clamp. Remove the dryer filter.
3) Set a new dryer filter carefully in the correct direction.
4) Mount the clamp of dryer filter and tighten a bolt.
Tightening torque
2.2 ± 0.7 lb·ft
(3.0 ± 0.9 N·m)
5) Tighten 2 flare nuts with double wrench.
NOTE) Remove the foreign objects at the flare portion of flare nuts. Apply the refrigerant oil to nuts to tighten the nuts.
Tightening torque
18.4 ± 3.7 lb·ft
(25.0 ± 5.0 N·m)
Discharge port
Flare nuts
Intake port
Clamp
Bolt
Dryer filter
130
10. Perform the following work while vacuuming (operating the vacuum pump for 1 hour or longer after the pressure drops to -14.65 psi (-101 kPa, -755 mmHg) or lower).
1) Connect the oil tube to the oil tank.
2) Move the No. 1 compressor until the compressor belt is tight, and tighten 4 bolts lightly.
REPLACEMENT OF MAIN COMPONENTS
Compressor belt
Bolts
NOTE) After mounting the compressor, tighten bolts lightly before giving the tension to the compressor belt, and check that the compressor is in the correct position.
Compressor belt
3) Slide the No. 1 compressor by turning the adjustment bolt to give tension to the compressor belt.
Adjust the belt tension to the standard value, and tighten 4 bolts firmly.
Tightening torque 31.0 lb·ft (42 N·m)
Compressor belt
Belt tension ※
Belt tension adjustment standard (Replacement)
Sonic
301~346 lbf (1,340~1,540 N)
Mechanical
(Reference value)
202 lbf (900 N)
Bolts
Adjus tm e nt bolt
Belt tension ※
Belt tension adjustment standard (Inspection)
Sonic
241~277 lbf (1,070~1,230 N)
Mechanical
(Reference value)
162 lbf (720 N)
Locknut
※ Measure the belt tension with a sonic belt tension gauge. Tension values for a mechanical belt tension gauge on the chart are reference values.
131
REPLACEMENT OF MAIN COMPONENTS
NOTE) Make sure that misalignment between the edge line of the crank pulley groove and the edge line of the compressor pulley groove is
1/8 inch (3 mm) or less when measured on the crankshaft axis.
4) Tighten a locknut of the adjustment bolt.
Tightening torque
7.4 ~ 11.1 lb·ft
(10 ~ 15 N·m)
1/8 inch or less
Crank pulley
Compressor pulley
5) Mount the grounding wire with a bolt.
6) Connect the connectors of the compressor heaters, the clutch (No. 2 compressor only) and the electromagnetic compressor capacity valve.
7) Fix the wire harnesses to their original positions with bundling bands.
Compressor heater
Bolt
Grounding wire
8) Mount the 3 stays and tighten 15 bolts.
Tightening torque
31.0 ± 6.2 lb·ft
(42.0 ± 8.4 N·m)
9) Refill the refrigerant oil as required.
Stays
Bolts
Bolts
11. After finishing vacuuming, refill the specified amount of refrigerant.
Standard amount of refrigerant 37.5 lbs (17.0 kg)
Calculate additional refrigerant refilling amount using the formula indicated below :
Refilling amount (lbs)
= (l
1
x 0.237) + (l
2
x 0.168) + (l
3
x 0.114) + (l
4
x 0.074) + (l
5
x 0.036) + (l
6
x 0.015)
Refilling amount (kg)
= (l
1
x 0.353) + (l
2
x 0.250) + (l
3
x 0.170) + (l
4
x 0.110) + (l
5
x 0.054) + (l
6
x 0.022)
132
REPLACEMENT OF MAIN COMPONENTS l
1
=Liquid piping Ф 7/8 inch total length (ft) l
2
=Liquid piping Ф 3/4 inch total length (ft) l
3
=Liquid piping Ф 5/8 inch total length (ft) l
4
=Liquid piping Ф 1/2 inch total length (ft) l
5
=Liquid piping Ф 3/8 inch total length (ft) l
6
=Liquid piping Ф 1/4 inch total length (ft) l
1
=Liquid piping Ф 22.22 mm total length (m) l
2
=Liquid piping Ф 19.05 mm total length (m) l
3
=Liquid piping Ф 15.88 mm total length (m) l
4
=Liquid piping Ф 12.70 mm total length (m) l
5
=Liquid piping Ф 9.52 mm total length (m) l
6
=Liquid piping Ф 6.35 mm total length (m)
NOTE) When more than one indoor unit is connected, add 2.2 lbs (1 kg) more refrigerant to the above-mentioned formula.
[When more than one indoor unit is connected]
Refilling amount (lbs)
= (l
1
x 0.237) + (l
2
x 0.168) + (l
3
x 0.114) + (l
4
x 0.074) + (l
5
x 0.036) + (l
6
x 0.015) + 2.2
Refilling amount (kg)
= (l
1
x 0.353) + (l
2
x 0.250) + (l
3
x 0.170) + (l
4
x 0.110) + (l
5
x 0.054) + (l
6
x 0.022) + 1.0
12. After refilling, run the engine 10 ~ 20 minutes and measure the belt tension again. If the belt tension is out of standard range, repeat adjust.
Belt tension ※
Belt tension adjustment standard (Replacement) Belt tension adjustment standard (Inspection)
Sonic
301 ~ 346 lbf (1,340 ~ 1,540 N)
Mechanical
(Reference value)
202 lbf (900 N)
Sonic
241 ~ 277 lbf (1,070 ~ 1,230 N)
Mechanical
(Reference value)
162 lbf (720 N)
※ Measure the belt tension with a sonic belt tension gauge. Tension values for a mechanical belt tension gauge on the chart are reference values.
13. Check the operating status by measuring high and low pressure and temperature of the refrigerant.
( Refer to P305 and after, [Standard Operation Data] for the standard value)
NOTE) After operation check, check that the service port cap and other parts are securely tightened.
133
CONTROL
CONTROL
1. System Control Functions
1)
System Block Diagram
134
CONTROL
2. Control Details
1)
Temperature Control Start / Stop
1. Condition to start temperature control operation of the outdoor unit
Temperature control starts when both of the following conditions are met.
Condition to start temperature control shown below is met. AND
The outdoor unit is not prohibited from starting.
2. Condition to start temperature control operation
Temperature control starts when at least one of the connected indoor units requests temperature control.
3. Condition to prohibit starting when the outdoor unit is stopped.
The outdoor unit is prohibited from starting when any of the following conditions is met.
When outdoor unit error or communication error is displayed. OR
Within 3 minutes after turning the power ON. OR
Within 3 minutes after engine stop. OR
Outside air temperature is lower than 14 ℉ (-10 ℃ ) in cooling operation.
4. Condition to stop temperature control during outdoor unit operation
Temperature control of the outdoor unit stops when any of the following conditions is met.
No connected indoor units request temperature control. OR
Outdoor unit error or communication error occurs. OR
Outside air temperature is lower than 10 ℉ (-12 ℃ ) in cooling operation.
5. Stopping method for the outdoor unit
Immediate stop control
The outdoor unit stops with this control when immediate stop is required among stops by error.
Normal stop control
The outdoor unit stops with this control when the remote controller stops the outdoor unit, or immediate stop is not required among stops by error.
2)
Starting the Outdoor Unit (Starting the Engine and Engaging the Compressor
Clutch)
1. Flow of starting control
Outdoor unit starting control is performed in the following order.
① Starting the engine
② Connecting the compressor
※ Warm-up starts when the system starts by turning the remote controller ON.
2. Starting the engine
Turn the starter ON to start the engine.
3. Connecting the compressor
The system engages compressor following the procedure below.
The system sets indicated engine speed to compressor engaging speed.
The system engages the compressor 2 when both of the following conditions are met (when the reversing valve switching is activated).
Actual engine speed is stable. AND
60 seconds have passed after completion of engine start.
135
CONTROL
4. Warm-up start
When the remote controller starts the system, the control system gives priority to keeping engine coolant temperature at a certain level within 15 minutes after engine start. To do so, the control system controls the hot gas bypass valve with engine coolant temperature and refrigerant low pressure.
For details, refer to Refer to P139, [ ④ Hot gas bypass valve control] .
3)
Transition from Start Control to Normal Operation Control
Start control transitions to normal operation control when any of the following conditions is met.
After completion of switching the reversing valve. (When the reversing valve switching is activated.) OR
After completion of engaging the compressors by the number specified at starting. (When the reversing valve switching is not activated.)
4)
Indicated Engine Speed
1. Indicated engine speed range during temperature control
Refer to P136, [ ① Refrigerant flow volume control by apparent engine speed] for the indicated engine speed during temperature control.
5)
Refrigerant Flow Volume
①
Refrigerant flow volume control by apparent engine speed
1. Concept of apparent engine speed
To simplify the calculation of refrigerant flow volume control, the following "apparent engine speed" is introduced in engine speed control during normal operation in temperature control operation.
(1) Apparent engine speed, indicated engine speed, compressor capacity control valve open position, and status of electromagnetic compressor capacity valve
<< 8 TON Cooling >>
Number of operating compressors
Apparent engine speed (rpm (min
-1
))
2
1
1700
1500
1000
800
750
700
650
600
550
500
450
400
350
350
Engine speed (rpm (min
(950P)
-1
))
ERPMmax = 1700
1500
1000
800
1000
950
900
800
1000
950
900
850
ERPMmin = 800
1200
Electromagnetic compressor capacity valve 1
OFF
OFF
OFF
OFF
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
Electromagnetic compressor capacity valve 2
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
ON
ON
ON
ON
ON
OFF
136
[MEMO]
<< 8 TON Heating >>
Number of operating compressors
Apparent engine speed (rpm (min
-1
))
2
1
3000
2000
1500
1000
800
750
700
650
600
550
500
450
400
400
Engine speed (rpm (min
-1
(950P)
))
ERPMmax = 3000
2000
1500
1000
800
900
850
800
1000
950
900
850
ERPMmin = 800
1200
Electromagnetic compressor capacity valve 1
OFF
OFF
OFF
OFF
OFF
ON
ON
ON
ON
ON
ON
ON
ON
ON
Electromagnetic compressor capacity valve 2
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
ON
ON
ON
ON
OFF
<< 15 TON Cooling >>
Number of operating compressors
Apparent engine speed (rpm (min
-1
))
2
1
550
500
450
400
2000
1500
1000
600
350
300
250
250
Engine speed (rpm (min
-1
(3Y)
))
ERPMmax = 2000
1500
1000
600
700
650
600
750
700
650
ERPMmin = 600
1200
Electromagnetic compressor capacity valve 1
OFF
OFF
OFF
OFF
ON
ON
ON
ON
ON
ON
ON
ON
Electromagnetic compressor capacity valve 2
OFF
OFF
OFF
OFF
OFF
OFF
OFF
ON
ON
ON
ON
OFF
137
CONTROL
<< 15 TON Heating >>
Number of operating compressors
Apparent engine speed (rpm (min
-1
))
2
1
2125
1500
1000
600
550
500
450
400
350
300
300
Engine speed (rpm (min
(3Y)
-1
))
ERPMmax = 2125
1500
1000
600
700
650
600
700
650
ERPMmin = 600
1200
Electromagnetic compressor capacity valve 1
OFF
OFF
OFF
OFF
ON
ON
ON
ON
ON
ON
ON
Electromagnetic compressor capacity valve 2
OFF
OFF
OFF
OFF
OFF
OFF
OFF
ON
ON
ON
OFF
2. Calculation of apparent engine speed
1) Calculation of required apparent engine speed (common to cooling and heating: every 30 seconds or when changing the operation capacity)
Cooing : Lower pressure equivalent temperature control
Heating: High pressure equivalent temperature control
2) Calculation of apparent engine speed for upper limit avoidance
<Cooling> The control system sets the lowest engine speed among the following 3 speeds as apparent engine speed for upper limit avoidance.
Compressor discharge pipe temperature avoidance: Engine speed is controlled so that the compressor discharge pipe temperature does not exceed the upper limit .
Refrigerant high pressure avoidance: Engine speed is controlled so that the refrigerant high pressure does not exceed the upper limit .
Engine coolant temperature avoidance: Engine speed is controlled so that the engine coolant temperature does not exceed the upper limit .
<Heating> The control system sets the lowest engine speed among the following 4 speeds as apparent engine speed for upper limit avoidance.
Compressor discharge pipe temperature avoidance: Engine speed is controlled so that the compressor discharge pipe temperature does not exceed the upper limit .
Refrigerant high pressure avoidance: Engine speed is controlled so that the refrigerant high pressure does not exceed the upper limit .
Low pressure avoidance: Engine speed is controlled so that the refrigerant low pressure is not below the lower limit .
Engine coolant temperature avoidance: Engine speed is controlled so that the engine coolant temperature does not exceed the upper limit .
3) Calculation of apparent engine speed for lower limit avoidance
<Cooling> Assuring refrigerant high-low pressure difference: Engine speed is controlled so that the difference between refrigerant high and low pressure is not below the lower limit .
<Heating> Lower limit avoidance is not applied.
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CONTROL
②
Outdoor heat exchanger liquid flow control valve
Outdoor heat exchanger liquid flow control valve controls the degree of superheat at the outlet of the outdoor heat exchanger.
1. Outdoor heat exchanger liquid flow control valve open position range
In cooling : Fixed at 0 steps (without control)
In heating : 60 ~ 500 steps
2. Initial open position
In cooling : 0 steps
In heating : Lower limit by apparent engine speed
3. Control during normal operation
<Heating>
This control works so that the degree of superheat at the outlet of the outdoor heat exchanger meets the standard value.
However, this control sets the lower limit of open position by apparent engine speed to maintain the lowest open position suitable for the amount of circulating refrigerant.
③
Sub heat exchanger liquid flow control valve
The sub heat exchanger liquid flow control valve is used for control of degree of superheat at the sub heat exchanger outlet, compressor intake temperature control (in heating only), freezing prevention control
(in cooling only) and abnormal engine coolant temperature avoidance control (in cooling only).
1. Sub heat exchanger liquid flow control valve open position range
In cooling : 0 ~ 500 steps
In heating : 0 ~ 500 steps
2. Initial open position
In cooling : 0 steps
In heating : Lower limit by apparent engine speed
3. Control during normal operation
<Cooling>
This control sets the upper limit of open position so that the degree of superheat at the sub heat exchanger is not too small. This control also sets the lower limit of open position so that the indoor heat exchanger liquid temperature is not too low, and the engine coolant temperature is not too high.
<Heating>
This control works so that the degree of superheat at the outlet of the sub heat exchanger meets the standard value.
However, this control sets the lower limit of open position by apparent engine speed to maintain the lowest open position suitable for the amount of circulating refrigerant.
④
Hot gas bypass valve control
This control works mainly for freezing prevention, high pressure avoidance, and cold start.
1. Antifreeze control (in cooling only)
To prevent freezing of the indoor heat exchanger, this control switches between ON and OFF depending on indoor heat exchanger temperature.
2. Refrigerant high pressure avoidance control
To prevent too high refrigerant pressure, this control switches between ON and OFF depending on refrigerant high pressure.
3. Cold start control
To raise engine coolant temperature quickly for assuring evaporation heat source at the start by the remote controller, this control switches between ON and OFF depending of refrigerant low pressure and engine coolant temperature.
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CONTROL
⑤
Subcooling valve control
Subcooling valve is used for the following purposes: Subcooling demand control • Subcooling demand control of the outdoor heat exchanger (cooling only) • Apparent engine speed control (cooling only) • Upper limit control of the intake degree of superheat • Intake temperature avoidance lower limit control • Intake degree of superheat lower limit control (heating only)
1. Subcooling valve open position range
In cooling : 0 ~ 500 steps
In heating : 0 ~ 500 steps
2. Initial open position
In cooling : Standard open position for apparent engine speed
In heating : 0 steps
3. Control during normal operation
<Cooling>
This control works so that the degree of subcool at the outlet of the outdoor unit and the degree of subcool of the outdoor heat exchanger meet the standard value.
However, this control sets the upper limit of open position so that the intake degree of superheat is not too small, and also sets the lower limit of open position so that the intake temperature is not too high.
<Heating>
This control works so that the degree of subcool of the liquid pipe at the inlet of the outdoor unit meets the standard value.
However, this control sets the upper and lower limit of open position so that the intake degree of superheat is not too small, and also sets the lower limit of open position so that the intake temperature is not too high.
6)
Defrosting (In Heating Only)
In heating, frost formation on the outdoor heat exchanger blocks heat absorption from the outside air, and causes deterioration of heating capacity. Defrost control is necessary to prevent such a problem.
Defrost control
1. Judgment for starting defrosting
1) Judgment of frost formation
The control system judges frost formation based on the relationship between defrosting detection temperature and outside air temperature, and starts defrost control.
2) Defrosting prohibiting conditions
Defrost control does not start if the following conditions are satisfied, even if the system detects frost formation.
Under starting control
When the specified length of time has not passed since the last defrost control, or start of remote control operation or temperature control.
2. How defrost control starts
Defrost control starts as follows.
(1) Oil return control is terminated when oil return control is working.
(2) The control system sends defrosting signal to all indoor units.
(3) The control system controls apparent engine speed and hot gas bypass valve so that refrigerant high-low pressure difference meets the specified value.
(4) Reversing valve is turned OFF when the refrigerant high-low pressure difference meets the specified value.
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CONTROL
3. How the system operates during defrost control
The system operates as follows during defrost control.
(1) Apparent engine speed is controlled by normal control in heating operation.
(2) Sub heat exchanger liquid flow control valve is set to standard upper limit open position, and normal control in heating operates after that.
(3) The open position of the outdoor heat exchanger liquid flow control valve is fixed at 0.
(4) The open position of the subcooling valve is fixed at 0.
(5) The open position of the oil bypass control valve is subject to normal control in heating operation.
(6) Outdoor fan air volume level is fixed at 0.
(7) Reversing valve is fixed OFF.
(8) Hot gas bypass valve is fixed OFF.
4. Judgment of the end of defrosting
1) Return to normal heating operation
The system returns to normal heating operation when any of the following conditions is met.
Specified time has passed from starting of defrost control. OR
High pressure equivalent temperature is higher than the specified value. OR
Outdoor heat exchanger liquid temperature is higher than the specified value.
2) Stop of defrost control
Defrost control stops and normal stop process operates when any of the following conditions is met.
When all the indoor units stops temperature control operation. OR
Any abnormality that requires the outdoor unit to stop running occurs.
7)
Outdoor Fan
1. Control in cooling operation
The following control operates to maintain refrigerant high pressure (refrigerant high-low pressure difference) and engine coolant (or engine oil) temperature, and to avoid abnormal engine coolant temperature.
Condition to increase fan air volume
Fan air volume is increased by 1 level when any of the following conditions is met.
The refrigerant high pressure is the specified value or higher. OR
The engine coolant temperature is the specified value or higher.
Condition to decrease fan air volume
Fan air volume is decreased by 1 level when any of the following conditions is met.
The refrigerant high pressure is lower than the specified value. OR
The engine coolant temperature is lower than the specified value.
2. Control in heating operation
The following control operates to maintain evaporating capacity and engine coolant (or engine oil) temperature, and to avoid abnormal engine coolant temperature.
Condition to increase fan air volume
The engine coolant temperature is the specified value or higher. OR
Apparent engine speed is the specified value or more and the difference between outside air temperature and low pressure equivalent temperature is the specified value or higher.
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CONTROL
Condition to decrease fan air volume
The engine compartment temperature is lower than the specified value. OR
The difference between outside air temperature and low pressure equivalent temperature is smaller than the specified value and the engine coolant temperature is lower than the specified value.
8)
Oil Bypass Control Valve
Oil bypass control valve is used for apparent engine speed demand control, abnormal compressor intake temperature avoidance control, and abnormal compressor intake degree of superheat avoidance control.
1. Oil bypass control valve open position range
0 ~ 500 steps (common to cooling and heating)
2. Initial open position
0 ~ 500 steps (common to cooling and heating)
3. Control during normal operation
<Common to cooling and heating>
This control sets standard open position for apparent engine speed so that the oil bypass amount suitable for the amount of circulating refrigerant is maintained.
However, this control sets the upper limit of open position to prevent excessive rise of compressor intake temperature, and also sets the lower limit of open position to prevent excessive fall of compressor intake degree of superheat.
9)
Compressor Heater
To protect the compressor, the system controls heater energization during engine stop.
10)
Drain Filter Heater / Drain Hose Heater
To prevent freezing of the exhaust water drain filter and hose, the system controls heater energization depending on outside air temperature regardless of whether the engine is running or not.
142
11)
Flow Chart of Backup Operation under Combined Installation
(Conceptual Chart)
(1) When 2 outdoor units is operating
CONTROL
This chart is a general conceptual flow chart.
Backup operation may not start depending on error type.
The number of retries until backup operation varies depending on error type.
Backup operation is reset when the outdoor unit detects an error (determinate error) during backup operation.
The reset of the remote controller may not be possible depending on error type.
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CONTROL
(2) When 1 outdoor units is operating
This chart is a general conceptual flow chart.
Backup operation may not start depending on error type.
The number of retries until backup operation varies depending on error type.
Backup operation is reset when the outdoor unit detects an error (determinate error) during backup operation.
The reset of the remote controller may not be possible depending on error type.
144
CONTROL
3. Function Settings
1)
Outdoor unit
Various function settings
The outdoor unit has EEPROM dip switches on the outdoor control PCB.
The contents and the factory defaults are as follows.
Be sure to set #4 pin of #1 EEPROM dip switch to "Enabled" if the deodorant kit is installed.
If not, the protection device may not work properly and result in smoke, fire or damage to the unit.
Do not touch the moving parts such as fan or belts around the engine.
You could be caught by the moving parts and be injured.
Even if the GHP is stopped, the fan may automatically start temporarily to protect units or maintain capacity.
Be sure to turn the electric leakage breaker OFF when you need to touch the moving parts.
List of EEPROM dip switch setting
EEPROM dip switch 1 (Setting can be changed with check code No. 80)
Pin No.
1
2
3
4
5
6
7
8
-
Snow blowing function ( ※ 1)
Deodorant kit ( ※ 2)
Conditional silent mode ( ※ 3)
Energy saving mode ( ※ 3)
Functions
Periodic inspection warning display
Backup function under combined in stllation ( ※ 3)
Reserved area ( ※ 4)
OFF : Not available ON : Available
OFF: Off ON: On
-
OFF : Not available ON : Available
OFF: Off ON: On
OFF: Off ON: On
OFF: Backup starts after error reset
ON: Automatic backup
-
Factory default
ON
OFF
Depend on models
Depend on models
OFF
OFF
Depend on models
Depend on models
145
CONTROL
2
3
4
5
6
EEPROM dip switch 2 (Setting can be changed with check code No. 81)
Pin No.
1
7
8
Functions
Setting of cool/heat switching ( ※ 3)
OFF : Indoor unit ON : Outdoor unit
Master control ( ※ 3)
-
-
Reserved area ( ※ 4)
Outdoor fan high static pressure mode
Large indoor unit connection ( ※ 3)
OFF:
OFF:
Prohibited
ON: Master collec-
OFF: tive
OFF:
ON:
-
-
-
Dependent collective
ON:
ON:
Individual setting
OFF : Not available / ON : Available
OFF: Disconnected?ON: Connected
Factory default
OFF
ON
ON
OFF
OFF
OFF
OFF
OFF
EEPROM dip switch 3 (Setting can be changed with check code No. 82)
Pin No.
1
6
7
4
5
8
2
3
-
-
Reserved area ( ※ 4)
Reserved area ( ※ 4)
Reserved area ( ※ 4)
-
-
-
Functions
-
-
-
-
-
-
-
-
Factory default
OFF
OFF
Depend on models
Depend on models
Depend on models
OFF
OFF
OFF
EEPROM dip switch 4 (Setting can be changed with check code No. 83)
Pin No.
1
6
7
4
5
8
2
3
-
-
Reserved area ( ※ 4)
-
Reserved area ( ※ 4)
Reserved area ( ※ 4)
Reserved area ( ※ 4)
-
Functions
-
-
-
-
-
-
-
-
Factory default
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
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CONTROL
EEPROM dip switch 5 (Setting can be changed with check code No. 84)
Pin No.
1
6
7
4
5
8
2
3
-
-
-
-
-
-
-
-
Functions
-
-
-
-
-
-
-
-
Factory default
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
EEPROM dip switch 6 (Setting can be changed with check code No. 85)
Pin No.
1
6
7
4
5
8
2
3
-
-
-
-
-
-
-
-
Functions
-
-
-
-
-
-
-
-
Factory default
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
※ 1. This setting is "On" only when the outdoor unit is cold district specification. Change this setting to "On" in the cold district or heavy snowfall area.
※ 2. Be sure to change this setting to "Available" when installing deodorizing option.
※ 3. As for combined installation, the setting of the master outdoor unit (outdoor unit with the outdoor-indoor communication wires connected) is reflected on the unit's operation.
※ 4. Do not rewrite this data.
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CONTROL
2)
Cool/Heat Switching Setting
There are the following 5 methods to switch between cooling and heating.
The indoor unit remote controller sets cooling or heating for individual outdoor unit system.
The cool/heat selector sets cooling or heating for individual outdoor unit system.
The indoor unit remote controller sets cooling or heating for multiple outdoor unit systems collectively in accordance with the collective master outdoor unit.
The cool/heat selector sets cooling or heating for multiple outdoor unit systems collectively in accordance with the collective master outdoor unit.
The cool/heat central controller sets cooling or heating for the outdoor unit systems collectively for each outdoor external control adapter.
The following is the explanation of each method.
The indoor unit remote controller sets cooling or heating for individual outdoor unit system.
(Refer to P145 for setting of check code No.81.)
1) It does not matter whether there is a wiring between outdoor units or not.
2) Set the master control to "Indoor unit" by setting #1pin to "OFF" in the check code No.81.
3) Set the master control to "Individual setting" by setting #2 and #3 pins to "ON" in the check code No.81.
The cool/heat selector sets cooling or heating for individual outdoor unit system.
(Refer to P145 for setting of check code No.81.)
1) It does not matter whether there is a wiring between outdoor units or not.
2) Set the master control to "Outdoor unit" by setting #1pin to "ON" in the check code No.81.
3) Set the master control to "Individual setting" by setting #2 and #3 pins to "ON" in the check code No.81.
The indoor unit remote controller sets cooling or heating for multiple outdoor unit systems collectively in accordance with the collective master outdoor unit. (Refer to P145 for setting of check code No.81.)
1) Install the outdoor external control adapter (sold separately) on either of the outdoor-outdoor or indoor-outdoor transmission line.
2) Set SS2 of the outdoor external control adapter to "OFF".
3) Make the desired outdoor unit "Master collective" and other outdoor units "Dependent collective" by setting #2 and #3 pins in the check code No. 81.
4) Set the master control of the outdoor unit designated as "Master collective" to "Indoor unit" by setting #1pin to
"OFF" in the check code No.81.
5) Set SS 1 of the outdoor external control adapter to "BOTH" (factory setting) or "C/H", and set SS 2 to "OFF"
(factory setting).
The cool/heat selector sets cooling or heating for multiple outdoor unit systems collectively in accordance with the collective master outdoor unit. (Refer to P145 for setting of check code No.81.)
1) Add the following items to " The indoor unit remote controller sets cooling or heating for multiple outdoor unit systems collectively in accordance with the collective master outdoor unit.
" shown above.
Install the cool/heat selector on the collective master outdoor unit.
Set the master control of the outdoor unit designated as "Master collective" to "Outdoor unit" by setting #1pin to "ON" in the check code No.81.
The cool/heat central controller sets cooling or heating for the outdoor unit systems collectively for each outdoor external control adapter.
(Refer to P145 for setting of check code No.81.)
1) Install the outdoor external control adapter (sold separately) on any of the outdoor-outdoor, indoor-outdoor or indoor-indoor transmission line.
2) Set all the outdoor units to "Dependent collective" by setting #2 pin to "OFF" and #3 pin to "ON" in the check code No.81.
3) Set SS 1 of the outdoor external control adapter to "BOTH" (factory set) or "C/H", and set SS 2 to "ON".
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CONTROL
4) Set DS2 and DS1 of the outdoor external control adapter so that they agree with the cooling / heating collective address of the outdoor control PCB with the check mode code No. dA. (Factory set addresses are all "OFF".)
5) Set SS 2 of the outdoor external control adapter to "ON".
6) Set "Dependent collective" by setting #2 pin to "OFF" and #3 pin to "ON" in the check code No.81.
7) If you use only one cool/heat central controller, set the upper 2 bits of the outdoor external control adapter to
"OFF". If more than one cool/heat central controller is used, assign each controller with a number from 0 ~ 3 with the upper 2 bits of the address setting switch of the outdoor external control adapter.
8) Set the address with the lower 3 bits of the address setting switch of the outdoor external control adapter and the check mode code No.dA.
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CONTROL
4. System Input/Output Specifications
1)
Outdoor Unit Input / Output Specifications
motor
Name
Outdoor fan
Functions
Heat exchange of refrigerant and cooling the engine coolant
Specifications
Rated: 280 V DC
DC brushless
Connector No.
DCBL PCB FM1:
CN7[1]-[2]-[3] CN10[1]-
[2]-[3]-[4]-[5] FM2:
CN8[1]-[2]-[4] CN12[1]-
[2]-[3]-[4]-[5]
Outside air temperature sensor
1. Judgement of ambient themperature under which the system operation is prohibited
Cooling operation is prohibited at lower than 14 ℉ (-10 ℃ )
Cooling operation is stopped at lower than 10 ℉ (-12 ℃ )
2. Full-open control for the electronic expansion valve of the stopped indoor unit
3. Outdoor fan air volume control
4. Detection of disconnection or short circuit
1. Compressor heater control
2. Detection of disconnection or short circuit
Refer to P177 and after, [Parts Characteristics] .
THO: CN6[9]-[10]
Engine compartment temperature sensor
E/G R: CN6[13]-[14]
Throttle valve Control of the engine speed Rated: 12 V DC
STM: CN6[16]-[18]-
[19]-[21]-[15]-[17]
Engine oil pressure switch
Oil level switch
1. Judgment of abnormal oil pressure
2. Detection of disconnection in the engine oil pressure switch
Judgment of oil leakage
Rated: 12 V DC
Circuit OFF:
14.5 psi (0.1 MPa)
Circuit ON:
5.8 psi (0.04 MPa)
Rated: 12 V DC
Normal : ON
Error : OFF
OLP: CN6[3]-[4]
OIL-LVL: CN4[5]-[6]
Electromagnetic gas valve
Starter
To supply or shut off the fuel gas to the outdoor unit
To support the engine for self-operation at start-up
Rated: 12 V DC
Rated: 12 V DC
GV1: CN8[4]-[10]
GV2: CN8[5]-[11]
-
Fuel gas flow control valve
Engine exhaust air temperature sensor
(unit with deodorant kit only)
Control of air/fuel ratio
Detection of excessive rise of engine exhaust air temperature
Rated: 12 V DC
Refer to P177 and after, [Parts Characteristics] .
FUEL: CN6[20]-[22]-
[26]-[24]-[23]-[25]
E/G E: CN6[7]-[8]
Engine speed sensor
1. Engine speed detection
2. Detection for engine overspeed abnormality
3. Detection of loss of engine speed control
WB(Ne) ※ 2: CN7[3]-[4]
WB(G2): CN7[1]-[2]
NOTE) Numbers in [ ] in the "connector No." column correspond with the pin numbers shown in circles in the wiring diagram.
※ 1. 8 TON only
※ 2. 15 TON only
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CONTROL
Name
Ignition coil
To generate high voltage necessary for the spark plugs
Functions Specifications
Rated: 12 V DC
Connector No.
IGN1: CN8[1]-[3]
IGN2: CN8[2]-[3]
IGN3: CN8[7]-[3]
IGN4 ※ 2: CN8[8]-[3]
Exhaust water drain heater
(unit with drain heater kit only)
Engine oil pan heater
(unit with drain heater kit only)
To turn ON to prevent freezing of exhaust water drain filter and exhaust water drain hose depending on outside air temperature
To turn ON to prevent engine oil from being too viscous
Rated : 200 V AC
Rated : 200 V AC
Cold district PCB
DH: CN3[1]-[4]
Cold district PCB
E/G OPH: CN3[2]-[5]
Engine coolant temperature sensor
1. Judgment of abnormal engine coolant temperature
2. Abnormal engine coolant temperature avoidance control
3. Preventive control for engine operation without engine coolant
4. Outdoor fan air volume control
5. Detection of disconnection or short circuit
Refer to P177 and after, [Parts Characteristics] .
WT: CN6[11]-[12]
Engine coolant pump
To circulate the engine coolant
Rated: 280 V DC
DC brushless
DCBL PCB
WP: CN9[1]-[2]-[3]
Compressor discharge pipe temperature sensor
Compressor intake temperature sensor
1. Detection of disconnection judgment temperature (detection of lower than 34 ℉ (1 ℃ ) for 10 minutes)
2. Detention od short circuit judgement temperature (detection of 248 ℉ (120 ℃ ) or higher for 1 minute)
1. Abnormal compressor intake temperature avoidance control
2. Detection of disconnection or short circuit
1. Subcooling valve control
2. Detection of disconnection or short circuit
C/P T1: CN4[27]-[28]
C/P T2: CN4[25]-[26]
C/P S: CN4[23]-[24]
Accumulator outlet temperature sensor
Sub heat exchanger liquid temperature sensor
Outdoor liquid pipe temperature sensor
1. Sub heat exchanger liquid flow control valve control
2. Detection of disconnection or short circuit
1. Subcooling valve control
2. Detection of disconnection or short circuit
Refer to P177 and after, [Parts Characteristics] .
AOT: CN4[13]-[14]
SOT: CN4[15]-[16]
ILT: CN4[29]-[30]
Outdoor heat exchanger liquid temperature sensor
1. Subcooling valve control
2. Detection of disconnection or short circuit
3. Sub heat exchanger liquid flow control valve control
THL: CN4[19]-[20]
NOTE) Numbers in [ ] in the "connector No." column correspond with the pin numbers shown in circles in the wiring diagram.
※ 1. 8 TON only
※ 2. 15 TON only
151
CONTROL
Name
Outdoor heat exchanger vapor temperature sensor
Refrigerant high pressure switch
Functions
1. Control of outdoor heat exchanger liquid flow control valve in heating operation
2. Detection of disconnection or short circuit in heating operation
1. Judgment to stop the operation at abnormally refrigerant high pressure
2. Detection of disconnection in the refrigerant high pressure switch
Specifications
Refer to P177 and after, [Parts Characteristics] .
Rated: 12 V DC
Circuit OFF:
551 psi (3.8 MPa)
Circuit ON:
421 psi (2.9 MPa)
Connector No.
THG: CN4[17]-[18]
HLSW1, 2 ※
CN30[3]-[4]
2:
Refrigerant high pressure sensor
Refrigerant low pressure sensor
1. Refrigerant high pressure control
(target control in heating)
2. Abnormally high refrigerant pressure avoidance control
3. Abnormally high refrigerant pressure emergency avoidance control
4. Outdoor fan air volume control
5. Hot gas bypass valve control
6. Detection for inadequate refrigerant
7. Detection for abnormally high refrigerant pressure
8. Detection of disconnection or short circuit in the refrigerant high pressure sensor
1. Judgment to stop operation at abnormally refrigerant low pressure
2. Refrigerant low pressure control in cooling
3. Abnormally low pressure avoidance control in heating
1. Refrigerant flow volume control in heating
2. Defrost control
Rated: 5 V DC
Pressure range:
0 ~ 653 psi
(0 ~ 4.5 MPa)
Rated: 5 V DC
Pressure range:
0 ~ 276 psi
(0 ~ 1.9 MPa)
PSH1:
CN4[33]-[31]-[32]
PSL: CN4[34]-[11]-[12]
Outdoor heat exchanger liquid flow control valve
Sub heat exchanger liquid flow control valve
1. Refrigerant flow volume control in heating
2. Low pressure avoidance in cooling operation
Rated: 12 V DC
Rated: 12 V DC
OEV: CN5[20]-[18]-
[25]-[27]-[21]-[23]
SEV: CN5[16]-[14]-[17]-
[19]-[13]-[15]
Subcooling valve
Oil bypass control valve
1. Refrigerant flow volume control in cooling
2. Abnormal intake temperature avoidance control
1. To control oil bypass amount suitable for the refrigerant flow amount
2. Abnormal intake temperature avoidance control
Rated: 12 V DC
Rated: 12 V DC
SCEV: CN5[12]-[10]-
[9]-[11]-[5]-[7]
OVEV: CN5[8]-[6]-[1]-
[3]-[4]-[2]
Compressor clutch
To turn ON/OFF (clutch engaged / disengaged) compressors depending on the calculated refrigerant flow volume for an outdoor unit
Rated: 12 V DC CP2: CN8[12]
NOTE) Numbers in [ ] in the "connector No." column correspond with the pin numbers shown in circles in the wiring diagram.
※ 1. 8 TON only
※ 2. 15 TON only
152
CONTROL
Name
Hot gas bypass valve
Reversing valve
Compressor heater
Functions
1. Engine coolant temperature maintaining control at engine start
2. Refrigerant high pressure avoidance control
3. Freezing prevention control in cooling operation
4. Pressure equalizing control at system stop
To turn ON in heating
NOTE) To switch the mode at the start of operation if the operation mode is different from the previous one.
To turn ON to prevent liquid entrapment in the compressor if the engine compartment temperature is low when the system stops
Specifications
Rated : 200 V AC
Rated : 200 V AC
Rated : 200 V AC
Connector No.
BV: CN11[1]-[7]
4PV: CN11[2]-[8]
C/P H1, 2: CN11[5]-[11]
Electromagnetic compressor capacity valve
Capacity control of the variable capacity compressor
Rated : 200 V AC
C/P V1: CN11[3]-[9]
C/P V2: CN11[4]-[10]
AC/DC converter
Switch for maintenance
AC/DC conversion
(e.g., 200 V AC → 12 V DC)
1. Switching of the PCB maintenance function mode
2. Operation of equipment
Transformer, diode
Refer to P233 and after, [Board Maintenance Functions]
-
-
NOTE) Numbers in [ ] in the "connector No." column correspond with the pin numbers shown in circles in the wiring diagram.
※ 1. 8 TON only
※ 2. 15 TON only
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TROUBLESHOOTING
TROUBLESHOOTING
1. Error Code Description and Possible Cause
RC display
AF
Error code
Outdoor control PCB
Code Sub code
30 n (Air net address)
Contents
Indoor drain failure
Error detection / Judgment
The float switch repeats ON and OFF 5 times or more while the temperature control is OFF.
AH
AJ
A0
31
22
63 n (Air net address) n (Air net address) n (Air net address)
Indoor dust collector failure Error signal is received or no operation signal is received from the dust collector (sold separately) when the dust collector is installed.
Indoor unit capacity setting error 1. The capacity code is not contained in the indoor control
PCB's memory, and the capacity setting adaptor is not connected.
2. When the non-compliant capacity of the model is set.
Indoor external protective device activation
There is an emergency stop call from the indoor unit.
A1
A3
A6
20
95 n (Air net address)
Indoor control PCB setting error Data can not be correctly received from the EEPROM.
n (Air net address)
Indoor unit abnormal drain water level
1. Drain water is detected in cooling/dehumidifying operation during compressor operation.
2. Drain water is detected in heating operation.
3. Drain water is detected again 3 minutes after drain water detection other than 1) and 2) above.
15 n (Air net address)
Indoor fan motor failure Detection condition varies depending on the indoor unit model.
A7 35 n (Air net address)
Indoor swing flap motor failure The limit switch does not reverse (ON/OFF) when the swing flap motor is activated for 30 seconds.
A8
A9
25
21 n (Air net address)
Indoor unit power supply voltage failure n (Air net address)
Indoor electronic expansion valve driving part failure
The input voltage for the indoor fan motor is lower than 150 V or
386 V or higher
The signal input to the electronic expansion valve is not normal during the initialization of the microcomputer.
CA 98 n (Air net address)
Indoor discharge air temperature sensor failure
Indoor discharge air temperature sensor disconnection or short circuit during operation.
CE 99 n (Air net address)
Indoor human detection · floor temperature sensor failure
Human detection · floor temperature sensor disconnection or short circuit during operation.
154
TROUBLESHOOTING
Error frequency until error display
1
Display
Warning
1
1
Warning
Error
※ 1
Z
Z
X
Method of diagnosis / repair
Treatment
N
N
Possible major causes Diagnosis / Repair
※ 2
N 1. Drain system failure
2. Water supply/drain water system failure of the humidifier
3. Indoor control PCB failure
1. Connector contact failure
2. Indoor dust collector failure
3. Indoor control PCB failure
1. Refer to P232, 58)Check Drain Water
2. Check humidifier for water leak
3. Inspect or replace indoor control PCB
1. Check connector connection
2. Inspect indoor dust collector
3. Inspect or replace indoor control PCB
1. Indoor unit capacity setting error
2. Indoor control PCB failure
1. Check indoor unit capacity setting
2. Inspect or replace indoor control PCB
1
1
1
1
1
1
1
1
1
Error
Error
B
X
N
N
1. An emergency stop call from the indoor unit
2. Remote controller field setting error
3. Indoor control PCB failure
Indoor control PCB failure
1. Check for an emergency stop call from the indoor unit
2. Check remote controller setting
3. Inspect or replace indoor control PCB
Inspect or replace indoor control PCB
Error
Error
Alert
Error
X
X
Z
X
Error B, E
Error X
Warning Z
N
N
N
N
N
N
N
1. Connector of drain float switch contact failure
2. Drain float switch failure
3. Check drain pipe
4. Connector of drain pump disconnection
5. Drain pump failure
6. Harness of drain pump disconnection
1. Contact with other objects
2. Indoor fan failure
3. Indoor fan motor failure
4. Indoor control PCB failure
5. Indoor fan PCB failure
1. Check connector connection
2. Check for inverse inclination and rising height of piping
3. Refer to P192, 12)Communication
Failure / Indoor Unit System Failure
1. Clean up objects
2. Refer to P192, 12)Communication
Failure / Indoor Unit System Failure
3. Inspect or replace indoor control PCB
4. Inspect or replace indoor fan PCB
1. Connector contact failure
2. Indoor swing flap motor or louver failure
3. Indoor control PCB failure
1. Check connector connection
2. Check for indoor swing flap motor or louver
3. Inspect or replace indoor fan PCB
Indoor power supply or power supply circuit failure
Inspect indoor power supply or power supply circuit
1. Connector contact failure
2. Indoor electronic expansion valve failure
3. Indoor control PCB failure
1. Check connector connection
2. Refer to P224, 42)Inspect for Blockage in the Indoor Electronic Expansion Valve
3. Inspect or replace indoor fan PCB
1. Connector contact failure
2. Indoor discharge air temperature sensor failure
3. Harness disconnection or short circuit
1. Connector contact failure
2. Indoor human detection · floor temperature sensor failure
3. Harness disconnection or short circuit
1. Check connector connection
2. Inspect indoor discharge air temperature sensor ( Refer to P231, 56)Check for
Readings of the Indoor Temperature
Sensors )
1. Check connector connection
2. Inspect human detection · floor temperature sensor
155
TROUBLESHOOTING
RC display
CJ
Error code
Outdoor control PCB
Code Sub code
17 n (Air net address)
Contents Error detection / Judgment
Indoor remote controller sensor failure
Indoor remote controller sensor disconnection or short circuit during operation.
C1 27
C4 18 n (Air net address) n (Air net address)
Indoor unit transmission failure
(Indoor control PCB - fan PCB,
Indoor control PCB - adapter
PCB)
Communication failure between indoor PCBs
Indoor heat exchanger liquid pipe temperature sensor disconnection or short circuit
One or more thermistors do not work due to disconnection or short circuit. (Input value is abnormal.)
C5 19 n (Air net address)
Indoor heat exchanger vapor pipe temperature sensor disconnection or short circuit
One or more thermistors do not work due to disconnection or short circuit. (Input value is abnormal.)
C6 28 n (Air net address)
Indoor unit combination failure
(Indoor control PCB - fan PCB)
Combination failure of the indoor PCBs.
C9 97 n (Air net address)
Indoor intake air temperature sensor disconnection or short circuit
One or more thermistors do not work due to disconnection or short circuit. (Input value is abnormal.)
EA 57
EC 80
0
0
3
Reversing valve switching failure
Overheated engine coolant
Overcooled engine coolant
1. The decision for reversing valve switching failure is
"FAILURE". OR
2. Compressor discharge temperature sensor detects 203
(95
℉
℃ ) or higher when the reversing valve "with switching"
is starting.
The engine coolant temperature sensor detects 221 or higher for 10 seconds during engine operation.
℉ (105 ℃ )
When engine coolant temperature sensor detectes 160 ℉ (71
) or higher for 60 seconds during engine starting, the unit be-
℃ comes error standby status. Detection continues for 15 minutes after that.
15 minutes after engine starting, the engine coolant temperature sensor detects lower than 122 ℉ (50 ℃ ) for 10 seconds.
156
TROUBLESHOOTING
Error frequency until error display
1
1
Display
Alert
Error
※ 1
Z
X
Method of diagnosis / repair
Treatment
N
Possible major causes
※ 2
N 1. Connector contact failure
2. Indoor remote controller sensor failure
3. Harness disconnection or short circuit
1. Indoor fan PCB failure
2. Connector connection failure
3. Indoor control PCB failure
Diagnosis / Repair
1. Check connector connection
2. Inspect indoor remote controller sensor
1. Inspect or replace indoor fan PCB
2. Check connector connection
3. Inspect or replace indoor control PCB
1
1
1
1
10 in a row
2/15 minutes Error
1
3 in a row
Error
Error
Error
Error
Error
Error
X
X
X
X
B
A
B
N
N
N
N
N
B
B
1. Connector connection failure
2. Indoor heat exchanger liquid pipe temperature sensor failure
3. Harness disconnection or short circuit
4. Indoor control PCB failure
1. Check connector connection
2. Inspect indoor heat exchanger liquid pipe temperature sensor ( Refer to
P231, 56)Check for Readings of the
Indoor Temperature Sensors )
3. Inspect or replace indoor control PCB
1. Connector connection failure
2. Indoor heat exchanger vapor pipe temperature sensor failure
3. Harness disconnection or short circuit
4. Indoor control PCB failure
1. Check connector connection
2. Inspect indoor heat exchanger vapor pipe temperature sensor ( Refer to
P231, 56)Check for Readings of the
Indoor Temperature Sensors )
3. Inspect or replace indoor control PCB
1. Indoor fan PCB failure
2. Capacity setting adaptor contact failure
3. Field setting error
1. Connector connection failure
2. Indoor intake air temperature sensor failure
3. Harness disconnection or short circuit
4. Indoor control PCB failure
1. Inspect or replace indoor fan PCB
2. Check for connector of capacity setting adaptor
3. Check field setting
1. Check connector connection
2. Inspect indoor intake air temperature sensor ( Refer to P231, 56)Check for
Readings of the Indoor Temperature
Sensors )
3. Inspect or replace indoor control PCB
1. Reversing valve failure
2. Inadequate refrigerant
1. Refer to P227, 49)Inspect Reversing
Valve
2. Refer to P222, 36)Inspect Refrigerant
Pressure (Inspect Refrigerant
Amount)
Refer to P186, 4)Engine Coolant Temperature Abnormality
1. Engine coolant circulation failure.
(Inadequate engine coolant.)
2. Engine coolant temperature sensor failure
3. Harness of engine coolant temperature sensor short circuit
4. Engine heat dissipation failure, etc.
1. Connector of engine coolant temperature sensor contact failure
2. Engine coolant temperature sensor failure
3. Harness of engine coolant temperature sensor disconnection
4. Thermostat failure
1. Check for connector of engine coolant temperature sensor connection
2. Refer to P218, 28)Inspect Engine
Coolant Temperature Sensor
3. Refer to P216, 25)Inspect Thermostat
157
TROUBLESHOOTING
RC display
EH
Error code
Outdoor control PCB
Code Sub code
80 10
E1
E3
40
84
86
20
30
0
1
2
3
4
0
Contents Error detection / Judgment
Engine coolant pump starting failure
Engine coolant pump speed failure
10 seconds after starting of the engine coolant pump, the pump speed is lower than 1,400 rpm (min
-1
).
When any of the following occurs at engine coolant pump operation:
1. Speed of lower than 1,400 rpm (min -1 ) is detected for 5 seconds. OR
2. Speed of 3,700 rpm (min
-1
) or more is detected for 5 seconds. OR
3. Speed of lower than 200 rpm (min -1 ) is detected for 2 seconds.
IPM failure IPM driver error signal is detected for 30 milliseconds when turning the engine coolant pump or fan motor ON. Or IPM driver error signal of 10 milliseconds or longer is detected twice or more in 1.4 seconds.
EEPROM failure occurs.
EEPROM failure
Outdoor unit model code failure Outdoor unit model code data setting failure
Programs do not agree between outdoor main microcomputer and engine microcomputer
Main microcomputer model code and engine microcomputer engine code do not agree.
Communication failure between outdoor main microcomputer and engine microcomputer
Communication failure between outdoor main microcomputer and engine microcomputer is detected for 5 seconds.
Communication failure between outdoor main microcomputer and I/F microcomputer
Refrigerant high pressure failure 1
1. Communication from the I/F microcomputer can not be received normally for 15 second. OR
2. Reception of error signal from the I/F microcomputer is received for 15 seconds. OR
3. Other outdoor unit's communication error between main microcomputer and I/F microcomputer is received for 15 seconds.
The refrigerant high pressure sensor 1 detects the specified high pressure or higher for 5 seconds during compressor operation.
1 Refrigerant high pressure failure 2
The refrigerant high pressure switch 1 or 2 OFF is detected for
1 second during compressor operation.
E4 88 0 Refrigerant low pressure abnormality
Refrigerant low pressure of lower than 12 psi (0.08 MPa ) is detected for 3 seconds during compressor operation.
158
TROUBLESHOOTING
Error frequency until error display
15 in a row
2/15 minutes
Display
Error
Error
※ 1
B
A
Method of diagnosis / repair
Treatment
B
Possible major causes
※ 2
B 1. Connector contact failure
2. Engine coolant pump failure
3. Harness disconnection
4. Outdoor control PCB failure
Diagnosis / Repair
1. Check connector connection
2. Refer to P215, 24)Inspect Engine
Coolant Pump
3/60 minutes Error B B IPM element failure 1. Inspect or replace DCBL PCB
2. Refer to P215, 24)Inspect Engine
Coolant Pump
Check outdoor control PCB 1 Error
Error
Error
C, E
E
E
N
N
N
EEPROM failure
3 in a row
1
Error B, E
Error B, E
N Engine microcomputer communication failure
Check outdoor control PCB
N I/F microcomputer communication failure Check outdoor control PCB
12/60 minutes
1
12/60 minutes
Error
Error A
Error
A
B
N
N
B
1. Connector of refrigerant high pressure switch or refrigerant high pressure sensor contact failure
2. Refrigerant high pressure switch failure
3. Harness of refrigerant high pressure switch disconnection or short circuit
4. Refrigerant high pressure sensor failure
5. Harness of refrigerant high pressure sensor disconnection or short circuit
6. Refrigerant system failure
(Blockage, overfilling, etc.)
7. Gas mixer failure
8. Condenser heat dissipation failure
1. Connector of refrigerant low pressure sensor contact failure
2. Refrigerant low pressure sensor failure
3. Harness of refrigerant low pressure sensor disconnection or short circuit
4. Refrigerant system failure
(Blockage, overfilling, etc.)
5. Evaporator heat absorption failure
1. Check for connector of refrigerant high pressure switch or refrigerant high pressure sensor connection
2. Refer to P187, 7)High Pressure Abnormality in Cooling Operation
3. Refer to P188, 8)High Pressure Abnormality in Heating Operation
1. Check for connector of refrigerant low pressure sensor connection
2. Refer to P189, 9)Refrigerant Low
Pressure Abnormality
159
TROUBLESHOOTING
RC display
E7
Error code
Outdoor control PCB
Code Sub code
86 10
11
12
21
22
Contents Error detection / Judgment
All fan motor starting failure or speed failure
Fan motor 1 starting failure
Fan motor 2 starting failure
Fan motor 1 speed failure
Fan motor 2 speed failure
No fan motor can operate due to starting failure or abnormal speed. (Refer to the following for details.)
The fan motor speed is lower than 50 rpm (min
-1
) after 10 seconds from fan motor starting direction. (Engine starting is prohibited while no fan motor's normal starting is confirmed when there is fan motor voltage direction at engine starting.)
When the fan motor is operating:
(No error detection for 10 seconds from running direction.)
1. Speed of lower than 50 rpm (min
-1
) is detected for 10 seconds. OR
2. Speed of 1,200 rpm (min -1 ) or more is detected for 10 seconds.
FE 81 0 Abnormal engine oil pressure Engine oil pressure switch ON is detected for 3 seconds when
10 seconds or longer have passed after engine starting.
10 Engine oil leakage Engine oil level switch OFF is detected for 5 seconds.
FF 58 0 Inadequate refrigerant oil Inadequate refrigerant oil of the operating outdoor unit is detected twice within 30 minutes.
FJ 47 0 Abnormal engine exhaust air temperature
The engine exhaust air temperature sensor detects 1,292
(700
℉
℃ ) or higher during compressor operation when deodorant kit is installed.
F3 91 0 Excessive compressor discharge pipe temperature
The compressor discharge pipe temperature sensor for the engaged compressor detects 248 ℉ (120 ℃ ) or higher for 3 seconds (the higher temperature is selected when 2 compressors are connected).
160
TROUBLESHOOTING
Error frequency until error display
1
6 in a row
Display
Error
Warning
Warning
※ 1
C
F
F
Method of diagnosis / repair
Treatment
N
N
Possible major causes Diagnosis / Repair
※ 2
B 1. Connector of fan motor contact failure
2. Fan motor failure
3. Harness of fan motor disconnection or short circuit
4. Outdoor control PCB failure
1. Check connector of fan motor connection
2. Refer to P217, 27)Inspect Outdoor Fan
Motor
1 Warning F N
Warning F N
2 in a row
1
2/60 minutes
1
2/15 minutes
6/24 minutes
Error A
Error B
Error
Error
Error
B
A
A
B
N
N
B
B
1. Connector of oil pressure switch contact failure
2. Oil pressure switch failure
3. Harness of oil pressure switch disconnection or short circuit
4. Low oil pressure
5. Noise or other causes
1. Check for connector of oil pressure switch connection
2. Refer to P186, 5)Oil Pressure Abnormality
1. Connector of oil level switch connection failure
2. Oil level switch failure
3. Harness of oil level switch disconnection or short circuit
4. Engine oil leakage
1. Check for connector of oil level switch connection
2. Refer to P186, 5)Oil Pressure Abnormality
1. Condenser heat dissipation failure
2. Refrigerant system blockage or leakage, etc.
3. Inadequate refrigerant oil
1. Refer to P190, 10)Overheated Refrigerant Discharge Temperature in Cooling Operation
2. Check refrigerant oil amount and leakage
1. Connector of engine exhaust air temperature sensor contact failure
2. Engine exhaust air temperature sensor failure
3. Harness of engine exhaust air temperature sensor disconnection or short circuit
4. Clogged deodorizing catalyst
1. Check for connector of engine exhaust air temperature sensor connection
2. Refer to P228, 52)Check for Readings of the Engine Exhaust Air Temperature Sensor
3. Check deodorizing catalyst
1. Connector of compressor discharge pipe temperature sensor contact failure
2. Compressor discharge pipe temperature sensor failure
3. Harness of compressor discharge pipe temperature sensor short circuit
4. Inadequate refrigerant / Blockage in refrigerant system / Compressor compression failure
5. Condenser heat dissipation failure
6. Entry of non-condensable gas
1. Check for connector of compressor discharge pipe temperature sensor connection
2. Refer to P190, 10)Overheated Refrigerant Discharge Temperature in Cooling Operation
3. Refer to P191, 11)Overheated Refrigerant Discharge Temperature in Heating Operation
161
TROUBLESHOOTING
RC display
F4
Error code
Outdoor control PCB
Code Sub code
87 0
Contents
Excessive compressor intake temperature
Error detection / Judgment
The compressor intake temperature sensor detects 140 ℉ (60
℃ ) or higher for 10 minutes during compressor operation.
2 Insufficient degree of superheat for compressor intake
After a compressor kicks in, length of time described below passed and lower than 36 ℉ (2 ℃ ) of ⊿ T at suction inlet is detected for 3 minutes.
1. In case of switch on from remote controller ··· 30 minutes
2. In case of other copmressor starts ··· 15 minutes
HC 70 0 Engine coolant temperature sensor disconnection
The engine coolant temperature sensor detects lower than 32 ℉
(0 ℃ ) for 3 minutes during engine operation.
80
HF EE
HJ
H3
H9
80
76
61
2
0
1
0
0
Engine coolant temperature sensor short circuit
The engine coolant temperature sensor detects 248 or higher for 1 minute.
℉ (120 ℃ )
Periodical inspection
Engine coolant empty
Refrigerant high pressure switch disconnection
When periodical inspection display is set at "DISABLED"
1. Engine running hours muinus last periodic inspection time is periodic inspection interval muinus 200 hours or more.
When periodical inspection display is set at "ENABLED"
1. Engine running hours muinus last periodic inspection time is between periodic inspection interval muinus 200 hours and periodic inspection interval puls 200 hours.
2. Engine running hours muinus last periodic inspection time is periodic inspection interval plus 200 hours or more.
After system stop due to overheated engine coolant temperature, engine coolant temperature is still 194 ℉ (90 ℃ ) or higher after 150 seconds passed.
The refrigerant high pressure switch 1 or 2 OFF is detected for
3 minutes.
Outside air temperature sensor disconnection
The outside air temperature sensor detects lower than -38
(-39 ℃ ) for 1 minute.
℉
JA 73
JC 88
1
0
1
4
Outside air temperature sensor short circuit
Refrigerant high pressure sensor 1 failure 1
The outside air temperature sensor detects 194 higher for 1 minute.
℉ (90 ℃ ) or
The refrigerant high pressure sensor 1 detects 551 psi (3.8
MPa) or higher at the start of operation after system stop due to refrigerant high pressure failure 1 detected by refrigerant high pressure sensor 1.
Refrigerant high pressure sensor 1 failure 2
When the refrigerant high pressure sensor 1 detects lower than
44 psi (0.3 MPa) for 30 seconds during compressor operation, the system stops temporarily. (Stopping procedure B.) When the refrigerant high pressure sensor 1 detects lower than 44 psi
(0.3 MPa) again at the next start of operation, it is identified as an error.
Refrigerant low pressure sensor failure
The refrigerant low pressure sensor detects lower than 12 psi
(0.08 MPa) at the restart of operation after system stop due to refrigerant low pressure failure.
162
TROUBLESHOOTING
Error frequency until error display
Display
2/10 hours Error
2/30 minutes
2/15 minutes
1
1
Error
Error
Error
Warning
※ 1
C
C
C, E
C, E
Z
Method of diagnosis / repair
Treatment
B
B
B
N
Possible major causes Diagnosis / Repair
※ 2
B 1. Connector of compressor intake temperature sensor contact failure
2. Compressor intake temperature sensor failure
3. Harness of compressor intake temperature sensor short circuit
4. Compressor failure
5. Reversing valve is locked in the middle position
1. Check for connector of compressor intake temperature sensor connection
2. Inspect compressor intake temperature sensor ( Refer to P229, 53)Check for
Readings of the Outdoor Temperature
Sensors )
3. Check compressor temperature
4. Check for temperature around the reversing valve ( Refer to P227, 49)Inspect Reversing Valve )
1. Connector contact failure
2. Engine coolant temperature sensor failure
3. Harness disconnection
1. Engine coolant temperature sensor failure
2. Harness short circuit
?
1. Check connector connection
2. Refer to P218, 28)Inspect Engine
Coolant Temperature Sensor
Refer to P218, 28)Inspect Engine Coolant Temperature Sensor
Conduct periodic inspection ( Refer to P38 and after, [PERIODIC INSPECTION] )
1 Warning Z N
1
1
1
1
1
1
1
1
Error
Error
Error
Error C, E
Error
Error
C, E
E
C
C, E
C
N
B Engine running without engine coolant refilled
Refer to P214, 23)Check Engine Coolant
Amount or Leakage Location
B
B
B
B
1. Connector contact failure
2. Refrigerant high pressure switch failure
3. Harness disconnection
1. Check connector connection
2. Refer to P222, 38)Inspect Refrigerant
High Pressure Switch
1. Connector contact failure
2. Outside air temperature sensor failure
3. Harness disconnection
1. Outside air temperature sensor failure
2. Harness short circuit
1. Refrigerant high pressure sensor failure
2. Harness short circuit
1. Check connector connection
2. Refer to P228, 51)Check for Readings of the Outside Air Temperature Sensor
Refer to P228, 51)Check for Readings of the Outside Air Temperature Sensor
Refer to P223, 39)Inspect Refrigerant
High Pressure Sensor
Error C B 1. Connector contact failure
2. Refrigerant high pressure sensor failure
3. Harness disconnection
1. Check connector connection
2. Refer to P223, 39)Inspect Refrigerant
High Pressure Sensor
Error C B 1. Connector contact failure
2. Refrigerant low pressure sensor failure
3. Harness disconnection
1. Check connector connection
2. Refer to P224, 46)Inspect Refrigerant
Low Pressure Sensor
163
TROUBLESHOOTING
RC display
JE
Error code
Outdoor control PCB
Code Sub code
71 0
Contents
Engine oil pressure switch disconnection
JJ 72 0
Error detection / Judgment
The engine oil pressure switch OFF is detected for 5 seconds at starting. (At the first and second times of failure detection, the engine is driven for 3 seconds and stops. At the third time detection and after, the system stops before engine starting.
Engine compartment temperature sensor disconnection
The engine compartment temperature sensor detects lower than -38 ℉ (-39 ℃ ) for 1 minute.
J3 78
91
J4 55
J5 53
J6 65
0
1
2
3
0
1
6
Engine compartment temperature sensor short circuit
The engine compartment temperature sensor detects 194
(90 ℃ ) or higher for 1 minute.
℉
Engine exhaust air temperature sensor disconnection
The engine exhaust air temperature sensor detects lower than
392 ℉ (200 ℃ ) for 4 minutes during compressor operation when deodorant kit is installed.
Compressor discharge pipe temperature sensor disconnection
Compressor discharge pipe temperature sensor short circuit
The compressor discharge pipe temperature sensor 1 detects lower than 34 ℉ (1 ℃ ) for 10 minutes during compressor 1 operation.
The compressor discharge pipe temperature sensor 2 detects lower than 34 ℉ (1 ℃ ) for 10 minutes during compressor 2 operation.
The compressor discharge pipe temperature sensor 1 detects
248 ℉ (120 ℃ ) or higher for 1 minute.
The compressor discharge pipe temperature sensor 2 detects
248 ℉ (120 ℃ ) or higher for 1 minute.
Accumulator outlet temperature sensor disconnection
The accumulator outlet temperature sensor detects lower than
-38 ℉ (-39 ℃ ) for 1 minute.
2
0
Accumulator outlet temperature sensor short circuit
The accumulator outlet temperature sensor detects 194
℃ ) or higher for 1 minute.
℉ (90
Compressor intake temperature sensor disconnection
The compressor intake temperature sensor detects lower than
-38 ℉ (-39 ℃ ) for 1 minute.
2
0
2
Compressor intake temperature sensor short circuit
The compressor intake temperature sensor detects 194
℃ ) or higher for 1 minute.
℉ (90
Outdoor heat exchanger liquid temperature sensor disconnection
The outdoor heat exchanger liquid temperature sensor detects lower than -38 ℉ (-39 ℃ ) for 1 minute.
Outdoor heat exchanger liquid temperature sensor short circuit
The outdoor heat exchanger liquid temperature sensor detects
194 ℉ (90 ℃ ) or higher for 1 minute.
164
TROUBLESHOOTING
Error frequency until error display
Display
5 in a row Error
1
1
2/15 minutes
1
1
Error
Error
Error
Error
Error
※ 1
C
C, E
C, E
C
C
C
Method of diagnosis / repair
Treatment
B
B
B
B
B
Possible major causes Diagnosis / Repair
※ 2
B 1. Connector contact failure
2. Engine oil pressure switch failure
3. Harness disconnection
1. Connector connection failure
2. Engine compartment temperature sensor failure
3. Harness disconnection
1. Check connector connection
2. Refer to P220, 34)Inspect Engine Oil
Pressure Switch
3. Check harness disconnection
1. Check connector connection
2. Inspect engine compartment temperature sensor ( Refer to P229, 53)Check for Readings of the Outdoor Temperature Sensors )
1. Engine compartment temperature sensor failure
2. Harness short circuit
1. Connector connection failure
2. Engine exhaust air temperature sensor failure
3. Harness disconnection
1. Check connector connection
2. Refer to P228, 52)Check for Readings of the Engine Exhaust Air Temperature Sensor
1. Connector connection failure
2. Compressor discharge pipe temperature sensor failure
3. Harness disconnection
1. Check connector connection
2. Refer to P227, 50)Check for Readings of the Compressor Discharge Pipe
Temperature Sensor
1
1
1
1
1
1
1
1
Error
Error
Error
C, E
C, E
C, E
Error C, E
Error
Error
Error
Error
C, E
C, E
C, E
C, E
B
B
1. Compressor discharge pipe temperature sensor failure
2. Harness short circuit
B
B
B
B
B
B
1. Connector connection failure
2. Accumulator outlet temperature sensor failure
3. Harness disconnection
1. Accumulator outlet temperature sensor failure
2. Harness short circuit
1. Check connector connection
2. Inspect accumulator outlet temperature sensor ( Refer to P229, 53)Check for
Readings of the Outdoor Temperature Sensors )
1. Connector connection failure
2. Compressor intake temperature sensor failure
3. Harness disconnection
1. Check connector connection
2. Inspect compressor intake temperature sensor ( Refer to P229, 53)Check for
Readings of the Outdoor Temperature Sensors )
1. Compressor intake temperature sensor failure
2. Harness short circuit
1. Connector connection failure
2. Outdoor heat exchanger liquid temperature sensor failure
3. Harness disconnection
1. Check connector connection
2. Inspect outdoor heat exchanger liquid temperature sensor ( Refer to P229,
53)Check for Readings of the Outdoor Temperature Sensors )
1. Outdoor heat exchanger liquid temperature sensor failure
2. Harness short circuit
165
TROUBLESHOOTING
RC display
J6
Error code
Outdoor control PCB
Code Sub code
85 0
Contents Error detection / Judgment
Outdoor heat exchanger vapor temperature sensor disconnection
The outdoor heat exchanger vapor temperature sensor detects lower than -38 ℉ (-39 ℃ ) for 1 minute.
2
J7 66 0
Outdoor heat exchanger vapor temperature sensor short circuit
The outdoor heat exchanger vapor temperature sensor detects
194 ℉ (90 ℃ ) or higher for 1 minute.
Sub heat exchanger liquid temperature sensor disconnection
The sub heat exchanger liquid temperature sensor detects lower than -38 ℉ (-39 ℃ ) for 1 minute.
J8 67
LE 75
LF 84
1
0
Sub heat exchanger liquid temperature sensor short circuit
The sub heat exchanger liquid temperature sensor detects
194 ℉ (90 ℃ ) or higher for 1 minute.
Outdoor liquid pipe temperature sensor disconnection
The outdoor liquid pipe temperature sensor detects lower than
-38 ℉ (-39 ℃ ) for 1 minute.
2
1
2
3
10
0
Outdoor liquid pipe temperature sensor short circuit
The outdoor liquid pipe temperature sensor detects 194
℃ ) or higher for 1 minute.
℉ (90
Igniter undervoltage
Igniter disconnection
Igniter overvoltage
Starter transformer voltage cut off
Engine starting failure
Igniter voltage of lower than 9 V is detected for 1 minute during engine operation. And misfire is detected.
Igniter voltage of lower than 0.5 V is detected for 1 minute during engine operation.
Igniter voltage of 17 V or higher is detected for 30 seconds during engine operation.
The system will stop immediately when the starter transformer voltage of 9 V or lower is detected for 1 second during engine operation. Detection continues for 20 seconds after that.
※ Error is not detected when the starter is ON.
When it is impossible to detect engine speed of 700 rpm (min -1 ) or higher during engine starting.
LJ
PE
PF
75
74
60
P8 74
0
7
0
1
Engine stop
Output failure of electromagnetic gas valve
Unintended starter operation
Engine speed of lower than minimum engine speed muinus 250 rpm (min
-1
) is detected for 1 second during engine operation.
The electromagnetic gas valve output is ON for 2 seconds when the electromagnetic gas valve should not operate.
The starter pinion motor voltage of 5 V or higher is detected for
3 seconds when the starter is OFF.
Insufficient engine starting speed
No engine speed pulse is detected for 5 seconds after starter
ON.
166
TROUBLESHOOTING
Error frequency until error display
Display
1
1
1
1
1
1
2/15 minutes
1
Error
Error
Error
Error
Error
Error
Error
Error
Method of diagnosis / repair
Treatment
C, E
C, E
C, E
C, E
C, E
B
B
B
B
B
B
B
Possible major causes Diagnosis / Repair
※ 1 ※ 2
C, E B 1. Connector connection failure
2. Outdoor heat exchanger vapor temperature sensor failure
3. Harness disconnection
1. Outdoor heat exchanger vapor temperature sensor failure
2. Harness short circuit
1. Check connector connection
2. Inspect outdoor heat exchanger vapor pipe temperature sensor ( Refer to
P229, 53)Check for Readings of the
Outdoor Temperature Sensors )
1. Connector connection failure
2. Sub heat exchanger liquid temperature sensor failure
3. Harness disconnection
1. Sub heat exchanger liquid temperature sensor failure
2. Harness short circuit
1. Check connector connection
2. Inspect sub heat exchanger liquid temperature sensor ( Refer to P229,
53)Check for Readings of the Outdoor Temperature Sensors )
1. Connector connection failure
2. Outdoor liquid pipe temperature sensor failure
3. Harness disconnection
1. Outdoor liquid pipe temperature sensor failure
2. Harness short circuit
1. Check connector connection
2. Inspect outdoor liquid pipe temperature sensor ( Refer to P229, 53)Check for
Readings of the Outdoor Temperature Sensors )
1. Igniter operation failure
2. Igniter power supply operation failure
Refer to P202, 12)Inspect Igniter, etc.
B B
1 Error B B
1 Error B N Transformer failure Refer to P199, 6)Inspect Starter Transformer
4 sets
4/15 minutes Error
1
2/15 minutes
Error
Error
B
B
B, E
2 in a row
Error
Error
C
C
B
B
N
B
1. Intake and exhaust air system failure
2. Ignition system failure
3. Compression system failure
4. Noise or other causes
5. Overload in cranking (Cold district only)
1.
2.
Refer to P184, 2)Engine will not Start
Refer to P176, [NOTE) Start prohibition control after "LF" (start failure) is displayed]
1. Inadequate engine output.
2. Stepping motor operation failure, etc.
Refer to P185, 3)Engine Starts But Stalls
Output failure of electromagnetic gas valve Inspect or replace outdoor control PCB
B
1. Starter relay melting abnormality
2. Outdoor control PCB failure
1. Refer to P200, 7)Operation Check of
Relay
2. Inspect or replace outdoor control PCB
1. Connector of engine speed sensor contact failure
2. Engine speed sensor failure
3. Harness of engine speed sensor disconnection
4. Starter motor failure
5. Transformer failure
6. Relay failure
Refer to P184, 2)Engine will not Start
167
TROUBLESHOOTING
RC display
P8
Error code
Outdoor control PCB
Code Sub code
74 4
-
82
3
0
1
97
Contents Error detection / Judgment
Engine speed control failure
Engine overspeed failure 1
Engine overspeed failure 2
Automatic address restart
(Short interruption of I/F microcomputer)
When 15 seconds or more have past after the start of the compressor,
1. Engine speed of lower than minimum engine speed muinus
50 rpm (min
-1
) is detected for 60 seconds. OR
2. Engine speed of lower than minimum engine speed muinus
100 rpm (min
-1
) is detected for 10 seconds. OR
3. Actual engine speed deviates from the indicated speed ± 300 rpm (min
-1
) for 60 seconds.
Engine speed of maximum engine speed plus 200 rpm (min
-1
) or higher is detected for 1 second during engine operation.
Engine speed of maximum engine speed plus 100 rpm (min or higher is detected for 10 second during engine operation.
-1
)
The power supply or the I/F PCB is reset, and initial communication (automatic address) restarts.
(Master and dependent outdoor unit detection.)
98
99
Power ON signal is received from the indoor unit
"Normal transmission impossible" is received from the I/F communication module
The indoor unit detects short break of power, and sends power
ON signal to the outdoor unit. (Master outdoor unit detection.)
"Normal transmission impossible" ※ is received from I/F PCB.
(Outdoor unit detection.) ※ A failure detected by I/F PCB when there is disconnection or short circuit of communication between outdoor and indoor units, or indoor unit's power supply is cut off.
UA
UC
UE
43
44
36
23
1 n (Air net address) n (Air net address) n (Air net address)
Excessed connecting all indoor units capacity
The capacity of connected indoor units is more than the memorized number of indoor units.
Incorrect indoor - outdoor units combination (Model, the number of units, etc.)
Incorrect indoor unit - remote controller combination (Corresponding remote controller)
Board type setting failure
There is a discrepancy of refrigerant type on the communication line.
This function is also used for the specification that detects refrigerant brand combination error.
(Indoor unit detection)
Address duplication
Indoor unit - central controller transmission failure
Air-net address duplication. (detected only when setting remote monitoring address)
Duplication of central control address. (Indoor unit detection)
Error information is transmitted directly to the outdoor unit only when the indoor unit does not have its own remote controller.
(Indoor unit detection)
168
TROUBLESHOOTING
Error frequency until error display
Display
3 in a row Error
※ 1
B
Method of diagnosis / repair
Treatment
Possible major causes
※ 2
B 1. Intake and exhaust air system failure
2. Ignition system failure
3. Compression system failure
4. Noise or other causes
Diagnosis / Repair
1. Check connector connection
2. Refer to P184, 2)Engine will not Start
3/15 minutes
3/15 minutes
1
1
1
Error
Error
-
-
-
B
B
B
B
B
1 Error
Outdoor unit detection
1
Indoor unit detection
-
Error
E
C, E
B Stepping motor operation failure, etc.
B
Refer to P187, 6)Over Speed
N
N
N
N
N
1. Connector of I/F PCB contact failure
2. Power for outdoor unit is OFF
(power failure, open phase)
3. I/F microcomputer resetting due to noise or other effect
1. Check connector of I/F PCB contact
2. Refer to P198, 1)Check Power Supply
System
Power for indoor unit is OFF
(power failure, open phase)
Refer to P198, 1)Check Power Supply
System
1. Power for indoor unit is OFF
(power failure, open phase)
2. Power supply failure of power supplying master unit
3. I/F PCB failure
4. Communication wire between indoor and outdoor units disconnection or short circuit
5. Communication failure caused by noise or other effect
1. Refer to P198, 1)Check Power Supply
System
2. Check wiring path
3. Inspect or check I/F PCB
4. Check for communication wire between indoor and outdoor units
5. Shield signal wire
The capacity of connected indoor units exceeds specified capacity.
1. Connected indoor unit's capacity is out of specified range
2. Refrigerant type or brand matching error
Check capacity of connected indoor units
1. Check indoor unit type
2. Check refrigerant type and brand
1
-
1
Warning
Alert
Error
Z
Z
X
N Address setting error Check address setting
N
N 1. Indoor unit signal wire or connector connection failure during operation
(disconnected or loosened)
2. Power for either indoor or outdoor unit is
OFF when the indoor and outdoor units are connected to separate power supplies. (Power failure, open phase)
3. Communication failure caused by noise or other effect
4. Indoor control PCB failure
1. Check remote controller power supply and indoor signal wire
2. Refer to P198, 1)Check Power Supply
System
3. Check fuse and transformer
4. Block noise path and shield remote controller wiring
5. Inspect or replace indoor control PCB
169
TROUBLESHOOTING
RC display
UF
Error code
Outdoor control PCB
Code Sub code
24 n (Air net address)
Contents
Refrigerant system is not set /
Improper wiring
UH
U0
U4
-
88
-
5
6
-
System failure
Refrigerant empty
Inadequate refrigerant
Transmission failure between indoor and outdoor units
Error detection / Judgment
Indoor unit system has no outdoor unit setting.
For example, indoor unit is connected to outdoor - outdoor unit line. (Indoor unit detection)
Communication address of indoor unit is not found between initial power ON and completion of automatic address setting.
(Indoor unit detection)
The following conditions are detected at outdoor unit starting operation (before engine starting).
1. Refrigerant high pressure is lower than 44 psi (0.30 MPa).
AND
2. Refrigerant low pressure is lower than 12 psi (0.08 MPa).
After starting defrost operation status, 90 seconds later, compressor discharge temperature sensor detects 212 ℉ (100 ℃ ) or higher.
The indoor unit detects indoor - outdoor unit transmission failure.
U5 1 n (Air net address)
Remote controller - indoor unit transmission failure
The remote controller - indoor unit transmission failure is detected.
U7 3
4
96
0
External control adapter failure is received
A failure occurs in the external control adapter, and the failure is received from the external control adapter.
(Master outdoor unit detection)
Communication failure between outdoor units 1
<Communication failure>
The transmission is interrupted for 10 seconds in the following time period.
1. During automatic address setting under combined installation.
Master: From decision signal transmission for automatic address setting start to automatic address setting completion.
Dependent: From confirmation signal transmission for automatic address setting decision to automatic address setting completion
2. During usual transmission under combined installation.
Master: Always.
Dependent: Always after receiving usual transmission from the master unit.
170
TROUBLESHOOTING
Error frequency until error display
Display
1 Error
※ 1
X
Method of diagnosis / repair
Treatment
Possible major causes
※ 2
N Improper wiring
Diagnosis / Repair
Check wiring
1
1
2/30 minutes
-
1
1
Error
Error
Error
Error
Error
X
B
A
X
X
Warning Z
N Signal wire between indoor and outdoor units improper wiring
Check signal wire between indoor and outdoor units
N 1. Refrigerant leakage (from flare connection or welded part)
2. Refrigerant low pressure sensor failure
3. Refrigerant high pressure sensor failure
Refer to P189, 9)Refrigerant Low Pressure Abnormality
N Inadequate refrigerant Refer to P222, 36)Inspect Refrigerant
Pressure (Inspect Refrigerant Amount)
N
N
N
1. Outdoor unit signal wire connection failure during operation (disconnected or loosened)
2. Power for either indoor or outdoor unit is
OFF when the indoor and outdoor units are connected to separate power supplies. (Power failure, open phase)
3. Communication failure between indoor and outdoor units caused by noise or other effect
4. Outdoor control PCB failure
1. Refer to P198, 1)Check Power Supply
System
2. Check signal wire between indoor and outdoor units
3. Check wiring path
4. Shield signal wiring between indoor and outdoor units
5. Inspect or replace outdoor control PCB
1. Remote controller signal wire contact failure or disconnection
2. Power of some of the indoor units is OFF, when one remote controller controls multiple indoor units.
3. Noise in remote controller wiring
4. Remote controller setting error
5. Remote controller PCB failure
6. Indoor control PCB failure
1. Check for remote controller power supply and signal wire
2. Refer to P198, 1)Check Power Supply
System
3. Check fuse and transformer
4. Block noise path and shield remote controller wiring
5. Check remote controller setting
6. Inspect or replace remote controller PCB
7. Inspect or replace indoor control PCB
Failure in the external control adapter.
Check external control adapter
1 Error B, E N 1. Power supply is OFF during operation.
(Power failure, open phase)
2. Outdoor unit signal wire connection failure during operation (disconnected or loosened)
3. Communication failure caused by noise or other effect
4. Outdoor control PCB failure
1. Refer to P198, 1)Check Power Supply
System
2. Check outdoor signal wire
3. Check wiring path
4. Shield signal wire
5. Inspect or replace outdoor control PCB
171
TROUBLESHOOTING
RC display
U7
Error code
Outdoor control PCB
Code Sub code
4 1
2
3
4
Contents Error detection / Judgment
Communication failure between outdoor units 2
<Automatic address setting failure>
Master unit: When any of the following occurs.
1. Memorized address of the outdoor unit connected to the indoor unit is a dependent unit address.
2. There are 3 or more dependent units.
3. As for combined installation, start signal from the dependent unit has discrepancy 10 times in a row.
4. The detected number of connected dependent units is more than memorized number.
5. Memorized automatic address and not memorized ones are mixed in the combined installation communication.
6. The master unit serial number memorized in the dependent unit does not agree with the actual master unit serial number.
(Excluding when the master unit serial number is not memorized.)
7. Automatic address setting completion direction is sent 10 times or more when memorized address is not yet decided.
Communication failure between outdoor units 3
<Model settings do not agree under combined installation>
Master unit: Model setting of master and dependent do not agree
Dependent unit: Dependent unit receives combined installation model settings discrepancy from the master unit.
Communication failure between outdoor units 4
<Automatic address memory data failure under combined
installation>
The following outdoor unit data are not memorized in combined installation automatic address, master unit memory or dependent unit memory.
1. Outdoor unit address
2. The number of connected indoor units
3. Outdoor unit serial number (Master unit: Other than FF is unacceptable / Dependent unit: FF is unacceptable)
Communication failure between outdoor units 5
<Insufficient number of connected dependent units under
combined installation>
The confirmed number of connected outdoor units is lower than the memorized number of outdoor units.
5 Communication failure between outdoor units 6
<Automatic address setting time out under combined installation>
Automatic address setting under combined installation does not terminate 10 minutes after starting to send the first
"Automatic address setting start under combined installation" signal.
(If automatic address under combined installation is not memorized, error decision terminates when check direction to the service person is displayed. If automatic address under combined installation is memorized, error decision terminates when "automatic address under combined installation" terminates.)
172
TROUBLESHOOTING
Error frequency until error display
1
Display
Error
※ 1
E
Method of diagnosis / repair
Treatment
Possible major causes Diagnosis / Repair
※ 2
N 1. Power supply is OFF during operation.
(Power failure, open phase)
2. Outdoor unit signal wire connection failure during operation (disconnected or loosened)
3. Communication failure caused by noise or other effect
4. Outdoor control PCB failure
1. Refer to P198, 1)Check Power Supply
System
2. Check outdoor signal wire
3. Check wiring path
4. Shield signal wire
5. Inspect or replace outdoor control PCB
1 Error E N
1 Error E N
1 Error E N
1 Error E N
173
TROUBLESHOOTING
RC display
U7
Error code
Outdoor control PCB
Code Sub code
4 6
U8 - -
Contents Error detection / Judgment
Communication failure between outdoor units 7
<Usual communication failure under combined installation>
Master unit: Among the following list, the same thing occurs
3 times or more within 10 seconds.
1. The master unit receives a reply to usual transmission from master to dependent 1 when 0 dependent unit is connected.
2. The master unit receives a reply to usual transmission from master to dependent 2 when 0 dependent unit is connected.
3. The master unit receives a reply to usual transmission from master to dependent 2 when 1 dependent unit is connected.
4. The master unit receives 1 or more replies to 1 usual transmission from master to dependent 1 when 2 dependent units is connected.
5. The master unit receives 2 or more replies to 1 usual transmission from master to dependent 1 when 2 dependent units is connected.
6. The master unit receives 2 or more replies to 1 usual transmission from master to dependent 2 when 2 dependent units is connected.
7. From the outdoor unit other than itself, the master unit receives usual transmission from master to dependent 1 or from master to dependent 2.
Main - sub remote controllers transmission failure
Sub remote controller detection
U9 - - Failure of other indoor units in the same system
An indoor unit detects an error to be treated with the procedure
A ~ E shown below.
5 n (Air net address)
Transmission failure between indoor and outdoor units
The outdoor unit detects transmission failure between indoor and outdoor units.
- 3 0 Normal communication is impossible 20 minutes after turning the power ON or rewiring.
※ 1) A: The system stops the engine immediately and disengages the compressor. The outdoor unit conducts 3-minute forced cooling
(operates fan motor forcibly for 3 minutes, then stops fan motor, and stops the engine coolant pump 10 seconds later).
(As for combined installation, 2 outdoor units stop immediataly and conduct cooling for 3 minutes.)
B: The system stops the engine immediately and disengages the compressor. The outdoor unit conducts ordinary cooling.
(The outdoor unit operates the fan motor until the engine coolant temperature and refrigerant high pressure reach a level below the specified values, then stops the engine coolant pump 10 seconds later). (As for combined installation, 2 outdoor units stop immediataly and each outdoor unit conducts cooling individually.)
C: The system stops the engine after the pump down and disengages the compressor. The outdoor unit conducts ordinary cooling.
(As for combined installation, 1 outdoor unit conducts pump down operation. When 2 outdoor units are operating, 1 unit stops first normally.)
D: The system suspends the outdoor unit start-up procedure.
174
TROUBLESHOOTING
Error frequency until error display
1
Display
Error
※ 1
B, E
Method of diagnosis / repair
Treatment
Possible major causes Diagnosis / Repair
※ 2
N 1. Power supply is OFF during operation.
(Power failure, open phase)
2. Outdoor unit signal wire connection failure during operation (disconnected or loosened)
3. Communication failure caused by noise or other effect
4. Outdoor control PCB failure
1. Refer to P198, 1)Check Power Supply
System
2. Check outdoor signal wire
3. Check wiring path
4. Shield signal wire
5. Inspect or replace outdoor control PCB
-
1
1
Error X
Depends on error content.
Error
-
B, E
E
N
N
N
1. Signal wire connection failure (disconnected or loosened)
2. Power supply is OFF during operation.
(Power failure, open phase)
3. Communication failure caused by noise or other effect
4. Remote controller PCB failure
1. Outdoor unit signal wire connection failure during operation (disconnected or loosened)
2. Power for either indoor or outdoor unit is
OFF when the indoor and outdoor units are connected to separate power supplies. (Power failure, open phase)
3. Communication failure between indoor and outdoor units caused by noise or other effect
4. Outdoor control PCB failure
1. Refer to P198, 1)Check Power Supply
System
2. Check signal wire
3. Check wiring path
4. Shield signal wire
5. Inspect or replace remote controller PCB
1. Refer to P198, 1)Check Power Supply
System
2. Check signal wire between indoor and outdoor units
3. Check wiring path
4. Shield signal wiring between indoor and outdoor units
5. Inspect or replace outdoor control PCB
1. Outdoor unit signal wire connection failure during operation (disconnected or loosened)
2. Power supply is OFF during operation.
(Power failure, open phase)
3. Communication failure caused by noise or other effect
4. Outdoor control PCB failure
1. Refer to P198, 1)Check Power Supply
System
2. Check outdoor signal wire
3. Check wiring path
4. Shield signal wire
5. Inspect or replace outdoor control PCB
E: The system prohibits the outdoor unit operation. (Including prohibiting starting.)
F: The system stops only the faulty fan motor.
X: The system stops only the faulty indoor unit.
Z: The system continues operation.
※ 2) B: Backup function under combined installation enabled
N: Backup function under combined installation disabled
175
TROUBLESHOOTING
NOTE) Start prohibition control after "LF" (start failure) is displayed
Depending on the starter signal ON time, the start failure reset is restricted.
Start failure reset is restricted in order to prevent starter overheating. (Unable to reset the "LF" indication)
In that case, try to reset the error with appropriate intervals.
Do not turn OFF the electric leakage breaker to reset the error.
Error reset disabled
Error reset is possible
Prohibition counter
Counting method of prohibition counter
Counter value is calculated once a second. At the calculation timing, the counter value increases by 12 when the starter is ON, and decreases by 1 when the starter is OFF.
Starter motor on off
Calculation timing per second
Prohibition counter value
176
TROUBLESHOOTING
2. Parts Characteristics
[Outdoor unit system]
Inspection item
Electric leakage breaker
(ELB)
Terminal block 1 (for power supply) (TB1)
Main PCB
DCBL PCB
Outdoor fan motors 1, 2
(FM1, 2)
Measurement point
Red-White-Black 1-2-3
Red-White-Black R-S-T
CN13[1]-[2] Red-White
CN5[1]-[2] Red-White
CN6[1] Black
DCBL PCB
FM1;
CN7 [3]-[2] Black-White
CN7 [2]-[1] White-Red
CN7 [3]-[1] Black-Red
FM1;
CN10 [1]-[5] Gray-Pink
FM1;
CN10 [1]-[2] Gray-Orange
CN10 [1]-[3] Gray-Blue
CN10 [1]-[4] Gray-Yellow
FM2;
CN8 [4]-[2] Black-White
CN8 [2]-[1] White-Red
CN8 [4]-[1] Black-Red
Normal voltage (V)
200 V AC
[Pseudo sine wave]
Maximum output
180 V AC [effective value]
(160 V AC
[absolute average])
4.5 ~ 5.5 V DC
2.5 VAC
[Pseudo sine wave]
Maximum output 180 V AC
[effective value]
(160 V AC [absolute average]) in proportion to engine speed
Outside air temperature sensor (THO)
FM2;
CN12 [1]-[5] Gray-Red
FM2;
CN12 [1]-[2] Gray-Orange
CN12 [1]-[3] Gray-Blue
CN12 [1]-[4] Gray-Yellow
CN6 [9]-[10] Red-Red
4.5 ~ 5.5 V DC
2.5 V AC
Engine compartment temperature sensor (E/G R)
CN6[13]-[14] White-White
Normal resistance value ( Ω )
2 ~ 4 Ω
(Measured with connector disconnected)
2 ~ 4 Ω
(Measured with connector disconnected)
Temperature
( ℉ ( ℃ ))
14 (-10)
32 (0)
50 (10)
68 (20)
86 (30)
104 (40)
122 (50)
Resistance
( Ω )
23.7 k
15.0 k
9.8 k
6.5 k
4.4 k
3.1 k
2.2 k
Remark
NOTE) Measure the voltage at
R-S (Red-White).
NOTE) Pulse signal
NOTE) Pulse signal
• Disconnection temperature is detected (lower than -38 ℉
(-39
℃
)).
Disconnection is detected for
1 minute (outside air temperature sensor disconnection →
61-0) (engine compartment temperature sensor disconnectiont → 72-0)
• Short circuit temperature is detected (194
℉
(90
℃
) or higher).
Shot circuit is detected for
1 minute (outside air temperature sensor short circuit →
61-1)
(engine compartment temperature sensor short circuit →
72-1)
177
TROUBLESHOOTING
[Engine system]
Inspection item
Throttle valve (STM)
Engine oil pressure switch
(OLP)
Measurement point
CN6[16] Brown
CN6[18] Red
CN6[19] Blue
CN6[21] Orange
CN6[15] Yellow
CN6[17] White
CN6[3]-[4] Brown-Brown
Normal voltage (V)
-30 ~ +30 V DC pulse wave
ON : 1 V DC or less
OFF : 11 ~ 13 V DC
Normal resistance value ( Ω )
1-2
2-3
4-5
5-6
1-3
4-6
120 Ω
(77
℉
25(
℃
))
240 Ω
(77
℉
25(
℃
))
Remark
1 M Ω or more (OFF)
1 Ω or less (ON)
Engine oil pressure switch disconnection is detected when engine oil pressure switch OFF is detected for 5 seconds before starter ON at engine starting.
(engine oil pressure switch disconnection → 71-0)
1 M Ω or more (OFF)
1 Ω or less (ON)
21 Ω
0.01 Ω (68
℉
20(
℃
))
Oil level switch (OIL-LVL) CN4[5]-[6] Blue
Electromagnetic gas valves
1, 2 (GV1, 2)
Starter (STR)
Starter pinion coil
Fuel gas flow control valve
(FUEL)
CN8[4]-[10] Black-White
CN8[5]-[11] Red-Green
Motor + side terminal-
Ground
Starter relay output side or starter pinion terminal-
Ground
CN6[20] Brown
CN6[22] Red
CN6[26] Blue
CN6[24] Orange
CN6[23] Yellow
CN6[25] White
CN6[7]-[8] Yellow-Yellow Engine exhaust air temperature sensor (E/G E)
(unit with deodorant kit only)
ON : 1 V DC or less
OFF : 11 ~ 13 V DC
11 ~ 13 V DC
11 ~ 19 V DC
11 ~ 13 V DC
-30 ~ +30 V DC pulse wave
0.24 Ω (68
℉
20(
℃
))
1-2
2-4
5-7
7-8
1-4
5-8
Temperature
(
℉
(
℃
))
392(200)
572 (300)
752 (400)
932 (500)
1112 (600)
1292 (700)
1472 (800)
120 Ω
(77
℉
25(
℃
))
240 Ω
(77 ℉ 25( ℃ ))
Resistance
( Ω )
371.1 k
52.6 k
11.5 k
3.53 k
1.38 k
0.64 k
0.34 k
• Disconnection temperature is detected (lower than 392
℉
(200 ℃ )).
When the deodorant option is installed, disconnection is detected for 4 minutes during compressor operation. (engine exhaust air temperature sensor disconnection → 72-6)
Power supply PCB
Engine speed sensor (WB)
(Ne is 15 TON only)
8 TON
CN1[1]-[2] Red-Black
CN1[7]-[8] Yellow-Black
CN1[3]-[4] Blue-Black
CN3[1]-[2] Red-White
15 TON
CN1[1]-[2] Red-Black
CN1[7]-[8] Yellow-Black
CN1[3]-[4] Blue-Black
CN3[1]-[2] Red-White
Ne; CN7[3]-[4]
Orange-Brown
G2; CN7[1]-[2] Red-Black
11 ~ 13 V DC
13 ~ 15 V DC
15 ~ 17 V DC
19 ~ 21 V DC
11 ~ 13 V DC
11 ~ 13 V DC
15 ~ 17 V DC
19 ~ 21 V DC
1100 ± 150 Ω (68 ℉ 20( ℃ ))
178
TROUBLESHOOTING
Inspection item
Ignition coils 1 ~ 4 (IG1 ~ 4)
(IG4 is 15 TON only)
Measurement point
1; CN8[1]-[3] White-Black
2; CN8[2]-[3] Yellow-Black
3; CN8[7]-[3] Blue-Black
4; CN8[8]-[3] Brown-Black
Igniter (IGN) Coil connector section
Normal voltage (V)
13~15 VDC
0-12 Vpulse wave
※
Do not measure with a circuit tester
Engine oil pan heater
(E/G OPH)
(Unit with drain heater kit only)
Exhaust water drain heater
(DH)
(Unit with drain heater kit only)
Cold district PCB
CN3[2]-[5] White-White
Cold district PCB
CN3[1]-[4] Yellow-Yellow
200 V AC
Normal resistance value ( Ω )
Primary resistance value
(68
℉
20(
℃
))
8 TON
15 TON
833 Ω
2.8 Ω
1.85 Ω
Remark
200 V AC
Refer to table below
(Resistance of exhaust water drain heater)
NOTE) When measuring resistance at the connector on the PCB, measured value is combined value because following 2 heaters are connected to one connector in parallel.
Exhaust water drain filter heater
Exhaust water drain hose heater
(Resistance of exhaust water drain heater)
8 TON
15 TON
On the PCB (combined value)
Drain filter
Drain hose
On the PCB (combined value)
Drain filter
Drain hose
421
833
851
476
667
1667
Ω
Ω
Ω
Ω
Ω
Ω
[Engine Coolant System]
Inspection item
Engine coolant temperature sensor (WT)
Measurement point
CN6[11]-[12] Black-Black
Engine coolant pump (WP) DCBL PCB ; CN9
[3]-[2] Black-White
[2]-[1] White-Red
[3]-[1] Black-Red
[Refrigerant system]
Normal voltage (V)
[Pseudo sine wave]
Maximum output 160 V AC
[effective value]
(130 V AC [absolute average])
Normal resistance value ( Ω )
Temperature
(
℉
(
℃
))
Resistance
( Ω )
122 (50)
176 (80)
212 (100)
17.6 k
6.1 k
3.3 k
230 (110) 2.5 k
Remark
• Disconnection temperature is detected (lower than 32
(0
℃
)).
℉
Disconnection is detected for
3 minutes during engine operation. (engine coolant temperature sensor disconnection →
70-0)
• Short circuit temperature is detected (248
℉
(120
℃
)).
Shot circuit is detected for
1 minute (engine coolant temperature sensor short circuit → 80-1)
8 TON
15 TON
16 ~ 25 Ω
10 ~ 18 Ω
179
TROUBLESHOOTING
Inspection item
Compressor discharge pipe temperature sensors 1, 2
(C/P T1, C/P T2)
Measurement point
1: CN4[27]-[28]
White-White
2: CN4[25]-[26]
Yellow-Yellow
Compressor intake temperature sensor (C/P S)
CN4[23]-[24] White-White
Accumulator outlet temperature sensor (AOT)
CN4[13]-[14] White-White
Sub heat exchanger liquid temperature sensor (SOT)
CN4[15]-[16] Blue-Blue
Outdoor liquid pipe temperature sensor (ILT)
CN4[29]-[30] Black-Black
Outdoor heat exchanger liquid temperature sensor
(THL)
Outdoor heat exchanger vapor temperature sensor
(THG)
CN4[19]-[20] Yellow-Yellow
CN4[17]-[18] White-White
Normal voltage (V)
Temperature
(
℉
(
℃
))
14 (-10)
32 (0)
50 (10)
68 (20)
86 (30)
104 (40)
122 (50)
131 (55)
140 (60)
149 (65)
158 (70)
167 (75)
Normal resistance value ( Ω )
Temperature
(
℉
(
℃
))
32 (0)
68 (20)
Resistance
( Ω )
182.9 k
70.4 k
122 (50)
176 (80)
212 (100)
248 (120)
20.2 k
7.0 k
3.7 k
2.1 k
Resistance
( Ω )
23.7 k
15.0 k
9.8 k
6.5 k
4.4 k
3.1 k
2.2 k
1.86 k
1.59 k
1.36 k
1.17 k
1.01 k
Remark
• Disconnection temperature is detected (lower than 41
(5 ℃ )).
℉
Disconnection is detected for
10 minutes during compressor
1 operation. (compressor discharge pipe temperature sensor 1 disconnection → 78-0)
Disconnection is detected for
10 minutes during compressor
2 operation. (compressor discharge pipe temperature sensor 2 disconnection → 78-1)
• Short circuit temperature is detected (248 ℉ (120 ℃ ) or higher).
Short circuit is detected for 1 minute (compressor discharge pipe temperature sensor 1 short circuit → 91-2) (compressor discharge pipe temperature sensor 2 short circuit →
91-3)
• Disconnection temperature is detected (lower than -38
(-39
℃
)).
℉
Disconnection is detected for
1 minute. (outdoor heat exchanger liquid temperature sensor disconnection → 65-0)
(sub heat exchanger liquid temperature sensor disconnection → 66-1) (outdoor liquid pipe temperature sensor disconnection → 67-0) (compressor intake temperature sensor disconnection → 53-0) (accumulator outlet temperature sensor disconnection → 55-0)
(outdoor heat exchanger gas temperature sensor disconnection → 85-0)
• Short circuit temperature is detected (194 ℉ (90 ℃ ) or higher).
Short circuit is detected for
1 minute. (outdoor heat exchanger liquid temperature sensor short circuit → 65-2)
(sub heat exchanger liquid temperature sensor short circuit → 66-1) (outdoor liquid pipe temperature sensor short circuit → 67-2) (compressor intake temperature sensor short circuit → 53-2) (accumulator outlet temperature sensor short circuit → 55-2) (outdoor heat exchanger gas temperature sensor short circuit → 85-
2)
180
Inspection item
Refrigerant high pressure switches 1, 2 (HLSW1, 2)
(HLSW2 is 15 TON only)
Measurement point
CN30[1]-[2] Red-Red
TROUBLESHOOTING
Normal voltage (V)
OFF: 11 ~ 13 V DC
ON : 1 V DC or less
Normal resistance value ( Ω )
1 M
1
Ω
Ω
or more (OFF)
or less (ON)
Remark
An error is detected when the sensor detects 551 psi. (3.8
MPa) (OFF). Normal state is resumed at the detection of 421 psi (2.9 MPa) (ON).
Disconnection is detected when transformer power supply is ON and refrigerant high pressure switch OFF is detected for
3 minutes. (refrigerant high pressure switch disconnection
→ 76-0)
Refrigerant high pressure sensor 1 (PSH1)
CN4[33]-[31]-[32]
Red-White-Black
Power supply voltage
4.75 ~ 5.25 V DC
CN4[33]-[32]
Output voltage
0.5 ~ 3.753 V DC
CN4[31]-[32]
Refrigerant low pressure sensor (PSL)
CN4[34]-[11]-[12]
Red-White-Black
Power supply voltage
4.75 ~ 5.25 V DC
CN4[34]-[12]
Output voltage
0.5 ~ 3.853 V DC
CN4[11]-[12]
Outdoor heat exchanger liquid flow control valve
(OEV)
CN5[20] Red
CN5[18] Brown
CN5[25] Blue
CN5[27] Orange
CN5[21] Yellow
CN5[23] White
Sub heat exchanger liquid flow control valve (SEV)
CN5[16] Red
CN5[14] Brown
CN5[17] Blue
CN5[19] Orange
CN5[13] Yellow
CN5[15] White
Subcooling valve (SCEV) CN5[12] Red
CN5[10] Brown
CN5[9] Blue
CN5[11] Orange
CN5[5] Yellow
CN5[7] White
11 ~ 13 V DC
11 ~ 13 V DC
11 ~ 13 V DC
Red-White
Red-Orange
Brown-Yellow
Brown-Blue
White-Orange
Yellow-Blue
Red-White
Red-Orange
Brown-Yellow
Brown-Blue
White-Orange
Yellow-Blue
(8 TON)
46 ± 4 Ω
(15 TON)
34.3 ± 4.3 Ω
(8 TON)
92 ± 8 Ω
(15 TON)
68.6 ± 8.6 Ω
(8 TON)
46 ± 4 Ω
(15 TON)
34.3 ± 4.3 Ω
(8 TON)
92 ± 8 Ω
(15 TON)
68.6 ± 8.6 Ω
Red-White
Red-Orange
Brown-Yellow
Brown-Blue
White-Orange
Yellow-Blue
46 ± 4
92 ± 8
Ω
Ω
NOTE) When the elecrtonic expansion valve is 5 cores
(without brown), substitute red core for brown core.
181
TROUBLESHOOTING
Inspection item
Oil bypass control valve
(OVEV)
Measurement point
CN5[8] Red
CN5[6] Brown
CN5[1] Blue
CN5[3] Orange
CN5[4] Yellow
CN5[2] White
Compressor clutch 2 (C/P2) CN8[12] White
Hot gas bypass valve (BV) CN11[1]-[7] Red-Red
Reversing valve (4PV)
Compressor heaters 1, 2
(C/P H1, 2)
CN11[2]-[8] Red-Red
CN11[5]-[11] Yellow-Yellow
Electromagnetic compressor capacity valves 1, 2
(C/PV1, 2)
1: CN11[3]-[9] Blue-Blue
2: CN11[4]-[10]
White-White
Normal voltage (V)
11 ~ 13 V DC
14.5 ~ 18.5 V DC
200 V AC
200 V AC
200 V AC
200 VAC
Normal resistance value ( Ω )
Red-White
Red-Orange
Brown-Yellow
Brown-Blue
White-Orange
Yellow-Blue
46 ± 4
92 ± 8
Ω
Ω
Remark
NOTE) When the elecrtonic expansion valve is 5 cores
(without brown), substitute red core for brown core.
4 Ω ± 20 %
NOTE) Be sure to measure voltage and resistance between the specified connector and the ground
(body ground).
1050 Ω
950 Ω
1.67 k Ω ± 7 %
NOTE) When measuring resistance at the connector on the PCB, the measured value is 1/2 of the actual value for one compressor heater, because 2 compressor heaters are connected to one connector in parallel.
1050 Ω
182
TROUBLESHOOTING
3. Failure Phenomenon
1)
The System will not Operate
Problem
No operation.
No display on the remote controller.
Remote controller display functions but the system does not operate
Possible Cause
Power supply system failure
Remote controller system failure
Communication system failure
Control system failure
Specific Example
Error in connecting the power supply wires
Contact failure / disconnection
Control unit failure
Electrical leakage breaker is
OFF
Contact failure / disconnection
Remote controller failure
Wiring error in the communication line
Contact failure / disconnection
Wiring error
Contact failure / disconnection
Control unit failure
For diagnosis and repair, Refer to P306 and after, [Wiring Diagram of the Outdoor Unit]
Inspection and Treatment
Refer to P198, 1)Check Power Supply
System
Refer to P198, 2)Check Control Unit
Refer to P198, 3)Locate Electric
Leakage Positions
Refer to P198, 4)Check Remote Control System
Inspect communication line (wire disconnection, internal short circuit)
Refer to P198, 2)Check Control Unit
183
TROUBLESHOOTING
2)
Engine will not Start
Problem
P8 (74-1) error
Possible Cause
Starter pinion does not work
Specific Example
Pinion drive coil failure
Starter unit failure
Transformer failure
Starter drive system terminal contact failure
Inspection and Treatment
Refer to P199, 5)Inspect
Starter
Refer to P199, 6)Inspect
Starter Transformer
Starter drive system failure
Relay failure
Fuel gas pressure failure
Refer to P200, 7)Operation
Check of Relay
Refer to P200, 8)Inspect Fuel
Gas Pressure
Intake and exhaust air system failure
Fuel gas
Incorrect air/ fuel ratio
Electromagnetic gas valve operation failure
Air system
Fuel system
Electromagnetic gas valve failure
Output failure
Blockage in the air inlet
Clogged air filter element
Engine throttle valve failure
Stuck engine throttle valve
Fuel gas flow control valve failure
Output failure
Refer to P200, 9)Inspect Electromagnetic Gas Valve
Air filter element inspection / replacement
Refer to P210, 16)Inspect Engine Throttle Valve / Fuel Gas
Flow Control Valve
P8 (74-4) error
LF (84) error
Blockage in the exhaust system
Air/fuel ratio failure
Blockage in the exhaust water drain hose
Freezing in exhaust water drain hose
Broken or twisted exhaust water drain hose
Blockage in the exhaust air heat exchanger or the exhaust muffler
Spark plug failure
Deposit formation or wet plug
Spark plug clearance is off the standard
Refer to P210, 17)Inspect Air
/ Fuel Ratio
Refer to P211, 19)Inspect Exhaust Water Drain Heater ※ 1
Inspect / adjust exhaust water drain hose
Inspect for exhaust air heat exchanger or the exhaust muffler
Refer to P201, 10)Inspect
Spark Plug
Ignition system failure
Compression system failure
Noise or other causes
Too heavy cranking load
High voltage cable failure
Igniter, etc. failure
Valve popping up
Valve clearance failure
Carbon deposit formation on valve or valve seat
Engine speed sensor reading failure
Malfunction caused by induction noise from the ignition system
Due to low temperature, engine oil is so viscous that the starter is not able to run the engine.
Refer to P201, 11)Inspect
High Voltage Cable
Refer to P202, 12)Inspect Igniter, etc.
Refer to P203, 13)Compression Inspection
Refer to P204, 14)Valve
Clearance Inspection /
Adjustment ※ 2
Refer to P205, 15)Treatment for Compression Failure due to Carbon Deposit
Refer to P211, 18)Check for
Contact Failure at the Starter
Drive System
Refer to P201, 11)Inspect
High Voltage Cable
Refer to P212, 20)Inspect Engine Oil Pan Heater ※ 1
※ 1. Unit with drain heater kit only
※ 2. 8 TON only
For diagnosis and repair, Refer to P306 and after, [Wiring Diagram of the Outdoor Unit] or Refer to P233 and after, [Board Maintenance Functions] .
184
TROUBLESHOOTING
3)
Engine Starts But Stalls
Problem Possible Cause Specific Example
Fuel gas pressure failure
Inspection and Treatment
Refer to P200, 8)Inspect Fuel Gas
Pressure
Fuel gas
Electromagnetic gas valve operation failure
Electromagnetic gas valve failure
Output failure
Refer to P200, 9)Inspect Electromagnetic Gas Valve
Intake and exhaust air system failure
Incorrect air/ fuel ratio
Air system
Fuel system
Blockage in the air inlet
Clogged air filter element
Engine throttle valve failure
Stuck engine throttle valve
Fuel gas flow control valve failure
Output failure
Air filter element inspection / replacement
Refer to P210, 16)Inspect Engine
Throttle Valve / Fuel Gas Flow Control Valve
LJ (75) error
P8 (74-4) error
Blockage in the exhaust system
Air/fuel ratio failure
Blockage in the exhaust water drain hose
Freezing in exhaust water drain hose
Broken or twisted exhaust water drain hose
Blockage in the exhaust air heat exchanger or the exhaust muffler
Spark plug failure
Deposit formation or wet plug
Spark plug clearance is off the standard
Refer to P210, 17)Inspect Air / Fuel
Ratio
Refer to P211, 19)Inspect Exhaust
Water Drain Heater ※ 1
Inspect / adjust exhaust water drain hose
Inspect for exhaust air heat exchanger or the exhaust muffler
Refer to P201, 10)Inspect Spark Plug
Ignition system failure
Compression system failure
High voltage cable failure
Ignition timing failure
Igniter, etc. failure
Valve popping up
Valve clearance failure
Carbon deposit formation on valve or valve seat
Refer to P201, 11)Inspect High Voltage Cable
Refer to P213, 21)Check Ignition
Timing ※ 2
Refer to P202, 12)Inspect Igniter, etc.
Refer to P203, 13)Compression Inspection
Refer to P204, 14)Valve Clearance Inspection / Adjustment ※ 2
Refer to P205, 15)Treatment for Compression Failure due to Carbon Deposit
LE (75-10) error
Noise or other causes
Starter drive system failure
Engine speed sensor reading failure
Starter drive system terminal contact failure
Malfunction caused by induction noise from the ignition system
Transformer failure
Starter drive system terminal contact failure
Refer to P211, 18)Check for Contact
Failure at the Starter Drive System
Refer to P201, 11)Inspect High Voltage Cable
Refer to P199, 6)Inspect Starter
Transformer
※ 1. Unit with drain heater kit only
※ 2. 8 TON only
For diagnosis and repair, Refer to P306 and after, [Wiring Diagram of the Outdoor Unit] or Refer to P233 and after, [Board Maintenance Functions] .
185
TROUBLESHOOTING
4)
Engine Coolant Temperature Abnormality
Problem
EC (80) error
EH (80) error
HC (70) error
HC (80) error
HJ (80) error
Possible Cause
Engine coolant circulation failure
Insufficient heat dissipation
Specific Example
Insufficient engine coolant
Inspection and Treatment
Refer to P214, 22)Check Engine Coolant
Circulation
Refer to P214, 23)Check Engine Coolant
Amount or Leakage Location
Engine coolant pump operation failure
Engine coolant pump failure
Output failure
Thermostat failure
Air temperature around the outdoor unit is too high
Short circuit
Clogged radiator fins
Outdoor fan motor operation failure
Outdoor fan motor failure
Output failure
Engine coolant temperature sensor failure
Disconnection / Short circuit
Refer to P215, 24)Inspect Engine Coolant Pump
Refer to P216, 25)Inspect Thermostat
Refer to P216, 26)Check Engine Coolant
Heat Dissipation Condition (in cooling)
Clean the radiator fins
Refer to P217, 27)Inspect Outdoor Fan
Motor
Refer to P218, 28)Inspect Engine Coolant Temperature Sensor
Sensor/Harness system failure
Lowered boiling point
Radiator cap failure Refer to P218, 29)Inspect Radiator Cap
For diagnosis and repair, Refer to P306 and after, [Wiring Diagram of the Outdoor Unit] or Refer to P233 and after, [Board Maintenance Functions] .
5)
Oil Pressure Abnormality
Problem Possible Cause
Engine oil pressure switch malfunction
Specific Example
Engine oil pressure switch failure
Contact failure
Inspection and Treatment
Refer to P220, 34)Inspect Engine Oil Pressure Switch
FE (81) error
JE (71) error
Low oil pressure
Insufficient engine oil amount
Engine oil leakage
Abnormal engine oil consumption
Refer to P218, 30)Check Engine Oil
Amount
Refer to P219, 31)Check Engine Oil Leakage
Refer to P219, 32)Check Engine Oil Consumption Amount
Noise or other causes
Check engine oil pressure
Clogged oil strainer
Malfunction caused by induction noise from the ignition system
Starter drive system terminal contact failure
Refer to P220, 33)Inspect Oil Pressure
Refer to P201, 11)Inspect High Voltage
Cable
Refer to P211, 18)Check for Contact Failure at the Starter Drive System
For diagnosis and repair, Refer to P306 and after, [Wiring Diagram of the Outdoor Unit] or Refer to P233 and after, [Board Maintenance Functions] .
186
TROUBLESHOOTING
6)
Over Speed
Problem
P8 (82) error
Possible Cause
Engine system failure
Specific Example
Engine throttle valve failure
Stuck engine throttle valve
Gas mixer operation failure
Fuel gas flow control valve failure
Output failure
Inspection and Treatment
Refer to P210, 16)Inspect Engine Throttle Valve / Fuel Gas
Flow Control Valve
For diagnosis and repair, Refer to P306 and after, [Wiring Diagram of the Outdoor Unit] or Refer to P233 and after, [Board Maintenance Functions] .
7)
High Pressure Abnormality in Cooling Operation
Problem
E3 (86) error
H3 (76) error
JA (73) error
Possible Cause
Heat exchange at the condenser
(outdoor unit side) is disturbed.
Outdoor fan motor operation failure
Specific Example
Obstacle (contact with other objects)
Outdoor fan motor failure
Output failure
Deteriorated heat
exchange capacity
Intake air temperature is too high
Clogged heat exchanger fins
/ obstacle
Environmental / installation conditions are severe
Short circuit, etc.
Inspection and Treatment
Clean up obstacle
Refer to P217, 27)Inspect Outdoor Fan Motor
Clean heat exchanger fins
Check and improvement of environmental conditions
Refrigerant system failure
Inappropriate refrigerant amount
Blockage in the refrigerant flow path
Overfilling
Blockage in the check valve
Clogged or broken pipe
Stop valve operation failure
(not fully opened)
Refer to P222, 36)Inspect Refrigerant Pressure (Inspect Refrigerant Amount)
Refer to P222, 37)Inspection
Check Valve (Refrigerant Pressure Increase)
Correct faulty parts
Check if stop valve is fully opened
Blockage in the strainer
Refer to P224, 44)Inspect Strainer
Sensor/Harness system failure
Gas mixer operation failure
Non-condensable gas incorporation into the refrigerant system
Refrigerant high pressure switch malfunction
Refrigerant high pressure switch failure
Contact failure / disconnection
Refrigerant high pressure sensor operation failure
Refrigerant high pressure sensor failure
Contact failure / disconnection
Engine throttle valve failure
Stuck engine throttle valve
Fuel gas flow control valve failure
Output failure
Replace refrigerant
Refer to P222, 38)Inspect Refrigerant High Pressure Switch
Refer to P223, 39)Inspect Refrigerant High Pressure Sensor
Refer to P210, 16)Inspect Engine
Throttle Valve / Fuel Gas Flow
Control Valve
For diagnosis and repair, Refer to P306 and after, [Wiring Diagram of the Outdoor Unit] or Refer to P233 and after, [Board Maintenance Functions] .
187
TROUBLESHOOTING
8)
High Pressure Abnormality in Heating Operation
Problem Possible Cause
Heat exchange at the condenser
(indoor unit) is disturbed.
Indoor fan motor operation failure
Deteriorated heat exchange capacity
(air flow is blocked)
Specific Example
Obstacle
(contact with other objects)
Indoor fan motor failure
Indoor fan capacitor failure
Output failure
Clogged heat exchanger fins
/ obstacle
Intake air temperature is too high
Dust or dirt on the air filters
Environmental conditions are severe
Short circuit, etc.
Inspection and Treatment
Clean up obstacle
Refer to P224, 41)Inspect Indoor
Fan Motor
Clean heat exchanger fins
Clean air filters
Check and improvement of environmental conditions
Inappropriate refrigerant amount
Overfilling
Blockage in the check valve
Refer to P222, 36)Inspect Refrigerant Pressure (Inspect Refrigerant Amount)
Refer to P222, 37)Inspection
Check Valve (Refrigerant Pressure Increase)
Correct faulty parts
E3 (86) error
H3 (76) error
JA (73) error
Refrigerant system failure
Sensor/Harness system failure
Gas mixer operation failure
Blockage in the refrigerant flow path
Clogged or broken pipe
Stop valve operation failure
(not fully opened)
Blockage in the strainer
Non-condensable gas incorporation into the refrigerant system
Indoor electronic expansion valve operation failure (Valve does not open)
Blockage in the indoor electronic expansion valve
Hot gas bypass valve operation failure
Refrigerant high pressure switch malfunction
Hot gas bypass valve operation failure
(Valve does not open)
Refrigerant high pressure switch failure
Contact failure / disconnection
Refrigerant high pressure sensor operation failure
Refrigerant high pressure sensor failure
Contact failure / disconnection
Engine throttle valve failure
Stuck engine throttle valve
Fuel gas flow control valve failure
Output failure
For diagnosis and repair, Refer to P306 and after, [Wiring Diagram of the Outdoor Unit]
Check if stop valve is fully opened
Refer to P224, 44)Inspect Strainer
Replace refrigerant
Refer to P224, 42)Inspect for
Blockage in the Indoor Electronic
Expansion Valve
Refer to P223, 40)Inspect Hot Gas
Bypass Valve
Refer to P222, 38)Inspect Refrigerant High Pressure Switch
Refer to P223, 39)Inspect Refrigerant High Pressure Sensor
Refer to P210, 16)Inspect Engine
Throttle Valve / Fuel Gas Flow
Control Valve
188
TROUBLESHOOTING
9)
Refrigerant Low Pressure Abnormality
Problem
E4 (88) error
JC (88) error
U0 (88) error
Possible Cause
In cooling
Heat exchange at the evaporator
(indoor unit) is disturbed
Indoor fan motor operation failure
Specific Example
Obstacle
(contact with other objects)
Indoor fan motor failure
Indoor fan capacitor failure
Deteriorated heat exchange capacity
Output failure
Dust or dirt on the air filters
Clogged heat exchanger fins
/ obstacle
Intake air temperature is too low
Short circuit, etc.
Inspection and Treatment
Clean up obstacle
Refer to P224, 41)Inspect Indoor Fan Motor
Clean air filters
Clean heat exchanger fins
Sub heat exchanger liquid flow control valve failure
Refer to P225, 47)Inspect Sub
Heat Exchanger Liquid Flow
Control Valve
In heating
Common to cooling/ heating
Refrigerant system failure
Heat exchange at the evaporator
(outdoor unit) is disturbed
Inappropriate refrigerant amount
Blockage in the refrigerant flow path
Hot gas bypass valve operation failure
Blockage in the refrigerant flow path
Outdoor fan motor operation failure
Deteriorated heat exchange capacity
Intake air temperature is too low
Deteriorated sub heat exchange capacity
Hot gas bypass valve operation failure
(Blockage condition)
Blockage in the hot gas bypass valve
Blockage in the stop valve
Obstacle
(contact with other objects)
Outdoor fan motor failure
Output failure
Clogged heat exchanger fins
/ obstacle
Environmental / installation conditions are severe
Poor circulation of engine coolant
Thermostat failure
Sub heat exchanger liquid flow control valve failure
Outdoor heat exchanger liquid flow control valve failure
Insufficient refrigerant amount
Insufficient filling
Refrigerant leakage
Blockage in the strainer
Blocked indoor electronic expansion valve
Blockage in the check valve
Sensor/Harness system failure
Refrigerant low pressure sensor operation failure
Refrigerant high pressure sensor operation failure
Refrigerant low pressure sensor failure
Contact failure / disconnection
Refrigerant high pressure sensor failure
Contact failure / disconnection
For diagnosis and repair, Refer to P306 and after, [Wiring Diagram of the Outdoor Unit]
Refer to P223, 40)Inspect Hot
Gas Bypass Valve
Clean up obstacle
Refer to P217, 27)Inspect
Outdoor Fan Motor
Clean heat exchanger fins
Refer to P224, 43)Check Environmental Conditions (Low
Intake Air Temperature)
Refer to P215, 24)Inspect Engine Coolant Pump
Refer to P216, 25)Inspect
Thermostat
Refer to P225, 47)Inspect Sub
Heat Exchanger Liquid Flow
Control Valve
Refer to P226, 48)Inspect
Outdoor Heat Exchanger Liquid Flow Control Valve
Refer to P222, 36)Inspect Refrigerant Pressure (Inspect
Refrigerant Amount)
Refer to P224, 44)Inspect
Strainer
Refer to P224, 42)Inspect for
Blockage in the Indoor Electronic Expansion Valve
Refer to P224, 45)Inspection
Check Valve (Refrigerant
Pressure Drop)
Refer to P224, 46)Inspect Refrigerant Low Pressure Sensor
Refer to P223, 39)Inspect Refrigerant High Pressure Sensor
189
TROUBLESHOOTING
10)
Overheated Refrigerant Discharge Temperature in Cooling Operation
Problem
F3 (91) error
J3 (78) error
J3 (91) error
Possible Cause
Heat exchange at the condenser
(outdoor unit side) is disturbed.
Outdoor fan motor operation failure
Specific Example
Obstacle
(contact with other objects)
Outdoor fan motor failure
Deteriorated heat exchange capacity
Output failure
Clogged heat exchanger fins
/ obstacle
Intake air temperature is too high
Environmental / installation conditions are severe
Short circuit, etc.
Inspection and Treatment
Clean up obstacle
Refer to P217, 27)Inspect Outdoor
Fan Motor
Clean heat exchanger fins
Check and improvement of environmental conditions
Inappropriate refrigerant amount
Blockage in the check valve
Refer to P222, 36)Inspect Refrigerant Pressure (Inspect Refrigerant Amount)
Refer to P222, 37)Inspection
Check Valve (Refrigerant Pressure Increase)
Correct faulty parts
Refrigerant system failure
Sensor/Harness system failure
Blockage in the refrigerant flow path
Clogged or broken pipe
Stop valve operation failure
(not fully opened)
Blockage in the strainer
Non-condensable gas incorporation into the refrigerant system
Hot gas leakage into the inlet side
Reversing valve leakage
Refrigerant high pressure switch malfunction
Refrigerant high pressure sensor operation failure
Refrigerant high pressure switch failure
Contact failure / disconnection
Refrigerant high pressure sensor failure
Contact failure / disconnection
Check if stop valve is fully opened
Refer to P224, 44)Inspect Strainer
Replace refrigerant
Refer to P227, 49)Inspect Reversing Valve
Refer to P222, 38)Inspect Refrigerant High Pressure Switch
Refer to P223, 39)Inspect Refrigerant High Pressure Sensor
Compressor discharge pipe temperature sensor operation failure
Refer to P227, 50)Check for Readings of the Compressor Discharge Pipe Temperature Sensor
Gas mixer operation failure
Engine throttle valve failure
Stuck engine throttle valve
Fuel gas flow control valve failure
Output failure
Refer to P210, 16)Inspect Engine
Throttle Valve / Fuel Gas Flow
Control Valve
Compressor operation failure
Sensor/Harness system failure
Compressor compression failure
Compressor discharge pipe temperature sensor
Disconnection / Short circuit
Refer to P231, 55)Check Operation Condition
Refer to P227, 50)Check for Readings of the Compressor Discharge Pipe Temperature Sensor
For diagnosis and repair, Refer to P306 and after, [Wiring Diagram of the Outdoor Unit] or Refer to P233 and after, [Board Maintenance Functions] .
190
TROUBLESHOOTING
11)
Overheated Refrigerant Discharge Temperature in Heating Operation
Problem
F3 (91) error
J3 (78) error
J3 (91) error
Possible Cause
Heat exchange at the condenser
(indoor unit) is disturbed.
Indoor fan motor operation failure
Deteriorated heat exchange capacity
(air flow is blocked)
Specific Example
Obstacle
(contact with other objects)
Indoor fan motor failure
Indoor fan capacitor failure
Output failure
Clogged heat exchanger fins / obstacle
Intake air temperature is too high
Dust or dirt on the air filters
Environmental conditions are severe
Short circuit, etc.
Refrigerant system failure
Sensor/Harness system failure
Inappropriate refrigerant amount
Blockage in the check valve
Blockage in the refrigerant flow path
Refrigerant high pressure switch malfunction
Refrigerant high pressure sensor operation failure
Clogged or broken pipe
Stop valve operation failure
(not fully opened)
Blockage in the strainer
Non-condensable gas incorporation into the refrigerant system
Indoor electronic expansion valve operation failure
(Valve does not open)
Blockage in the indoor electronic expansion valve
Hot gas bypass valve operation failure
Hot gas leakage into the inlet side
Hot gas bypass valve operation failure (Valve does not open)
Reversing valve leakage
Refrigerant high pressure switch failure
Contact failure / disconnection
Refrigerant high pressure sensor failure
Contact failure / disconnection
Refer to P222, 36)Inspect Refrigerant Pressure (Inspect Refrigerant Amount)
Refer to P222, 37)Inspection
Check Valve (Refrigerant Pressure Increase)
Correct faulty parts
Check if stop valve is fully opened
Refer to P224, 44)Inspect Strainer
Replace refrigerant
Refer to P224, 42)Inspect for
Blockage in the Indoor Electronic
Expansion Valve
Refer to P223, 40)Inspect Hot Gas
Bypass Valve
Refer to P227, 49)Inspect Reversing Valve
Refer to P222, 38)Inspect Refrigerant High Pressure Switch
Refer to P223, 39)Inspect Refrigerant High Pressure Sensor
Compressor discharge pipe temperature sensor failure
Refer to P227, 50)Check for Readings of the Compressor Discharge Pipe Temperature Sensor
Gas mixer operation failure
Engine throttle valve failure
Stuck engine throttle valve
Fuel gas flow control valve failure
Output failure
Inspection and Treatment
Clean up obstacle
Refer to P224, 41)Inspect Indoor
Fan Motor
Clean heat exchanger fins
Clean air filters
Check and improvement of environmental conditions
Refer to P210, 16)Inspect Engine
Throttle Valve / Fuel Gas Flow
Control Valve
Compressor operation failure
Sensor/Harness system failure
Compression failure of the compressor
Compressor discharge pipe temperature sensor
Disconnection / Short circuit
Refer to P231, 55)Check Operation Condition
Refer to P227, 50)Check for Readings of the Compressor Discharge Pipe Temperature Sensor
For diagnosis and repair, Refer to P306 and after, [Wiring Diagram of the Outdoor Unit]
191
TROUBLESHOOTING
12)
Communication Failure / Indoor Unit System Failure
Problem Possible Cause
Drain system failure
Specific Example Inspection and Treatment
Refer to P232, 58)Check Drain
Water
AF (30) error Indoor drain failure
A3 (95) error
A6 (15) error
A7 (35) error
CA (98) error
CJ (17) error
C4 (18) error
C5 (19) error
C9 (97) error
UC (36) error
Humidifier failure
Drain pump operation failure
Water supply/drain water system failure of the humidifier
Drain pump failure
Output failure
Contact failure / disconnection
Check humidifier for water leak
Refer to P232, 59)Inspect
Drain Pump
Inappropriate drain water level
Indoor control PCB failure
Indoor unit address number setting error
Outdoor unit address number setting error
Drain float switch failure
Drain pipe failure Rise / Slope
Refer to P232, 60)Inspect
Drain Float Switch
Refer to P232, 58)Check Drain
Water
Clean up obstacle
Indoor fan operation failure
Obstacle (contact with other objects)
Indoor fan motor failure
Indoor fan capacitor failure
Output failure
Indoor swing flap motor operation failure
Indoor swing flap motor failure
Sensor/Harness system failure
Sensor/Harness system failure
Sensor/Harness system failure
Indoor control PCB failure
Sensor/Harness system failure
Indoor control PCB failure
Sensor/Harness system failure
Refer to P224, 41)Inspect Indoor Fan Motor
Check indoor swing flap motor or louver
Indoor discharge air temperature sensor operation failure
Indoor remote
controller sensor operation failure
Indoor heat exchanger liquid pipe temperature sensor operation failure
Indoor discharge air temperature sensor failure
Disconnection / Short circuit
Indoor remote controller sensor failure
Disconnection / Short circuit
Indoor heat exchanger liquid pipe temperature sensor failure
Connection failure / Disconnection
/ Short circuit
Refer to P231, 56)Check for
Readings of the Indoor Temperature Sensors
Inspect indoor remote controller sensor
Refer to P231, 56)Check for
Readings of the Indoor Temperature Sensors
Indoor control PCB failure
Inspect or replace indoor control
PCB
Indoor heat exchanger vapor pipe temperature sensor operation failure
Indoor heat exchanger vapor pipe temperature sensor failure
Connection failure / Disconnection
/ Short circuit
Refer to P231, 56)Check for
Readings of the Indoor Temperature Sensors
Indoor control PCB failure
Indoor intake air temperature sensor operation sensor
Indoor control PCB failure
Inspect or replace indoor control
PCB
Intake air temperature sensor failure
Connection failure / Disconnection
/ Short circuit
Refer to P231, 56)Check for
Readings of the Indoor Temperature Sensors
Inspect or replace indoor control
PCB
Duplicated assignment of the same indoor unit address number
Duplicated assignment of the same outdoor unit address number
Check address number setting
192
TROUBLESHOOTING
Problem
U5 (1) error
U7 (4) error
- (5) error
Possible Cause
Remote controller line failure
Indoor control PCB failure
Communication failure between outdoor units
Transmission failure between indoor and outdoor units
Outdoor unit signal wire connection failure during operation. (disconnected or loosened)
Communication failure caused by noise or other effect
Power supply is OFF during operation. (Power failure, open phase)
Outdoor unit signal wire connection failure during operation. (disconnected or loosened)
Communication failure caused by noise or other effect
Power supply is OFF during operation. (Power failure, open phase)
Specific Example
Power of some of the indoor units is OFF, when one remote controller controls multiple indoor units.
Noise in remote controller wiring
Remote controller signal wire contact failure or disconnection
Indoor control PCB failure
Outdoor control PCB failure
Outdoor control PCB failure
Inspection and Treatment
Refer to P198, 1)Check Power
Supply System
Check fuse and transformer
Block noise path and shield the remote controller wiring
Check for remote controller power supply and signal wire
Inspect or replace indoor control
PCB
Check outdoor signal wire
Check wiring path
Shield signal wire
Refer to P198, 1)Check Power
Supply System
Inspect or replace outdoor control PCB
Check outdoor signal wire
Check wiring path
Shield signal wire
Refer to P198, 1)Check Power
Supply System
Inspect or replace outdoor control PCB
For diagnosis and repair, Refer to P306 and after, [Wiring Diagram of the Outdoor Unit]
193
TROUBLESHOOTING
13)
Gas Heat Pump is Operating but Not Cooling
Problem
The compressor clutch is not engaged
Compressor operates, but there is no cool air flow
Equipment protection function is operating
Indoor heat exchange failure
Possible Cause
Compressor clutch operation failure
Sensor/Harness system failure
Specific Example
Compressor clutch failure
Contact failure
Output failure
Indoor intake air temperature sensor malfunction (Sensor judges the room temperature lower than the actual value and the temperature control is not turned on.)
Heat exchanger temperature sensor malfunction (Sensor judges the heat exchanger temperature lower than the actual value and the freezing prevention control is turned on in cooling.)
Inspection and Treatment
Refer to P232, 61)Inspect Compressor
Clutch
Refer to P231, 56)Check for Readings of the Indoor Temperature Sensors
※ Measure the refrigerant pressure and temperature during operation, and check the refrigerant cycle.
Refer to P222, 36)Inspect Refrigerant
Pressure (Inspect Refrigerant Amount)
Refer to P231, 55)Check Operation
Condition
Inappropriate refrigerant amount
Insufficient filling
Refrigerant leakage
Refer to P222, 36)Inspect Refrigerant
Pressure (Inspect Refrigerant Amount)
Refrigerant flow path failure (Warm air is coming out)
Reversing valve failure
Refer to P227, 49)Inspect Reversing
Valve
Other refrigerant flow path failure
Indoor electronic expansion valve operation failure
Hot gas bypass valve operation failure
Subcooling valve operation failure
Indoor electronic expansion valve failure
Hot gas bypass valve failure
Subcooling valve failure
Refer to P224, 42)Inspect for Blockage in the Indoor Electronic Expansion
Valve
Refer to P223, 40)Inspect Hot Gas Bypass Valve
Refer to P231, 55)Check Operation
Condition
Sub heat exchanger liquid flow control valve operation failure
Room temperature has lowered extremely
(Freezing prevention control for the indoor heat exchanger is activated)
Insufficient air flow volume
Sub heat exchanger liquid flow control valve failure
Protection circuit for the refrigerant system is engaged, and avoidance control is active
Refer to P225, 47)Inspect Sub Heat Exchanger Liquid Flow Control Valve
Blocked indoor electronic expansion valve
Check protection circuit engagement status or avoidance control operation
Refer to P224, 42)Inspect for Blockage in the Indoor Electronic Expansion
Valve
Refer to P224, 44)Inspect Strainer Blocked strainer
Blockage in the other refrigerant flow path failure
Dust or dirt on the indoor air filters Clean indoor air filters
Clogged heat exchanger fins
Indoor fan motor failure
Clean heat exchanger fins
Indoor fan motor operation failure
Indoor fan capacitor failure
Output failure
Refer to P224, 41)Inspect Indoor Fan
Motor
194
TROUBLESHOOTING
Problem
Engine speed does not increase
Improper installation
Possible Cause
During avoidance control, etc.
Engine failure
Specific Example
Refrigerant high pressure avoidance control
The unit is under control to avoid excessive increase in discharge temperature
The unit is under control to avoid excessive increase in engine coolant temperature
Inadequate engine output.
Pressure loss in piping is large
Pipe branch failure
Piping length between indoor and outdoor units is too long
There are too many bends in piping
Piping after branching is too long
Pipe size is improper
Height difference in piping is too large
Mounting angle / position of the branching pipe is incorrect
Another branch is made after a branch header
Inspection and Treatment
Refer to P187, 7)High Pressure Abnormality in Cooling Operation
Refer to P190, 10)Overheated Refrigerant Discharge Temperature in Cooling
Operation
Refer to P186, 4)Engine Coolant Temperature Abnormality
Refer to P185, 3)Engine Starts But
Stalls
Actual length is within 541 ft (165 m)
Equivalent length is within 623 ft (190 m)
Within 197 ft (60 m) from the first branching
Between indoor - outdoor units
Outdoor unit is higher: Within 164 ft (50 m)
Outdoor unit is lower: Within 131 ft (40 m)
Permissible height difference between indoor units : Within 49 ft (15 m)
Indoor unit selection error
The total capacity of connected indoor units is too large
Within 130 %
(The capacity exceeding the rating makes performance go down)
For diagnosis and repair, Refer to P306 and after, [Wiring Diagram of the Outdoor Unit]
195
TROUBLESHOOTING
14)
Gas Heat Pump is Pperating but Not Heating
Problem Possible Cause
The compressor clutch is not engaged
Compressor clutch operation failure
Sensor/Harness system failure
Specific Example
Compressor clutch failure
Contact failure
Output failure
Indoor intake air temperature sensor malfunction
(Sensor judges the room temperature higher than the actual value, and temperature control is not turned on.)
Short circuit
The compressor is operating, but fails to output the rated performance
Inspection and Treatment
Refer to P232, 61)Inspect Compressor
Clutch
Refer to P231, 56)Check for Readings of the Indoor Temperature Sensors
※ Measure the refrigerant pressure and temperature during operation, and check the refrigerant cycle.
Refer to P222, 36)Inspect Refrigerant
Pressure (Inspect Refrigerant
Amount)
Refer to P231, 55)Check Operation
Condition
Thermostat operation failure
Thermostat failure
Blockage in the engine coolant flow path
Refer to P216, 25)Inspect Thermostat
Insufficient air flow volume
Intake air temperature is too low
Outdoor fan failure
Clogged fins
Short circuit
Refer to P217, 27)Inspect Outdoor
Fan Motor
Clean heat exchanger fins
Insufficient refrigerant circulation amount
Insufficient refrigerant amount
Blocked indoor electronic expansion valve
Blocked strainer
Refer to P222, 36)Inspect Refrigerant
Pressure (Inspect Refrigerant
Amount)
Refer to P224, 42)Inspect for Blockage in the Indoor Electronic Expansion Valve
Refer to P224, 44)Inspect Strainer
Refer to P224, 42)Inspect for Blockage in the Indoor Electronic Expansion Valve
Indoor electronic expansion valve operation failure
Hot gas bypass valve operation failure
Outdoor heat exchanger liquid flow control valve operation failure
Sub heat exchanger liquid flow control valve operation failure
Indoor electronic expansion valve failure
Hot gas bypass valve failure
Outdoor heat exchanger liquid flow control valve failure
Sub heat exchanger liquid flow control valve failure
Refer to P223, 40)Inspect Hot Gas Bypass Valve
Refer to P226, 48)Inspect Outdoor
Heat Exchanger Liquid Flow Control
Valve
Refer to P225, 47)Inspect Sub Heat
Exchanger Liquid Flow Control Valve
Equipment protection function is operating
Protection circuit for the refrigerant system is engaged, and avoidance control is active
Check protection circuit engagement status or avoidance control operation
Indoor heat exchange failure
Insufficient air flow volume
Indoor fan motor operation failure
Dust or dirt on the indoor air filters
Clogged heat exchanger fins
Indoor fan motor failure
Indoor fan capacitor failure
Output failure
Clean indoor air filters
Refer to P224, 41)Inspect Indoor Fan
Motor
196
TROUBLESHOOTING
Problem Possible Cause
During avoidance control, etc.
Specific Example
Refrigerant high pressure avoidance control
The unit is under control to avoid excessive increase in discharge temperature
Inspection and Treatment
Refer to P188, 8)High Pressure Abnormality in Heating Operation
Refer to P190, 10)Overheated Refrigerant Discharge Temperature in Cooling Operation
Refer to P186, 4)Engine Coolant Temperature Abnormality
Engine speed does not increase
Sensor/Harness system failure
The unit is under control to avoid excessive increase in engine coolant temperature
High pressure sensor malfunction (Sensor judges the high pressure higher than the actual value, and the engine speed does not increase.)
Refer to P223, 39)Inspect Refrigerant
High Pressure Sensor
Improper installation
Engine failure
Pressure loss in piping is large
Branching failure in piping
Inadequate engine output.
Piping length between indoor and outdoor units is too long
There are too many bends in piping
Piping after branching is too long
Pipe size is improper
Height difference in piping is too large
Mounting angle / position of the branching pipe is incorrect
Another branch is made after a branch header
Refer to P185, 3)Engine Starts But
Stalls
Actual length is within 541 ft (165 m)
Equivalent length is within 623 ft (190 m)
Within 197 ft (60 m) from the first branching
Between indoor - outdoor units
Outdoor unit is higher: Within 164 ft (50 m)
Outdoor unit is lower: Within 131 ft (40 m)
Permissible height difference between indoor units : Within 49 ft (15 m)
Indoor unit selection error
The total capacity of connected indoor units is too large
For diagnosis and repair, Refer to P306 and after, [Wiring Diagram of the Outdoor Unit]
Within 130 %
(The capacity exceeding the rating makes performance go down)
197
TROUBLESHOOTING
4. Procedure for Inspection and Treatment
1)
Check Power Supply System
1. Check that the power supply wires of the indoor and outdoor units are correctly connected as specified in the installation manual.
2. Check that the power supply voltage (230 V AC or 208 V AC) is applied to indoor and outdoor units at the power supply terminal.
2)
Check Control Unit
1. Control unit on indoor units
Check the input/output voltage (230 V AC or 208 V AC) of the transformer in the indoor unit.
If 230 V ACor 208 V AC is not applied to the transformer, the fuse may be blown.
2. Control unit on outdoor units
1) Turn the power supply ON.
2) Check for power supply voltage (230 V AC or 208 V AC) in the outdoor unit.
If the LED 11 (yellow) on the main board does not light up even though 200 V AC is applied, the sub PCB or the main PCB may be faulty.
Check the input/output voltage.
3)
Locate Electric Leakage Positions
If the electrical leakage breaker activates, measure the insulation resistance using a megohmmeter to locate a leakage position.
Be sure to turn OFF the electrical leakage breaker and disconnect the ground wiring (CN4) on the EMC
PCB before measuring the insulation resistance.
Eelectric leakage breaker
Standard insulation resistance value
Measuring condition 500 V insulation tester
Variable resistor
Disconnected
Connected
10 M
1 M
Ω
Ω
or more
or more
[Procedure for Locating Electric Leakage Positions]
1. Locate the 200 V system devices
Disconnect the connectors for the 200 V system devices (reversing valve, hot gas bypass valve, compressor heater and oil bypass control valve) on the main PCB, the connectors (outdoor fan and engine coolant pump) on the DCBL PCB, and measure insulation resistance. If the resistance recovers with these connectors disconnected, leakage occurs in any of the devices. Inspect each device for leakage.
2. Locate the remote control system
Disconnect the power supply wires to each indoor unit at the terminals on the terminal block and measure the insulation resistance. If the resistance recovers, the indoor unit may be considered as a location of leakage.
NOTE) Never use a megohmmeter in the inspection of the communication system.
4)
Check Remote Control System
Inspect the terminals of the indoor units and the remote controllers for a failure, such as contact failure, disconnection, etc.
198
TROUBLESHOOTING
5)
Inspect Starter
1. Check output voltage applied to the starter
1) Output voltage applied to the starter motor.
(1) Select "Actuators output condition/individual actuating (code No. 20)" in the check mode of the board maintenance functions. Then turn ON "Main side output permission", "Engine side output permission", and "Starter transformer" in order.
(2) Check the output voltage (12 V DC) between the
B terminal of the starter and the body ground.
2) Output voltage applied to the pinion drive coil
(1) Select "Actuators output condition / individual actuating (code No. 20)" in the check mode of the board maintenance functions. Then check that
"starter ON" is displayed.
(2) Check the output voltage (12 V DC) between the
S terminal of the starter and the body ground.
B terminal
M terminal
S terminal
2. Inspect starter unit
Turn OFF the power supply, and measure the resistance at the locations shown in the right table.
Check that each measured value does not greatly deviate from the standard value.
Location
S terminal - Body ground
B terminal - Body ground
M terminal - Body ground
S terminal - M terminal
S termina - B terminal
B termina - M terminal
Standard resistance value
(68 ℉ (20 ℃ ))
0.24 Ω
∞
0.01 Ω
0.24 Ω
∞
∞
6)
Inspect Starter Transformer
1. Check primary input voltage
1) Select "Actuators output condition/individual actuating (code No. 20)" in the check mode of the board maintenance functions. Then turn ON "Main side output permission", "Engine side output permission", and "Starter transformer" in order.
2) Check the input voltage (200 V AC) at CN11[6]-[12] on the main PCB.
2. Check secondary output voltage
Check the output voltage (12 V AC) between the cathode side and anode side of the diode (2 locations).
If output voltage at the secondary side (200 V AC) is not normal although the input voltage on the primary side (200 V AC) is normal, the starter transformer is considered to be faulty.
3. Inspect starter transformer unit
Turn OFF the power supply, and check the insulation resistance between the primary terminal and the secondary terminal.
Primary terminal
Starter transformer
Secondary terminal
Cathode side
Anode side (ground)
Diode
199
TROUBLESHOOTING
7)
Operation Check of Relay
1. Check operation of starter relay (RY1)
1) Select "Actuators output condition/individual actuating (code No. 20)" in the check mode of the board maintenance functions. Then check that "starter ON" is displayed.
2) Check that 12 V DC is applied at CN10[4]-[6] on the main PCB.
If 12 V DC is not applied, the output circuit of the main PCB is considered to be faulty.
3) In the same way, when the "starter" is turned ON, check that 12 V DC is applied between the [3] pin of the starter relay (RY1) and the ground.
If 12 V DC is not applied, the starter relay (RY1) or transformer power is considered to be faulty.
[Operation of the Starter Circuit]
1) Turning the starter drive power ON
(1) After turning ON the operation switch, 200 V AC is applied from the CN11[6]-[12] on the main PCB to the primary coil of the starter transformer.
(2) The starter drive voltage, 12 V DC, is output from the secondary terminal of the transformer and applied to the starter transformer.
2) Driving the starter
12 V DC output from CN10 on the main PCB turns RY1 ON. This applies 12 V DC to the starter pinion coil to activate the starter.
8)
Inspect Fuel Gas Pressure
Inspect the gas presssure of fuel gas.
Standard pressure value 0.29 psi (2.0 kPa)
9)
Inspect Electromagnetic Gas Valve
1. Inspect electromagnetic gas valve unit
1) Turn OFF the electric leakage breaker.
2) Disconnect the connector to the electromagnetic gas valve, and measure the resistance between the terminals on each of the two electromagnetic gas valves for a magnet coil disconnection.
Standard resistance value 21.0 Ω
Electromagnetic gas valves
2. Check output voltage
1) Select "Actuators output status/individual actuating (code No. 20)" in the check mode of the board maintenance functions. Then turn ON "Main side output permission", "Engine side output permission", and (alone either "Electromagnetic gas valve 1" or "Electromagnetic gas valve 2") in order.
2) Check the output voltage (12 V DC) to the electromagnetic gas valve at each terminals (GV1: CN8[10]-[4],
GV2: CN8[11]-[5]) on the main PCB.
If the output voltage is not normal even though the "electromagnetic gas valve" is turned ON, the switching circuits on the main PCB are considered to be faulty.
200
TROUBLESHOOTING
10)
Inspect Spark Plug
1. Spark check of spark plug
1) Close the fuel gas valve.
2) Pull the caps to remove the cables.
NOTE) Do not pull the cable.
3) Remove the spark plugs with a plug wrench.
Cap
4) Attach the spark plug to the high voltage a cable, and make the spark plug body (screw part) contact to the engine.
Be sure to get your hand off of the spark plug, before engine cranking.
5) Select "Actuators output condition/individual actuating (code No. 20)" in the check mode of the board maintenance functions. Turn ON "Main side output permission", "Engine side output permission", "Starter transformer", "Ignition circuit drive signal", and "Starter" in order so that the starter can operate for 5 seconds to crank the engine. Check if there is a spark at the electrode of the spark plug.
2. Inspect spark plug electrodes
1) Check for burnout, dirt or abnormal wear on the electrode portion of the spark plug.
2) Check the clearance of the electrodes with a feeler gauge.
Plug
Feeler gauge
Electrode clearance standard value
0.016 ~ 0.039 inch
(0.4 ~ 1.0 mm)
3) Mount the spark plugs as before.
NOTE) When mounting the spark plug, make sure to tighten it first by hand. After that use a plug wrench to tighten it up to the specified torque.
Tightening torque 15 ~ 22lb·ft (20 ~ 30 N·m)
11)
Inspect High Voltage Cable
Connection failure of the high voltage cable to the connector or an internal disconnection of the cable may cause malfunctions due to noise influence including a sudden engine stall, oil pressure or engine coolant temperature abnormality from unknown causes.
1. Turn OFF the electric leakage breaker.
2. Inspect for connection failure of the high voltage cable connector to the spark plug or ignition coil.
3. Measure resistance at both sides of the high voltage cable and check for any abnormality such as disconnection.
201
TROUBLESHOOTING
[ 8 TON ]
Standard resistance value
High voltage cable #1
High voltage cable #2
High voltage cable #3
5.7 ± 2.2 k
4.6 ± 1.8 k
3.5 ± 1.3 k
Ω
Ω
Ω
High voltage cable 3
High voltage cable 1
High voltage cable 2
[ 15 TON ]
Standard resistance value
High voltage cable #1
High voltage cable #2
1.9 ~ 5.0 k Ω
High voltage cable #3
High voltage cable #4
High voltage cables
12)
Inspect Igniter, etc.
1. Output voltage check of the igniter.
1) Select "Actuators output condition/individual actuating (code No. 20)" in the check mode of the board maintenance functions. Then turn ON "Ignition circuit drive signal" to supply power to the igniter.
2) Disconnect the ignition coil connector, and check that 12 V DC is applied between the plus (+) terminal of the connector and the body.
[ 8 TON ] [ 15 TON ]
Connectors
Connectors
2. Inspect ignition coil
1) Turn OFF the electric leakage breaker.
2) Check that there is no disconnection or internal short circuit in the ignition coil.
[ 8 TON ] [ 15 TON ]
Standard resistance value
Connector
Standard resistance value
2.8 Ω
(68 ℉ (20 ℃ ))
1.85 Ω
(68 ℉ (20 ℃ ))
Connector
202
TROUBLESHOOTING
3. Inspect engine speed sensor
1) Turn OFF the electric leakage breaker.
2) Measure the resistance value between both terminals of the engine speed sensor.
[ 8 TON ]
Standard resistance value (68 ℉ (20 ℃ ))
Engine speed sensor G2 1,100 ± 150 Ω
[ 15 TON ]
Standard resistance value (68
Engine speed sensor G2
Engine speed sensor Ne
℉ (20 ℃
1,100 ± 150
))
Ω
Engine speed sensor G2
Engine speed sensor G2
Engine speed sensor Ne
13)
Compression Inspection
Measure the compression of each engine cylinder with a compression gauge to assure correct engine output.
1. Close the fuel gas valve.
2. Pull the caps to remove the cables.
NOTE) Do not pull the cable.
3. Remove the spark plugs with a plug wrench.
Cap
4. Insert part ⑤ of the adapter into the plug hole and tighten it.
5. Attach part ③ of the compression gauge to part ④ of the adapter and turn part ③ in the direction indicated by arrow until the turning effort becomes heavy. The rubber portion of part ⑤ is firmly pressed against the plug hole and thus fixed tightly.
6. Select "Engine throttle valve open position (code
No. 15)" in the check mode of the board maintenance functions. Then set the engine throttle valve to 500-step position (fully opened position).
7. Install the compression gauge at a safe location apart from moving parts.
Pressure standard value
Limit pressure
Compression gauge
Adapter
203 psi (1.4 MPa) or higher
160 psi (1.1 MPa)
8. Select "Actuators output condition/individual actuating (code No. 20)" in the check mode of the board maintenance functions. Turn ON "Main side output permission", "Engine side output permission", "Starter transformer", and "Starter" in order so that the starter can operate for 5 seconds to crank the engine, and measure the compression.
9. Push part ① to reset the gauge to "zero". Repeat the above procedure for other cylinders.
203
TROUBLESHOOTING
14)
Valve Clearance Inspection / Adjustment
[ 8 TON only ]
1. Close the fuel gas valve.
2. Hold and pull the cap to remove the cables
(3 places).
NOTE) Do not pull the cable.
3. Remove 3 spark plugs with a plug wrench.
4. Remove the cylinder head cover.
1) Unscrew a bolt to remove the blow-by hose connected to the cylinder head cover.
2) Unscrew 3 nuts to remove the cylinder head cover.
5. Wipe out the oil on the contact surface between the removed cylinder head cover and cylinder head.
Nuts
Caps
Blow-by hose
Bolt
6. Turn the crank pulley by hand, and align the top dead center mark on the crank pulley with the top dead center mark on the engine block.
Top dead center
Crank pulley
Front side
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TROUBLESHOOTING
7. Check that the intake rocker arm of No. 1 cylinder does not move when the crank pulley is turned approximately 60 ˚ clockwise and counterclockwise.
(Set No. 1 cylinder to the top dead center.)
NOTE) If the intake rocker arm of No. 1 cylinder moves, turn the crank pulley by another 1 revolution so that the top dead center marks align with each other again.
8. At the top dead center, adjust the intake valve clearance on No. 1 and No. 3 cylinders and exhaust valve clearance on No. 1 and No. 2 cylinders by loosening the adjustment nuts as shown in the illustration.
9. Turn the crank pulley by 1 revolution by hand so that the top dead center marks align with each other again.
10. Adjust the intake valve clearance on No. 2 cylinder and exhaust valve clearance on No. 3 cylinder by loosening the adjustment nuts as shown in the illustration.
Front side
No.1 intake
No.3 intake
No.2 exhaust
No.2 intake
No.1 exhaust
No.3 exhaust
Rear side
Adjustment nuts
Valve clearance standard value
When the engine is hot 0.014 ± 0.002 inch (0.35 ± 0.05 mm)
When the engine is cold 0.010 ± 0.002 inch (0.25 ± 0.05 mm)
NOTE)
Do not use a feeler gauge with a blade thickness of 0.008 inch (0.2 mm) or more.When adjusting a clearance of 0.008 inch (0.2 mm) or more, use two blades of feeler gauge.
Do not use a feeler gauge with bent or rusty blades.
When adjusting a valve clearance (while warm), set the target in the range from 0.013 inch (0.33 mm) ~ 0.015
inch (0.38 mm) (allows the insertion of a 0.013 inch (0.33 mm) blade but not a 0.015 inch (0.38 mm) blade).
15)
Treatment for Compression Failure due to Carbon Deposit
[Rinse treatment]
When carbon deposits are formed on the valve seat or valve and prevent the valve from sealing up the combustion chamber, clean the valve seat or valve in the manner explained below using a valve cleaner.
Carbon
Intake valve
Combustion chamber
[ 8 TON ]
1. Close the fuel gas valve.
2. Hold and pull the cap to remove the cables
(3 places).
NOTE) Do not pull the cable.
3. Remove 3 spark plugs with a plug wrench.
Caps
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TROUBLESHOOTING
4. Disconnect the connector for the igniter.
Be sure to disconnect the igniter connector before valve cleaning. Failure to do so may cause a fire.
5. Move a clamp to remove the air intake hose.
6. Select "Engine throttle valve open position (code
No. 15)" in the check mode of the board maintenance functions. Then set the engine throttle valve to 500-step position (fully opened position).
7. Unscrew 3 nuts to remove the cylinder head cover.
Igniter
Nuts Air intake hose Clamp
8. Turn the crankshaft by hand and set it at the position where the intake and exhaust valves of No. 1 cylinder do not move, when the crankshaft is turned 60 ˚ clockwise and counterclockwise.
(Set No. 1 cylinder to the top dead center.)
9. Supply valve cleaner into the gas mixer through the mouth of the gas mixer for 20 seconds and wait for
10 minutes.
10. Cover all 3 plug holes with rag, and turn the crank pulley 240° by hand.
11. Repeat the steps 8.~10. for No. 2 and No. 3 cylinders.
12. Cover all 3 plug holes with rag, and turn the crank pulley 3 ~ 4 turns by hand and drain valve cleaner.
13. Attach the cylinder head cover with 3 nuts.
14. Cover all 3 plug holes with rag. And select "Actuators output condition/individual actuating (code No.
20)" in the check mode of the board maintenance functions. Turn ON "Main side output permission",
"Engine side output permission", "Starter transformer", and "Starter" in order so that the starter can operate for 5 seconds to crank the engine.
15. Attach the spark plugs, air intake hose, and igniter connector as before.
Front side
No.3 intake
No.3 exhaust
Gas mixer
Rear side
No.2 exhaust
No.2 intake
No.1 intake No.1 exhaust
Air intake hose Valve cleaner
206
16. Remove the blow-by hose at the cylinder head cover side.
17. Run the engine.
18. Supply 1/2 can of valve cleaner to the gas mixer through the hose disconnected.
NOTE) Supply valve cleaner intermittently while making sure that there is no engine stall or over speed.
TROUBLESHOOTING
Cylinder head cover
Blow-by hose
Take extra precaution while cleaning any parts with the engine running. There are possibilities that your fingers or clothing could be caught by the crank pulley or other moving parts.
Do not apply the valve cleaner to the hot portion in cleaning the engine valves. Fire could occur.
19. Reconnect the blow-by hose to the head cover and keep the engine running until no more white smoke is emitted from the exhaust port. Then stop the engine.
20. Check if the compression has recovered sufficient pressure. ( Refer to P203, [Compression Inspection] )
If the compression does not recover, repeat steps 1. ~ 14..
[ 15 TON ]
1. Close the fuel gas valve.
2. Hold and pull the cap to remove the cables
(4 places).
NOTE) Do not pull the cable.
3. Remove 4 spark plugs with a plug wrench.
4. Disconnect the connector for the igniter.
Caps
Igniter
Be sure to disconnect the igniter connector before valve cleaning. Failure to do so may cause a fire.
5. Move a clamp to remove the air intake hose.
6. Unscrew 3 bolts to remove the cylinder head cover.
Air intake hose
Clamp
Cylinder head cover
Bolts
(3 pieces)
207
TROUBLESHOOTING
7. Turn the crankshaft by hand and set it at the position where the intake and exhaust valves of No. 1 cylinder do not move, when the crankshaft is turned 60 ˚ clockwise and counterclockwise.
(Set No. 1 cylinder to the top dead center.)
8. Select "Engine throttle valve open position (code
No. 15)" in the check mode of the board maintenance functions. Then set the engine throttle valve to 500-step position (fully opened position).
9. Supply valve cleaner into the gas mixer through the mouth of the gas mixer for 20 seconds and wait for
10 minutes.
10. Cover all 4 plug holes with rag, and turn the crank pulley by 1 revolution by hand.
11. Close the cylinder head cover with all plug holes covered with rag. And select "Actuators output condition/individual actuating (code No. 20)" in the check mode of the board maintenance functions.
And turn ON "Main side output permission",
"Engine side output permission", "Starter transformer", and "Starter" in order so that the starter can operate for 5 seconds to crank the engine.
12. Open the cylinder head cover with all plug holes covered with rag. And turn the crank shaft by hand and set it at the position where the intake and exhaust valves of No. 4 cylinder do not move, when the crank shaft is turned 60 ˚ clockwise and counterclockwise.
13. Attach the cylinder head cover with 3 bolts.
14. Repeat steps 8. ~ 11..
15. Attach the spark plugs, air intake hose, and igniter connector as before.
16. Remove the blow-by hose at the cylinder head cover side.
17. Run the engine.
18. Supply 1/2 can of valve cleaner to the gas mixer through the hose disconnected.
NOTE) Supply valve cleaner intermittently while making sure that there is no engine stall or over speed.
Rear side
No.4 intake
No.4 exhaust
No.3 exhaust
No.3 intake
No.2 intake
No.2 exhaust
No.1 exhaust
No.1 intake
Front side
Air intake hose Valve cleaner
Gas mixer
Blow-by hose Cylinder head cover
Take extra precaution while cleaning any parts with the engine running. There are possibilities that your fingers or clothing could be caught by the crank pulley or other moving parts.
208
TROUBLESHOOTING
19. Reconnect the blow-by hose to the head cover and keep the engine running until no more white smoke is emitted from the exhaust port. Then stop the engine.
20. Check if the compression has recovered sufficient pressure. ( Refer to P203, [Compression Inspection] )
If the compression does not recover, repeat steps 1. ~ 14..
[Treatment during engine operation]
[Common to all models]
1. Run the outdoor unit.
2. Move a clamp to remove the air intake hose.
Air intake hose
Clamp
3. Lift the air intake hose a little bit off the gas mixer, insert the nozzle of a valve cleaner, and supply about 1/2 can of valve cleaner.
NOTE) Supply valve cleaner intermittently while making sure that there is no engine stall or over speed.
4. Pull out the nozzle of the valve cleaner, and connect the air intake hose as before.
5. Keep the engine running until no more white smoke is emitted from the exhaust port. Then stop the engine.
6. Move the clamp as before.
Air intake hose Valve cleaner
Gas mixer
Take extra precaution while cleaning any parts with the engine running. There are possibilities that your fingers or clothing could be caught by the crank pulley or other moving parts.
Do not apply the valve cleaner to the hot portion in cleaning the engine valves. Fire could occur.
209
TROUBLESHOOTING
16)
Inspect Engine Throttle Valve / Fuel Gas Flow Control Valve
[Engine throttle valve]
1. Turn OFF the electric leakage breaker.
2. Disconnect the engine throttle valve relay connector and measure resistance between each pair of terminals of the stepping motor.
Motor coil resistance
Terminal No.
Standard value
(77 ℉ (25 ℃ ))
1 - 2 (White-Brown)
2 - 3 (Brown-Orange)
4 - 5 (Yellow-Red)
5 - 6 (Red-Blue)
1 - 3 (White-Orange)
4 - 6 (Yellow-Blue)
120
240
Ω
Ω
Connector terminal arrangement
(at the valve side)
Engine throttle valve
[Fuel gas flow control valve]
1. Turn OFF the electric leakage breaker.
2. Disconnect the fuel gas flow control valve relay connector and measure resistance between each pair of terminals of the fuel gas flow control valve.
Fuel gas flow control valve
Motor coil resistance
Terminal No.
Standard value
(77 ℉ (25 ℃ ))
1 - 2 (White-Brown)
2 - 4 (Brown-Orange)
5 - 7 (Yellow-Red)
7 - 8 (Red-Blue)
1 - 4 (White-Orange)
5 - 8 (Yellow-Blue)
120
240
Ω
Ω
Connector terminal arrangement
(at the valve side)
[Check output]
1. Select "Engine throttle valve open position (code No. 15)" in the check mode of the board maintenance functions. Then check the operation of the engine throttle valve by setting the valve to 500-step position (fully opened position).
2. Select "Fuel gas flow control valve open position (code No. 16)" in the check mode of the board maintenance functions. Then check the operation of the fuel gas flow control valve by setting the valve to 500-step position
(fully opened position).
17)
Inspect Air / Fuel Ratio
Measure the engine exhaust air from the exhaust port with an O
2
meter or an exhaust gas concentration meter.
O
2 meter
Air/fuel ratio standard value
3 ~ 10 % / 2,400 rpm (min
-1
)
210
TROUBLESHOOTING
18)
Check for Contact Failure at the Starter Drive System
A contact failure at the terminal of the starter drive system may lead to an engine stall caused by noise.
Check for looseness.
In particular; ① Capacitor connection terminals (2 places)
② Diode connection terminals (2 places)
③ Body ground connection terminal section (both ends)
④ Starter transformer cord connection terminal section (both ends), etc.
To starter B terminal To compressor bracket
①
④
④
②
To starter transformer
To body ground
③
③
19)
Inspect Exhaust Water Drain Heater
[ Unit with drain heater kit only ]
1. Check heater output
1) Select "Actuators output condition/individual actuating (code No. 20)" in the check mode of the board maintenance functions. Then turn ON "Exhaust water drain heater".
2) Measure the voltage between both ends of the connector with the heater connected, and check that 200 V DC is applied.
3) Select "Actuators output condition/individual actuating (code No. 20)" in the check mode of the board maintenance functions. Then turn OFF
"Exhaust water drain heater".
4) Measure the voltage between both ends of the connector with the heater connected, and check the voltage is 0 V.
Exhaust water drain filter heater
Measure point
Exhaust water drain hose heater
2. Check heater resistance value
1) Turn OFF the electric leakage breaker.
2) Check the heater resistance value at CN3[1]-[4] on the cold district PCB.
3) Disconnect the heater connector and check the resistance between both ends of the connector.
On the cold district PCB (combined value)
Exhaust water drain filter heater
Exhaust water drain hose heater
Standard resistance value
[ 8 TON ] [ 15 TON ]
421 Ω
833 Ω
851 Ω
476
667
Ω
Ω
1,667 Ω
211
TROUBLESHOOTING
3. Check temperature sensor readings
1) Check outside air temperature and engine compartment temperature with the monitor mode of the board maintenance functions.
2) Measure actual temperature with a thermometer, and check for the sensor reading's extreme deviation from the actual temperature.
3) Measure each sensor's resistance value at the terminals on the main PCB, and check for extreme deviation from the standard value.
Code No.
Outside air temperature
Engine compartment temperature
No. 4d
No. 50
Measure point (on main PCB)
Outside air temperature CN6[9]-[10]
Engine compartment temperature
CN6[13]-[14]
Temperature
14 ℉ (-10 ℃ )
32 ℉ (0 ℃ )
50 (10 ℃ )
68 ℉ (20 ℃ )
86 ℉ (30 ℃ )
104 ℉ (40 ℃ )
122 ℉ (50 ℃ )
Standard resistance value
23.7 k Ω
15.0 k Ω
9.8 k Ω
6.5 k Ω
4.4 k Ω
3.1 k Ω
2.2 k Ω
20)
Inspect Engine Oil Pan Heater
[ Unit with drain heater kit only ]
1. Check heater output
1) Select "Actuators output condition/individual actuating (code No. 20)" in the check mode of the board maintenance functions. Then turn ON "Engine oil pan heater".
2) Measure the voltage between both ends of the connector with the heater connected, and check that 200 V DC is applied.
3) Select "Actuators output condition/individual actuating (code No. 20)" in the check mode of the board maintenance functions. Then turn OFF
"Engine oil pan heater".
4) Measure the voltage between both ends of the connector with the heater connected, and check the voltage is 0 V.
2. Check heater resistance value
Disconnect the heater connector and check the resistance between both ends of the connector.
Measure point
Engine oil pan heater
Standard resistance value
833 Ω (per 1 piece)
212
TROUBLESHOOTING
3. Check temperature sensor readings
1) Check outside air temperature and engine compartment temperature with the monitor mode of the board maintenance functions.
2) Measure actual temperature with a thermometer, and check for the sensor reading's extreme deviation from the actual temperature.
3) Measure each sensor's resistance value at the terminals on the main PCB, and check for extreme deviation from the standard value.
Code No.
Outside air temperature
Engine compartment temperature
No. 4d
No. 50
Measure point (on main PCB)
Outside air temperature CN6[9]-[10]
Engine compartment temperature
CN6[13]-[14]
Temperature
14 ℉ (-10 ℃ )
32 ℉ (0 ℃ )
50 ℉ (10 ℃ )
68 ℉ (20 ℃ )
86 ℉ (30 ℃ )
104 ℉ (40 ℃ )
122 (50 ℃ )
Standard resistance value
23.7 k Ω
15.0 k Ω
9.8 k Ω
6.5 k Ω
4.4 k Ω
3.1 k Ω
2.2 k Ω
21)
Check Ignition Timing
[ 8 TON only ]
1. Connect a pickup clip of a timing light to the high voltage cable of the No. 1 cylinder.
High voltage cable 1
2. Check the ignition timing by aiming the timing light at the timing scale located behind the crank pulley on the front side of the engine.
Engine speed
1,200 rpm (min -1 )
Ignition timing
17° ± 3°
Timing light
213
TROUBLESHOOTING
22)
Check Engine Coolant Circulation
Reduction of engine coolant circulation amount due to blockage in the piping or other causes will cause a large difference between the radiator inlet and outlet temperatures.
1. Check temperature difference between radiator inlet and outlet to judge if the engine coolant circulation is normal.
2. Check engine coolant temperature during engine running by selecting "Engine coolant temperature
(code No. 51)" in the monitor mode of the board maintenance functions.
Rough guide of difference between the radiator inlet and outlet temperatures
In cooling 50 ~ 82 ℉ (10 ~ 28 ℃ )
23)
Check Engine Coolant Amount or Leakage Location
1. Check the engine coolant amount.
1) Select "Engine coolant refilling (code No. 0A)" in the check mode of the board maintenance functions. Then turn the engine coolant pump
ON.
2) Check that the engine coolant level in the reserve tank is not lower than reference line.
3) Remove the radiator cap and check if the water level is full.
Temperature difference
Reference line
Radiator cap
2. Check for engine coolant leakage.
1) Check the engine coolant hoses for cracks or deterioration.
2) Check if the engine coolant hose clamps are attached securely.
3) Check the engine coolant hoses and connections for leakage.
4) Check the radiator cap for leakage.
Radiator cap
214
TROUBLESHOOTING
When refilling engine coolant, be sure to use AISIN Coolant S.
When refilling engine coolant, be sure to mix with the following balance 50 ~ 60 vol%
(engine coolant: 0.55, water: 0.45).
Amount of engine coolant
8 TON
15 TON
3.96 gal (15 L)
6.87 gal (26 L)
24)
Inspect Engine Coolant Pump
1. Inspect engine coolant pump unit
[Check during operation]
1) Select "Engine coolant refilling (code No. 0A)" in the check mode of the board maintenance functions. Then turn the engine coolant pump ON.
2) Check the engine coolant pump for abnormal noise.
3) Check the engine coolant pump for abnormal vibration.
4) Check the engine coolant circuit for air intrusion.
5) Check that the engine coolant level in the reserve tank is not lower than reference line.
6) Check around the reserve tank for the evidence of engine coolant spout.
[Check during system stop]
Turn OFF the electric leakage breaker and check the motor coil resistance value of the engine coolant pump.
Engine coolant pump
Reference line
Standard resistance value
8 TON
15 TON
16 ~ 25
10 ~ 18
Ω
Ω
2. Check connector condition
1) Check the connectors on the DCBL PCB for disconnection or connection failure.
2) Check the relay connectors between the DCBL PCB and engine coolant pump for disconnection or connection failure.
3. Check DCBL PCB body
1) Check input voltage to the DCBL PCB
(1) Check that approximately 15 V DC of power supply voltage is applied at CN1[1]-[2] on the DCBL PCB.
(2) Check that approximately 200 V AC of power supply voltage is applied at CN5[1]-[2] on the DCBL PCB.
2) Check output voltage from the DCBL PCB
(1) Select "Engine coolant refilling (code No. 0A)" in the check mode of the board maintenance functions.
Then turn the engine coolant pump ON.
(2) Check that approximately 160 V AC of engine coolant pump power supply voltage is applied at CN9[1]-[2],
[1]-[3], and [2]-[3] on the DCBL PCB.
(3) Check that approximately 280 V DC of power supply voltage is applied at CN4[1]-[3] on the DCBL PCB.
215
TROUBLESHOOTING
3) Check output current from the DCBL PCB
(1) Select "Engine coolant refilling (code No. 0A)" in the check mode of the board maintenance functions.
Then turn the engine coolant pump ON.
(2) Check power supply current value for the engine coolant pump at CN9[1], [2], and [3] on the DCBL PCB with a clamp tester.
25)
Inspect Thermostat
When the engine coolant circulation amount is not normal even if the engine coolant pump is in good shape ( Refer to P215, [Inspect Engine Coolant
Pump] ), the thermostat may be improper.
Touch the hoses at each end of the thermostat, and check for temperature difference.
In thermostat opening: Without extreme temperature difference
In thermostat closing: With extreme temperature difference
Thermostats
Thermostat (140 ℉ (60 ℃ ) open)
Temperature at the start of opening 140 ℉ (60 ℃ )
Temperature at full opening
Thermostat valve lift amount
163 ℉ (73 ℃ )
0.33 inch (8.5 mm)
Thermostat (158 ℉ (70 ℃ ) open)
Temperature at the start of opening 158 ℉ (70 ℃ )
Temperature at full opening
Thermostat valve lift amount
181 ℉ (83 ℃ )
0.33 inch (8.5 mm)
26)
Check Engine Coolant Heat Dissipation Condition (in cooling)
If the radiator temperature is high as a whole in spite of a normal temperature difference between the inlet and outlet ( Refer to P214, [Check Engine Coolant Circulation] ), the radiator may be insufficiently dissipating heat.
1. Is ambient temperature around the outdoor unit excessively high due to short circuit or other causes?
2. Are the radiator fins clogged or covered by dirt?
Short circuit
Radiator portion
Eaves
Hot air from the adjacent outdoor unit
216
TROUBLESHOOTING
27)
Inspect Outdoor Fan Motor
1. Inspect outdoor fan motor body
[Check during operation]
1) Check the outdoor fan motor body for abnormal noise.
2) Check the outdoor fan motor body for abnormal vibration.
3) Select "Outdoor fan motor 1 speed (code No. 25)" and
"Outdoor fan motor 2 speed (code No. 26)" in the check mode of the board maintenance functions. Then check there is no speed difference between both fan motors at arbitrary fan speed (100 ~ 1,200 rpm (min
-1
)).
Fan motors
4) Select "Outdoor fan motor 1 speed (code No. 25)" and "Outdoor fan motor 2 speed (code No. 26)" in the check mode of the board maintenance functions. Then check there is no fan motor speed deviation under constant speed condition.
[Check during system stop]
1) Check the outdoor fans for crack or damage.
2) Turn OFF the electric leakage breaker and check the motor coil resistance value of the outdoor fan motors.
(Measured with connector disconnected)
Measurement point
On DCBL PCB
Standard resistance value
Fan motor 1
CN7 [3] Black - [2] White
CN7 [2] White - [1] Red
Fan motor 2
CN7 [3] Black - [1] Red
CN8 [4] Black - [2] White
CN8 [2] White - [1] Red
CN8 [4] Black - [1] Red
2 ~ 4 Ω
2. Check connector condition
1) Check the connectors on the DCBL PCB for disconnection or connection failure.
2) Check the relay connectors between the DCBL PCB and outdoor fan motors for disconnection or connection failure.
3. Check DCBL PCB body
1) Check input voltage to the DCBL PCB
(1) Check that approximately 15 V DC of power supply voltage is applied at CN1[1]-[2] on the DCBL PCB.
(2) Check that approximately 200 V AC of power supply voltage is applied at CN5[1]-[2] on the DCBL PCB.
2) Check output voltage from the DCBL PCB
(1) Select "Outdoor fan motor 1 speed (code No. 25)" and "Outdoor fan motor 2 speed (code No. 26)" in the check mode of the board maintenance functions. Then set each fan's speed to 1,200 rpm (min
-1
), and check operation.
(2) Check that approximately 180 V AC of power supply voltage for the outdoor fan motors is applied at CN7
[1]-[2], [1]-[3], [2]-[3], and at CN8[1]-[2], [1]-[4], [2]-[4] on the DCBL PCB.
(3) Check that approximately 280 V DC of power supply voltage is applied at CN4[1]-[3] on the DCBL PCB.
3) Check output current from the DCBL PCB
(1) Select "Outdoor fan motor 1 speed (code No. 25)" and "Outdoor fan motor 2 speed (code No. 26)" in the check mode of the board maintenance functions. Then set each fan's speed to 1,200 rpm (min
-1
), and check operation.
(2) Check power supply current value for outdoor fan motors at CN7[1], [2], [3] and at CN8[1], [2], [4] on the
DCBL PCB with a clamp tester.
217
TROUBLESHOOTING
28)
Inspect Engine Coolant Temperature Sensor
1. Check the relay connector for the engine coolant temperature for looseness or contact failure.
2. Check for disconnection or short circuit at CN6[11]-
[12] on the main PCB and relay connector.
Resistance value
∞
0 Ω
Condition
Disconnection
Short circuit
3. Check engine coolant temperature by selecting
"Engine coolant temperature (code No. 51)" in the monitor mode of the board maintenance functions.
4. Measure actual temperature with a thermometer, and check for the sensor reading's extreme deviation from the actual temperature.
5. Measure the resistance value of the engine coolant temperature sensor at CN6[11]-[12] on the main
PCB, and check for extreme deviation from the standard value.
Temperature
122 ℉ (50 ℃ )
176 ℉ (80 ℃ )
212 ℉ (100 ℃ )
230 ℉ (110 ℃ )
29)
Inspect Radiator Cap
1. Check the gaskets are not cracked or deformed.
Gaskets
Engine coolant temperature sensor
Standard resistance value
17.6 k Ω
6.1 k Ω
3.3 k Ω
2.5 k Ω
2. Confirm that the operating pressure of the radiator cap is
7.3 ± 1.5 psi (0.05 ± 0.01 MPa).
Radiator cap
Cap tester
Adapter
30)
Check Engine Oil Amount
Check the engine oil amount with an oil level gauge on the sub oil reservoir.
NOTE) When the outdoor unit is running or just has stopped, wait for 5 minutes before you check the engine oil amount.
Specified amount (sub oil reservoir)
8 TON
15 TON
B level -3/8 ~ 0 inch (-10 ~ 0 mm)
7.93 gal (30 L)
A level -3/8 ~ 0 inch (-10 ~ 0 mm)
8.45 gal (32 L)
218
Oil level gauge
31)
Check Engine Oil Leakage
1. Check the engine block and the gasket for oil leakage.
2. Check if the engine oil hose clamps are attached securely.
3. Check the engine oil hoses and hose connections for leakage.
4. Check the sub oil reservoir for oil leakage.
Sub oil reservoir
TROUBLESHOOTING
32)
Check Engine Oil Consumption Amount
Check oil consumption amount based on the oil level lowering and data from the previous inspection.
Excessive oil consumption causes carbon deposits on the spark plug electrode, which leads to spark failure and eventually causes an engine start failure.
Such a problem is considered to be caused by the valve drive system (valve stem seal) failure or piston ring failure.
Consumption
(fl oz/h)
=
Standard value
[ 8 TON ]
Oil level difference (inch) x 172
Running hours (hours)
0.03 ~ 0.10 fl oz
Consumption
(fl oz/h)
Standard value
=
[ 15 TON ]
Oil level difference (inch) x 198
Running hours (hours)
0.03 ~ 0.10 fl oz
Consumption
(cm 3 / h)
=
Standard value
Oil level difference (mm) x 200
Running hours (hours)
1.0~3.0 cm 3 /h
Consumption
(cm 3 / h)
=
Standard value
Oil level difference (mm) x 230
Running hours (hours)
1.0~3.0 cm 3 /h
Oil level difference
Oil level gauge
Oil level difference
Oil level gauge
219
TROUBLESHOOTING
33)
Inspect Oil Pressure
Oil pressure does not rise if oil supply is not normal due to causes such as oil strainer blockage.
1. Measure oil pressure with an oil pressure gauge attached to the mounting hole (PT 1/8) of the engine oil pressure switch during operation.
2. Check the engine oil level with an oil level gauge. If the level is low (close to the level "L"), add 0.53 ~ 0.79 gal
(2 ~ 3 L) of engine oil.
Pressure standard value
21.8 ~ 72.5 psi (150 ~ 500 kPa)
In case of 1,800 rpm (min
-1
)
[ 8 TON ] [ 15 TON ]
Engine oil pressure switch Engine oil pressure switch
34)
Inspect Engine Oil Pressure Switch
1. Check for contact failure due to loosening, at the engine oil pressure switch terminal or other causes.
2. Inspect the engine oil pressure switch to see if it is functioning normally by checking electric continuity between the terminals.
[ 8 TON ]
Engine
Engine oil pressure switch operation
Under shutdown condition
At operation
There is continuity
There is no continuity
[ 15 TON ]
Engine oil pressure switch
220
Engine oil pressure switch
TROUBLESHOOTING
35)
Technical Data When Replacing the Refrigerant System Parts
NOTE) Refer to the followings when you replace the refrigerant system parts.
Flare nuts tightening torque
1/4 inch (6.35 mm) 10 ~ 13 lb·ft (14 ~ 18 N·m)
Nominal outer diameter
3/8 inch (9.52 mm)
1/2 inch (12.70 mm)
5/8 inch (15.88 mm)
3/4 inch (19.05 mm)
25 ~ 31 lb·ft (34 ~ 42 N·m)
36 ~ 45 lb·ft (49 ~ 61 N·m)
50 ~ 60 lb·ft (68 ~ 82 N·m)
74 ~ 89 lb·ft (100 ~ 120 N·m)
Additional refilling amount of the refrigerant oil when repairing the refrigerant system
When doing refrigerant pump down 0 gal (0 cm
3
) ※ 1
When recovering refrigerant
When recovering refrigerant vapor
0.11 gal (400 cm
3
) ※ 1
0.11 gal (400 cm
3
) ※ 2
When accumulator is replaced
When oil separator is replaced
0.26 gal (1,000 cm
3
) ※ 3
0.53 gal (2,000 cm
3
) ※ 3
When other part is replaced (except compressor) Actual measurement ※ 3
※ 1. When replacing the parts that do not contain the refrigerant oil inside such as discharge pipes, expansion valves, or dryer filters
※ 2. When the compressor (including dryer filter) is replaced. (You must supply refrigerant oil into the compressor unit separately. For details, refer to Refer to P116, [Replacing the Compressor] )
※ 3. If the other parts are replaced together, total of refilling amount required for each replaced part must be added.
Standard amount of refrigerant
Standard amount of refrigerant
8 TON
15 TON
25.4 lbs (11.5 kg)
37.5 lbs (17.0 kg)
Additional refilling amount of the refrigerant when repairing the refrigerant system
(Calcuate using the formula indicated below)
Refilling amount (lbs)
= ( λ
1
x 0.237) + ( λ
2
x 0.168) + ( λ
3
x 0.114) + ( λ
4
x 0.074) + ( λ
5
x 0.036) + ( λ
6
x 0.015)
Refilling amount (kg)
= ( λ
1
x 0.353) + ( λ
2
x 0.25) + ( λ
3
x 0.17) + ( λ
4
x 0.11) + ( λ
5
x 0.054) + ( λ
6
x 0.022)
λ
1
=Liquid piping Φ 7/8 inch total length (ft)
λ
2
=Liquid piping Φ 3/4 inch total length (ft)
λ
3
=Liquid piping Φ 5/8 inch total length (ft)
λ
4
=Liquid piping Φ 1/2 inch total length (ft)
λ
5
=Liquid piping Φ 3/8 inch total length (ft)
λ
6
=Liquid piping Φ 1/4 inch total length (ft)
λ
λ
λ
λ
λ
λ
1
2
3
4
5
6
=Liquid piping Ф 22.22 mm total length (m)
=Liquid piping Ф 19.05 mm total length (m)
=Liquid piping Ф 15.88 mm total length (m)
=Liquid piping Ф 12.70 mm total length (m)
=Liquid piping Ф 9.05 mm total length (m)
=Liquid piping Ф 6.35 mm total length (m)
NOTE) When more than one indoor unit is connected, add 2.2 lbs (1 kg) more refrigerant to the above-mentioned formula.
[When more than one indoor unit is connected]
Refilling amount (lbs)
= ( λ
1
x 0.237) + ( λ
2
x 0.168) + ( λ
3
x 0.114) + ( λ
4
x 0.074) + ( λ
5
x 0.036) + ( λ
6
x 0.015) + 2.2
Refilling amount (kg)
= ( λ
1
x 0.353) + ( λ
2
x 0.25) + ( λ
3
x 0.17) + ( λ
4
x 0.11) + ( λ
5
x 0.054) + ( λ
6
x 0.022) + 1.0
221
TROUBLESHOOTING
36)
Inspect Refrigerant Pressure (Inspect Refrigerant Amount)
1. Operate all indoor units.
2. Measure the refrigerant pressure at the pressure detection port provided in the engine compartment.
If the measured pressure deviates from the reference value, there is a problem in heat exchange at the evaporator or condenser, or in the refrigerant system.
NOTE) When replacing the refrigerant system parts,
Refer to P221, [Technical Data When Replacing the Refrigerant System Parts] .
Reference values of refrigerant pressure during operation
Mode
In cooling
In heating
Refrigerant low pressure
72.5 ~ 145 psi
(0.5 ~ 1.0 MPa)
58.0 ~ 131 psi
(0.4 ~ 0.9 MPa)
Refrigerant high pressure
232 ~ 464 psi
(1.6 ~ 3.2 MPa)
348 ~ 464 psi
(2.4 ~ 3.2 MPa)
37)
Inspection Check Valve (Refrigerant Pressure Increase)
If the check valve becomes blocked, liquid refrigerant remains in the condenser reducing the heat dissipating area, which increases the refrigerant pressure.
1. When refrigerant flow forward direction, measure the temperature at each end of the check valve, and check for extreme temperature difference 9 ℉ (5 ℃ ).
2. If the temperature difference between these positions is large, the check valve is blocked. Replace the check valve.
Check valve
Temperature difference
NOTE) When replacing the refrigerant system parts, Refer to P221, [Technical Data When Replacing the Refrigerant System Parts] .
38)
Inspect Refrigerant High Pressure Switch
1. Check electric continuity of refrigerant high pressure switch
Check the continuity at CN30[1]-[2] on the main PCB under engine shutdown condition.
If there is no continuity or continuity breaks when the switch has an impact, there is contact failure. Replace the switch with a new one.
2. Check operation of the refrigerant high pressure switch
During operation, select "Refrigerant high pressure 1 (code No. 40)" in the monitor mode of the board maintenance functions. Then check the pressure when the refrigerant high pressure switch activates (when continuity is lost) watching the pressure value and continuity from CN30[1]-[2] on the main PCB.
(Contact is OFF at 551 psi (3.8 MPa) or higher)
[ 8 TON ] [ 15 TON ]
Refrigerant high pressure sensor 1
Refrigerant high pressure switch 1
Refrigerant high pressure sensor 1
Refrigerant high pressure switch 2
Refrigerant high pressure switch 1
NOTE) When replacing the refrigerant system parts, Refer to P221, [Technical Data When Replacing the Refrigerant System Parts] .
222
TROUBLESHOOTING
39)
Inspect Refrigerant High Pressure Sensor
1. Check for contact failure of connectors on the main PCB
Select "Refrigerant high pressure 1 (code No. 40)" in the monitor mode of the board maintenance functions, and check if the pressure is displayed again when you disconnect and connect the refrigerant high pressure sensor connector of CN4 on the main PCB.
Repair if there is a contact failure.
2. Check for power supply voltage for the refrigerant high pressure sensor
Check power supply voltage of the refrigerant high pressure sensor at CN4[33]-[32] on the main PCB.
Standard voltage Within 5 ± 0.25 V DC
3. Check for output voltage of the refrigerant high pressure sensor
1) Measure output voltage with a tester on high-pressure sensor at
CN4[31]-[32] on the main PCB. Then refer to the figure to read the standard pressure.
2) Make sure the valve compared with high-pressure gauge is not much different.
NOTE) When replacing the refrigerant system parts, Refer to P221,
[Technical Data When Replacing the Refrigerant System
Parts] .
40)
Inspect Hot Gas Bypass Valve
1. Turn OFF the electric leakage breaker.
2. Check the coil resistance for hot gas bypass valve at CN11[1]-[7] on the main PCB.
Standard resistance value 1,050 Ω
3. Select "Actuators output condition/individual actuating (code No. 20)" in the monitor mode of the board maintenance functions, and check that "Hot gas bypass valve" is OFF.
4. Check that 200 V AC is not applied at CN11[1]-[7] on the main PCB.
5. Select "Actuators output condition/individual actuating (code No. 20)" in the check mode of the board maintenance functions. Then turn ON "Hot gas bypass valve" to check if the hot gas bypass valve is activated.
6. Check that 200 V AC is applied at CN11[1]-[7] on the main PCB.
7. Measure the pipe temperature at outlet side of the electromagnetic gas valve of the hot gas bypass valve.
The temperature is a little lower than the discharge temperature in normal status.
If the valve is blocked, the temperature does not rise when the valve opens.
[ 8 TON ] [ 15 TON ]
Hot gas bypass valves
Coil
Coil
Hot gas bypass valves
NOTE) When replacing the refrigerant system parts, Refer to P221, [Technical Data When Replacing the Refrigerant System Parts] .
223
TROUBLESHOOTING
41)
Inspect Indoor Fan Motor
Check the motor coil resistance and output voltage at the indoor fan motor connector.
42)
Inspect for Blockage in the Indoor Electronic Expansion Valve
Make judgment by checking if the temperature difference of the pipes at each end of the electronic expansion valve is normal.
43)
Check Environmental Conditions (Low Intake Air Temperature)
Check if the intake air temperature of the outdoor heat exchanger is abnormally low due to a short circuit or influence of other equipment.
1. Select "Outside air temperature (code No. 4d)" in the monitor mode of the board maintenance functions to check intake air temperature.
Temperature limit for operation (outdoor heat exchanger intake air temperature) 14 ℉ (-10 ℃ )
44)
Inspect Strainer
If the strainer just before the electronic expansion valve is fully or partially blocked, the refrigerant pressure becomes low.
1. Measure the temperature of the pipes at each end of the strainer, and check for extreme temperature difference (9 ℉ (5 ℃ ) or more).
2. If the temperature difference between these positions is large, the strainer is blocked. Replace the strainer.
NOTE) When replacing the refrigerant system parts, Refer to
P221, [Technical Data When Replacing the Refrigerant System Parts] .
Strainer
Temperature difference
45)
Inspection Check Valve (Refrigerant Pressure Drop)
If the check valve is blocked, the refrigerant pressure drops.
1. Measure the temperature of the pipes at each end of the check valve, and check for extreme temperature difference (9 ℉ (5 ℃ ) or more).
2. If the temperature difference between these positions is large, the check valve is blocked. Replace the check valve.
NOTE) When replacing the refrigerant system parts, Refer to
P221, [Technical Data When Replacing the Refrigerant System Parts] .
Check valve
Temperature difference
46)
Inspect Refrigerant Low Pressure Sensor
1. Check for contact failure of connectors on the main PCB
1) Turn ON the electric leakage breaker.
2) Select "Refrigerant low pressure 1 (code No. 40)" in the monitor mode of the board maintenance functions.
3) Disconnect and connect the refrigerant low pressure sensor connector of CN4 on the main PCB, and check if the pressure is displayed again.
4) If there is contact failure, repair it.
2. Check power supply voltage of the refrigerant low pressure sensor
Check power supply voltage of the refrigerant low pressure sensor at CN4[34]-[12] on the main PCB.
Standard voltage Within 5 ± 0.25 V DC
224
TROUBLESHOOTING
3. Check output voltage of the refrigerant low pressure sensor
1) Measure output voltage with a tester on low-pressure sensor at
CN4[11]-[12] on the main PCB. Then refer to the figure to read the standard pressure.
2) Make sure the valve compared with low-pressure gauge is not much different.
NOTE) When replacing the refrigerant system parts, Refer to P221,
[Technical Data When Replacing the Refrigerant System
Parts] .
47)
Inspect Sub Heat Exchanger Liquid Flow Control Valve
1. Check if the mechanical part of the sub heat exchanger liquid flow control valve is locked
When the valve is driven with the mechanical part locked, the motor idles, making a soft clicking sound.
1) Turn ON the electric leakage breaker.
2) Check if the valve makes the sound when it is fully closed (when the power is turned ON), and makes no sound when it is opened.
If the valve makes the sound both when it is fully closed and opened, there is a fault in the valve.
[ 8 TON ] [ 15 TON ]
Coil
Coil
Mechanical part
Mechanical part
2. Check motor coil resistance
1) Turn OFF the electric leakage breaker.
2) Measure the resistance between each coils.
※ When the electronic expansion valve is 5 cores (without brown), substitute red core for brown core.
3. Check electric continuity of the connector and wiring.
1) Check for disconnection of the connector.
2) Disconnect the connector and check electric continuity of the wiring.
[ 8 TON ]
Standard resistance value
Red-White (5-6)
Red-Orange (5-3)
46 ± 4 Ω
Brown-Yellow (2-4)
Brown-Blue (2-1)
White-Orange (6-3)
Yellow-Blue (4-1)
92 ± 8 Ω
[ 15 TON ]
Standard resistance value
Red-White (5-6)
Red-Orange (5-3)
34.3 ± 4.3 Ω
Brown-Yellow (2-4)
Brown-Blue (2-1)
White-Orange (6-3)
Yellow-Blue (4-1)
68.6 ± 8.6 Ω
NOTE) When replacing the refrigerant system parts, Refer to P221, [Technical Data When Replacing the Refrigerant System Parts] .
225
TROUBLESHOOTING
48)
Inspect Outdoor Heat Exchanger Liquid Flow Control Valve
1. Check if the mechanical part of the outdoor heat exchanger liquid flow control valve is locked.
When the valve is driven with the mechanical part locked, the motor idles, making a soft clicking sound.
1) Turn ON the electric leakage breaker.
2) Check if the valve makes the sound when it is fully closed (when the power is turned ON), and makes no sound when it is opened.
If the valve makes the sound both when it is fully closed and opened, there is a fault in the valve.
[ 8 TON ] [ 15 TON ]
Coil Coil
Mechanical part
Mechanical part
2. Check motor coil resistance
1) Turn OFF the electric leakage breaker.
2) Measure the resistance between each coils.
※ When the electronic expansion valve is 5 cores (without brown), substitute red core for brown core.
3. Check electric continuity of the connector and wiring.
1) Check for disconnection of the connector.
2) Disconnect the connector and check electric continuity of the wiring.
[ 8 TON ]
Standard resistance value
Red-White (5-6)
Red-Orange (5-3)
46 ± 4 Ω
Brown-Yellow (2-4)
Brown-Blue (2-1)
White-Orange (6-3)
Yellow-Blue (4-1)
92 ± 8 Ω
[ 15 TON ]
Standard resistance value
Red-White (5-6)
Red-Orange (5-3)
34.3 ± 4.3 Ω
Brown-Yellow (2-4)
Brown-Blue (2-1)
White-Orange (6-3)
Yellow-Blue (4-1)
68.6 ± 8.6 Ω
NOTE) When replacing the refrigerant system parts, Refer to P221, [Technical Data When Replacing the Refrigerant System Parts] .
226
TROUBLESHOOTING
49)
Inspect Reversing Valve
If the slide valve is locked at the middle position due to the operation failure of the reversing valve, the hot gas leaks into the inlet side, increasing the intake temperature and eventually, increases of the discharge temperature.
1. Turn ON the electric leakage breaker.
2. Check that a hissing noise is not generated from the reversing valve unit during operation.
3. Check if there is a temperature difference of refrigerant vapor on the low pressure side between the inlet and outlet of the reversing valve.
4. Check output voltage (200 V AC) is not continuously applied to the electromagnetic coil, during connection at CN11 [2]-[8] on the main PCB in cooling.
Outlet side in cooling
Outlet side in heating
Coil
Inlet side
NOTE) When replacing the refrigerant system parts, Refer to P221, [Technical Data When Replacing the Refrigerant System Parts] .
50)
Check for Readings of the Compressor Discharge Pipe Temperature Sensor
1. Check for disconnection or short circuit between terminals on the main PCB and relay connector.
Resistance value
∞
0 Ω
Condition
Disconnection
Short circuit
2. Check compressor discharge pipe temperature during operation with the monitor mode of the board maintenance functions.
3. Measure actual temperature with a thermometer, and check for the sensor reading's extreme deviation from the actual temperature.
4. Measure the resistance value of the compressor discharge pipe temperature sensor on the main PCB, and check for extreme deviation from the standard value.
Code No.
Compressor discharge pipe temperature 1
Compressor discharge pipe temperature 2
No.46
No.47
Measure point (on main PCB)
Compressor discharge pipe temperature 1
Compressor discharge pipe temperature 2
CN4[27]-[28]
CN4[25]-[26]
Compressor discharge pipe tempera -
Temperature
32 ℉ (0 ℃ )
68 ℉ (20 ℃ )
122 ℉ (50 ℃ )
176 ℉ (80 ℃ )
212 ℉ (100 ℃ )
248 ℉ (120 ℃ )
Standard resistance value
182.9 k
70.4 k
20.2 k
7.0 k Ω
3.7 k Ω
2.1 k Ω
Ω
Ω
Ω
227
TROUBLESHOOTING
51)
Check for Readings of the Outside Air Temperature Sensor
1. Select "Outside air temperature (code No. 4d)" in the monitor mode of the board maintenance functions to check outside air temperature.
2. Measure actual temperature with a thermometer, and check for the sensor reading's extreme deviation from the actual temperature.
3. Measure the resistance value of the outside air temperature sensor at CN6[9]-[10] on the main PCB, and check for extreme deviation from the standard value.
Temperature Standard resistance value
-4 ℉ (-20 ℃ ) 39.6 k Ω
14 ℉ (-10 ℃ )
32 ℉ (0 ℃ )
24.0 k
15.0 k
Ω
Ω
50 ℉ (10 ℃ )
68 ℉ (20 ℃ )
86 ℉ (30 ℃ )
9.6 k
6.4 k
4.2 k
Ω
Ω
Ω
104 ℉ (40 ℃ ) 3.0 k Ω
52)
Check for Readings of the Engine Exhaust Air Temperature Sensor
[ Unit with deodorant kit only ]
1. Check engine exhaust air temperature by selecting
"Engine exhaust air temperature (code No. 53)" in the monitor mode of the board maintenance functions.
2. Measure actual temperature with a thermometer, and check for the sensor reading's extreme deviation from the actual temperature.
3. Measure the resistance value of the engine exhaust air temperature sensor at CN6[7]-[8] on the main
PCB, and check for extreme deviation from the standard value.
Temperature
572 ℉ (300 ℃ )
752 ℉ (400 ℃ )
842 ℉ (450 ℃ )
932 ℉ (500 ℃ )
1,112 ℉ (600 ℃ )
1,202 ℉ (650 ℃ )
1,292 ℉ (700 ℃ )
1,382 ℉ (750 ℃ )
1,472 ℉ (800 ℃ )
1,652 ℉ (900 ℃ )
Standard resistance value
52.6 k Ω
11.5 k Ω
6.1 k Ω
3.5 k Ω
1.4 k Ω
0.9 k Ω
0.6 k Ω
0.5 k Ω
0.3 k Ω
0.2 k Ω
[ 8 TON ] [ 15 TON ]
Engine exhaust air temperature sensor
228
Engine exhaust air temperature sensor
TROUBLESHOOTING
53)
Check for Readings of the Outdoor Temperature Sensors
1. Check each outdoor temperature with the monitor mode of the board maintenance functions.
2. Measure actual temperature with a thermometer, and check for the sensor reading's extreme deviation from the actual temperature.
3. Measure each sensor's resistance value at the terminals on the main board, and check for extreme deviation from the standard value.
[ 8 TON ]
Outdoor heat exchanger liquid pipe temperature sensor
Outdoor heat exchanger vapor pipe temperature sensor
Sub heat exchanger liquid temperature sensor
Compressor intake temperature sensor
Outdoor liquid pipe temperature sensor
[ 15 TON ]
Outdoor heat exchanger liquid pipe temperature sensor
Accumulator outlet temperature sensor
※ Engine compartment temperature sensor is attached on the top panel
Outdoor liquid pipe temperature sensor
Outdoor heat exchanger vapor pipe temperature sensor
Accumulator outlet temperature sensor
Sub heat exchanger liquid temperature sensor
Compressor intake temperature sensor
※ Engine compartment temperature sensor is attached on the top panel
229
TROUBLESHOOTING
Compressor intake temperature
Accumulator outlet temperature
Outdoor heat exchanger vapor pipe temperature
Outdoor heat exchanger liquid temperature
Outdoor liquid pipe temperature
Sub heat exchanger liquid temperature
Engine compartment temperature
Temperature
14 ℉ (-10 ℃ )
32 ℉ (0 ℃ )
50 ℉ (10 ℃ )
68 ℉ (20 ℃ )
86 ℉ (30 ℃ )
104 ℉ (40 ℃ )
Standard resistance value
24.0 k
15.0 k
9.7 k
6.4 k
4.4 k
3.0 k
Ω
Ω
Ω
Ω
Ω
Ω
Code No.
No. 44
No. 45
No. 49
No. 4A
No. 4b
No. 4c
No. 50
Temperature
122 ℉ (50 ℃ )
140 ℉ (60 ℃ )
158 ℉ (70 ℃ )
176 ℉ (80 ℃ )
194 ℉ (90 ℃ )
212 ℉ (100 ℃ )
Measure point (on main PCB)
CN4[23]-[24]
CN4[13]-[14]
CN4[17]-[18]
CN4[19]-[20]
CN4[29]-[30]
CN4[15]-[16]
CN6[13]-[14]
Standard resistance value
2.2 k
1.6 k
1.1 k
0.9 k
0.6 k
0.5 k
Ω
Ω
Ω
Ω
Ω
Ω
54)
Inspect Subcooling Valve
1. Check if the mechanical part of the subcooling valve is locked
When the valve is driven with the mechanical part locked, the motor idles, making a soft clicking sound.
1) Turn ON the electric leakage breaker.
2) Check if the valve makes the sound when it is fully closed (when the power is turned ON), and makes no sound when it is opened.
If the valve makes the sound both when it is fully closed and opened, there is a fault in the valve.
[ 8 TON ] [ 15 TON ]
Coil
Coil
Mechanical part
Mechanical part
230
TROUBLESHOOTING
2. Check motor coil resistance
1) Turn OFF the electric leakage breaker.
2) Measure the resistance between each coils.
※ When the electronic expansion valve is 5 cores
(without brown), substitute red core for brown core.
3. Check electric continuity of the connector and wiring.
Standard resistance value
Blue-Brown
Brown-Yellow
Orange-Red
46 ± 4 Ω
Red-White
Blue-Yellow
Orange-White
92 ± 8 Ω
1) Check for disconnection of the connector.
2) Disconnect the connector and check electric continuity of the wiring.
NOTE) When replacing the refrigerant system parts, Refer to P221, [Technical Data When Replacing the Refrigerant System Parts] .
55)
Check Operation Condition
Measure the temperature difference between indoor intake air and indoor discharge air.
NOTE) The values are only for reference, as they vary depending on the ambient conditions or between the individual units.
Indoor unit temperature difference
(Intake - Discharge)
In cooling
In heating
⊿
⊿
T = 18 ~ 27
T = 27 ~ 36
℉
℉
(10 ~ 15
(15 ~ 20
℃
℃
)
)
56)
Check for Readings of the Indoor Temperature Sensors
1. Check each indoor temperature with the monitor mode of the board maintenance functions.
2. Measure actual temperature with a thermometer, and check for the sensor reading's extreme deviation from the actual temperature.
3. Check each indoor temperature sensors' resistance value on the indoor PCB, and check for extreme deviation from the standard value.
Code No.
Indoor heat exchanger vapor pipe temperature
Indoor heat exchanger liquid pipe temperature
Indoor intake air temperature sensor
Measure point (on indoor control PCB)
Indoor heat exchanger vapor pipe temperature
Indoor heat exchanger liquid pipe temperature
Indoor intake air temperature sensor
No. Fc
No. Fd
No. FE
X11A
X12A
X13A
Temperature Standard resistance value
14 ℉ (-10 ℃ ) 112.0 k Ω
32 ℉ (0 ℃ )
50 ℉ (10 ℃ )
65.8 k
40.0 k
Ω
Ω
68 ℉ (20 ℃ )
86 ℉ (30 ℃ )
104 ℉ (40 ℃ )
122 ℉ (50 ℃ )
25.0 k
16.1 k
10.6 k
7.2 k
Ω
Ω
Ω
Ω
57)
Check Indoor Air Intake Status
Check for a blockage at the indoor unit inlet, clogged air filter, and indoor fan motor operation.
231
TROUBLESHOOTING
58)
Check Drain Water
1. Put water into the drain pan gradually taking care so that electric parts do not get wet.
2. Start the cooling operation and operate the drain pump.
3. Check the operating sound of the drain pump motor, and confirm water comes out of the drain port.
※ Depending on indoor unit model, you can check the drain condition through the transparent connector near the indoor unit.
[EX. AXCP type]
Water inlet
Refrigerant pipes
Bucket
Drain pipe
Pump
Water inlet lid
Open
Close
59)
Inspect Drain Pump
1. Check operation
Inspect the pump operation by observing the operating sound and visual inspection of the drain flow through the pipe.
2. Check output voltage
If the drain pump does not operate, check if these is output voltage at the output terminal on the indoor control
PCB.
3. Inspect drain pump motor
Measure the coil resistance between the lead wire terminals and check that there is no disconnection or short circuit.
60)
Inspect Drain Float Switch
Check the electric continuity of the drain float switch.
NOTE) "A3 (95)" is displayed when there is a disconnection in float switch connection and also if the float switch is not connected.
Normal
Failure
There is continuity
There is no continuity
61)
Inspect Compressor Clutch
1. Check output voltage
1) Select "Actuators output condition/individual actuating (code No. 20)" in the check mode of the board maintenance functions. Then turn ON
"Compressor clutch 2".
2) Check output voltage (12 V DC).
2. Inspect compressor clutch
Measure the resistance between the electromagnetic clutch connector and the ground, and check that there is no coil disconnection or other faults.
NOTE) Disconnect the connector before measuring the resistance.
Circuit tester
Connector
232
TROUBLESHOOTING
5. Board Maintenance Functions
1)
Outline of the Maintenance Function
Arrangement of the LEDs and buttons for board maintenance functions
LED display is assigned as follows unless otherwise stated.
LED 1 ~ 4: Data display.
LED 5 ~ 6: Code number display (code No.00 ~ E7)
Alternate display of code number and indoor
unit number (code No.E8 ~ FF)
Display after turning the power ON
After turning the power ON, the display is switched "Model type/Capacity" → "Model code/Main software version" → "Engine software version" as follows.
Model type Outdoor unit capacity
1 second
Model code
※ Model type
LED 5: Model series
2: 15 TON (3Y engine model)
1: 8 TON (950P engine model)
Main software version
1 second
1 second
LED 4: Indoor unit connection scheme
C: Multi type
※ Outdoor unit capacity
45.0 : 8 TON
71.0 : 15 TON
※ When approximately 10 seconds have passed, the display proceeds to running hours display mode.
Engine software version
I/F software version
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Function and display of each mode
Mode
Running hours display
Monitor
Command
Check
Main functions
Running hours and other information display
Various input / output data display
Commands for operation start
/ engine speed, etc.
Rewriting the stored data, or activating individual devices
Normal
OFF
Green lights up
Mode indicator LED
During maintenance setting
Check mode
(setting from a PC)
Repeat of 5 red-green flashes/off
Repeat of 5 red flashes/ green lighting up
Repeat of 3-second red lighting up/off
Repeat of 3-second red lighting up/7-second green lighting up
Red/Green light up
Red lights up
Repeat of 5 red-green flashes/red-green lighting up
Repeat of red lighting up/
5 green flashes
-
-
Display contents of error sign (error LED)
Error
Alert
Warning
Error standby
: Always flashing ↑ Higher display priority
: Flashs 9 times
: Flashs 8 times
: Flashs 7 times
In abnormal compressor discharge pipe temperature avoidance : Flashs 5 times
In high pressure avoidance : Flashs 4 times
In abnormal engine coolant temperature avoidance
In low pressure avoidance
Normal
: Flashs 3 times
: Flashs 2 times
: OFF ↓ Lower display priority
One flashing cycle is composed of 10 flashes (on/off). (EX. 7 flashes ··· 7 "on"s and 3 "off"s out of 10 "on"s.)
Method of switching modes
: Press [MODE] switch for 1 second
: Press [SET] + [CLEAR] switches simultaneously for 2 seconds
NOTE)
In the following cases, check mode is not available.
(1) Less than approximately 20 seconds after power ON
(2) When the maintenance checker is connected
(3) During remote control operation
(4) During engine operation
When the maintenance checker is connected during check mode, check mode continues although the board maintenance function display is changed to running hours display mode.(Check mode can be cancelled with a maintenance checker.)
When none of the switches are operated for 10 minutes, the display returns to the running hours display mode.
234
2)
Code List for Each Mode
Code No.
00
01
D
Functions
Ⅲ communication forced master setting
Indoor / outdoor unit re-wiring recognition
Monitor Command
○
○
Check
○
●
※
※
Remark
Available only in automatic address setting
Only indoor unit re-wiring recognition during automatic address setting is available in command mode
03
04
06
Cooling pump down operation
Heating pump down operation
Refrigerant recovery (vacuuming) operation
○
○
○
○
○
○
07
08
Forced defrosting
Energy saving test operation
○
●
○
●
Auxiliary function. This function does not work regardless of setting.
Test operation mode of
"Eco Cooling Mat"
09
0A
11
Retrofit check
Engine coolant refilling
Actual engine speed (min
-1
)
●
●
●
● ※
12
13
14
Indicated engine speed (min
-1
)
Apparent engine speed (min
-1
)
Total required apparent engine speed (10 min
-1
)
●
●
○
●
●
○
※
※
※
Simultaneous setting with code
No. 13 and 14 is not available
Simultaneous setting with code
No. 12 and 14 is not available
Simultaneous setting with code
No. 12 and 13 is not available
20
25
26
28
15
16
17
18
29
2A
33
40
41
2c
30
31
32
Throttle valve open position (steps)
Fuel gas flow control valve open position (steps)
Engine spark advance angle (0.1°)
Engine coolant pump flow volume (%)
Actuators output status/individual actuating
Outdoor fan motor 1 speed (min
-1
)
Outdoor fan motor 2 speed (min
-1
)
Subcooling valve open position (steps)
Outdoor heat exchanger liquid flow control valve open position (steps)
Sub heat exchanger liquid flow control valve open position (steps)
Oil bypass control valve open position (steps)
Apparent engine speed control to avoid abnormality
Motor-operated valve control to avoid abnormality
Protection operation status
Outdoor unit input status
Refrigerant high pressure 1 (0.01 MPa)
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
※
※
※
※
※
※
●
●
●
●
●
●
●
※
※
※
※
● ※
● ※
● ※
※
※
※
42
Refrigerant low pressure (0.01 MPa)
(
Refrigerant high pressure 1 equivalent temperature
℃ )
Refrigerant low pressure equivalent temperature ( ℃ )
●
●
●
43 ●
○ : Available for only master unit., ● : Available for both master and dependent units., ◎ : Available for both master and dependent units, although some functions are not available for dependent unit.
※ : Not available when maintenance checker is connected. (No code is available in check mode.)
235
TROUBLESHOOTING
TROUBLESHOOTING
Code No.
44
78
79
7A
72
73
74
75
6A
6b
70
71
62
63
68
69
55
56
60
61
50
51
53
54
4A
4b
4c
4d
45
46
47
49
Functions
Compressor intake temperature ( ℃ )
Accumulator outlet temperature ( ℃ )
Compressor 1 discharge pipe temperature ( ℃ )
Compressor 2 discharge pipe temperature ( ℃ )
Outdoor heat exchanger vapor pipe temperature ( ℃ )
Outdoor heat exchanger liquid temperature ( ℃ )
Outdoor liquid pipe temperature ( ℃ )
Sub heat exchanger liquid temperature ( ℃ )
Outside air temperature (
Engine compartment temperature (
Engine coolant temperature ( ℃ )
Engine exhaust air temperature ( ℃ )
Starter voltage (0.1 V)
℃ )
℃ )
Igniter voltage (0.1 V)
Starter transformer voltage (0.1 V)
Engine running hours (hours)
Last periodical inspection time (hours)
Compressor 1 running hours (hours)
Compressor 2 running hours (hours)
Number of starter on/off times (times)
Number of Engine on/off times (times)
Number of compressor 1 on/off times (times)
Number of compressor 2 on/off times (times)
Serial code
Model code
OEM code
Model type (multi)
Outdoor unit series and capacity (0.1 kW)
Additional function
Main microcomputer programming version
Engine microcomputer programming version
IF microcomputer programming version
Monitor Command
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
Check
●
●
●
Remark unit with deodorant kit only
※ Unit in check mode: hours/10
※ Unit in check mode: hours/10
※ Unit in check mode: hours/10
● ※ Unit in check mode: hours/10
● ※ Unit in check mode: times/100
● ※ Unit in check mode: times/100
● ※ Unit in check mode: times/100
● ※ Unit in check mode: times/100
Factory default setting
Factory default setting
Factory default setting
Factory default setting
Factory default setting
Factory default setting
7b Periodical inspection ● ● ※
Check of periodic inspection time / periodic inspection reset
80
81
82
83
84
85
98
99
EEPROM dip switch 1
EEPROM dip switch 2
EEPROM dip switch 3
EEPROM dip switch 4
EEPROM dip switch 5
EEPROM dip switch 6
Tc set value ( ℃ )
Te set value ( ℃ )
◎
◎
◎
◎
◎
◎
○
◎
◎
◎
◎
◎
※
※
※
※
※
○
○ : Available for only master unit., ● : Available for both master and dependent units., ◎ : Available for both master and dependent units, although some functions are not available for dependent unit.
※ : Not available when maintenance checker is connected. (No code is available in check mode.)
236
TROUBLESHOOTING b2 b3 b4 b5
9c
9d b0 b1 b6 b7 b8 b9 c0
Code No.
9A
9b c1
Functions
Electronic expansion valve open position of the indoor unit whose is stopped in heating mode (steps)
Electronic expansion valve open position of the indoor unit whose temperature control is stopped in heating mode (steps)
Heating indoor SC target set value (steps)
Heating hot start high pressure set value (0.01 MPa)
Error log 1 (latest)
Error log 2 (previous)
Error log 3 (2 times ago)
Error log 4 (3 times ago)
Error log 5 (4 times ago)
Error log 6 (5 times ago)
Error log 7 (6 times ago)
Error log 8 (7 times ago)
Error log 9 (8 times ago)
Error log 10 (9 times ago)
Address under combined installation
Number of connected units under combined installation (Number of outdoor units)
EX4 address
Number of connected indoor units
Monitor Command
○
○
○
○
●
●
●
●
●
●
●
●
●
●
●
○
Check Remark d0 d1
○
○ d6 d9 dA db
E0 d2 d3 d4 d5
E8
E9
EA
Eb
Ec
Ed
Number of connected BS units (BS unit is used for cooling/heating simultaneous operation system)
Number of D Ⅲ terminals
Number of D Ⅲ outdoor units
Number of D Ⅲ BS units (BS unit is used for cooling/ heating simultaneous operation system)
Number of D Ⅲ zones
Air net address number
Cooling/heating collective address number
Low noise address number
Switching of indoor unit number display
Indoor electronic expansion valve open position forced setting in shutdown status
Indoor electronic expansion valve open position forced setting when temperature control is OFF
Indoor electronic expansion valve open position forced setting when temperature control is ON
Indoor unit heat exchanger fan air volume forced setting in shutdown status
Indoor unit heat exchanger fan air volume forced setting when temperature control is OFF
Indoor unit heat exchanger fan air volume forced setting when temperature control is ON
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
※
※
※
※
※
※
○ ※
○ ※
○ ※
○ : Available for only master unit., ● : Available for both master and dependent units., ◎ : Available for both master and dependent units, although some functions are not available for dependent unit.
※ : Not available when maintenance checker is connected. (No code is available in check mode.)
237
TROUBLESHOOTING
Code No.
F8
Functions
Indoor electronic expansion valve actual open position
Monitor Command
○
Check Remark
F9
FA
Fb
Fc
Fd
FE
FF
Remote controller unit number / Remote controller code
Indoor unit air net address number
Indoor unit capacity (0.1 kW)
Indoor heat exchanger vapor pipe temperature ( ℃ )
Indoor heat exchanger liquid pipe temperature ( ℃ )
Indoor intake air temperature ( ℃ )
○
○
○
○
○
○
Indoor unit operation status / collective test operation ○ ○
○ : Available for only master unit., ● : Available for both master and dependent units., ◎ : Available for both master and dependent units, although some functions are not available for dependent unit.
※ : Not available when maintenance checker is connected. (No code is available in check mode.)
238
TROUBLESHOOTING
3)
Running Hours Display Mode
Running hours display mode shows the following in accordance with system status.
System status
Normal (other than below)
During automatic address
Display contents
Engine running hours ⇔ Central control setting status ※
Automatic address progress status
※ Central control (Remote monitoring) function is disabled but shows on display.
Normal display
Running hours are displayed by 0.1 hours.
(Display central control setting status for one second every 10 seconds)
9 second
LED 6 ~ 2 Lights up
LED 1 Flashes
1 second
LED 6, 5 Lights up rc
LED 4 ~ 2 OFF
Lights up Central control master unit : P
Central control dependent unit / not set
: c
LED 1
Central control dummy master unit
Dependent unit under combined installation
: d
: -
The table below shows the function by switch operation in this case.
Function of each switch
Switch Functions / 7-segment LEDs display
No operation Display of engine running hours (by 0.1 hours)
Error status (error code) is displayed while the switch is pressed.
(When there is more than one error, up to 8 errors are shown in order.)
※ LED 5, 6: Error main code
※ LED 1 ~ 3 : Error sub code
Example) The following shows normal error with code "80-0"
[UP] switch
LED 4 display
Error : Middle ―
Warning, Alert : Lower _
239
TROUBLESHOOTING
Switch
[UP] switch
Functions / 7-segment LEDs display
The following shows warning with code "80-0"
LED 4 display
Error : Middle ―
Warning, Alert : Lower _
※ As for the dependent unit's failure, 100 is added to the sub code.
(80 - 0 → 80 - 100 display)
※ Error standby of the dependent unit is displayed regarded as warning or alert.
"Error standby" means that some failure occurred, but the number of the failures is not enough to be determined as an error.
The following shows no error
[DOWN] switch
Error standby status (error code) is displayed while the switch is pressed.
(When there is more than one error, up to 8 errors are shown in order.)
The display content is the same as in [UP] switch.
240
Switch
TROUBLESHOOTING
Functions / 7-segment LEDs display
Displays the indoor unit on/off status while the switch is pressed
Indoor unit 18 + n Indoor unit 2 + n
Indoor unit 0 + n
[INDOOR UNIT] switch
[MODE] switch
[CLEAR] switch
Indoor unit 1 + n
Indoor unit group Indoor unit Run/Stop status
Indoor unit 15 + n Indoor unit 3 + n
※ LED 1 ~ 5: Display the indoor unit on/off status.
LED lights up: Indoor unit is operating
LED is OFF: Indoor unit is stopped
In example above, indoor units 20, 22, 23, 24, 25, 27, 29, 30, 34,
35, 37 are operating
※ LED 6: Displays the indoor unit group
0: 0 ~ 19, 2: 20 ~ 39, 4: 40 ~ 59, 6: 60 ~ 63
When the number of indoor units is 20 or less, the display is 0 only
When the number of indoor units is 21 ~ 40, the display changes as
0 → 2 → 0
When the number of indoor units is 41 ~ 60, the display changes as
0 → 2 → 4 → 0
When the number of indoor units is 61 ~ 64, the display changes as
0 → 2 → 4 → 6 → 0
※ n: LED 6 display x 10 (In example above, 2 x 10 = 20)
※ The indoor unit number means the order the indoor units were registered to the outdoor unit
Switching modes
Switches monitor mode by pressing for 1 second
No function
241
TROUBLESHOOTING
Switch Functions / 7-segment LEDs display
Displays output status with 7-segment LEDs while the switch is pressed
The segment corresponding to the working component lights up, LED 6 shows "o"
[SET] switch
[UP] + [CLEAR] switches pressed simultaneously
Resetting errors
Pressing [UP] + [CLEAR] switches simultaneously for 1 second cancels the error and displays the following
※ Segment status in the diagram above shows the actual LED status as follows (common to all functions)
Lights up
Flashes
OFF No display or
242
During automatic address
During automatic address, the system displays the progress as follows.
※ Error display by [UP] or [DOWN] switch is possible as " ■ Normal display ".
1) During connection check of the indoor unit
TROUBLESHOOTING
During automatic address
0: Checking the connection of the indoor unit
1: Checking the connection of the outdoor unit
2: Checking the connection by a service person
3: Display of connection status determination
Elapsed time from automatic address start (by 0.1 minutes)
P: Master unit, c: Dependent unit, - : Not determined
(Flashes when the data is not memorized)
※ When connection check of the indoor unit is finished, the system proceeds to "2) Connection check of the outdoor unit" automatically.
2) During connection check of the outdoor unit
※ When connection check of the outdoor unit is finished, the system proceeds to the following status.
When the address number is memorized, the system proceeds to "4) When connection status is determined" automatically.
When the address number is not memorized, the system proceeds to "3) When connection check by a service person is required" automatically.
3) When connection check by a service person is required
When an outdoor unit has indoor units connected to itself, it can become the master unit, and displays as follows.
Alternately displayed
Indoor unit Number of connected units Outdoor unit Number of connected units
(If connected number is 1, these is no dependent unit)
When an outdoor unit has no indoor units connected to itself, it will be regarded as a dependent unit, and displays as follows.
Address Dependent unit address No.
※ In this case, when [SET] switch of the master unit is pressed for 2 seconds, both master and dependent units proceed to "4) When connection status is determined".
(Be sure to confirm connection status before pressing [SET] switch.)
243
TROUBLESHOOTING
4) When connection status is determined
When the outdoor unit is determined as the master unit, the display shows as follows.
Indoor unit
Alternately displayed
Number of connected units Outdoor unit Number of connected units
(If the number of connected units is 1, these is no dependent unit)
When the outdoor unit is determined as the dependent unit, the display shows as follows.
Address Dependent unit address No.
※ Determinate display proceeds to engine running hours display after 10 seconds.
Error during automatic address
The following error is detected during automatic address.
Error code
3-0
4-1
4-2
4-3
4-4
4-5
Error contents
Indoor unit disconnected. Number of indoor units not matching.
Communication failure between outdoor units 2
(Automatic address setting failure under combined installation)
Communication failure between outdoor units 3
(Model settings do not agree under combined installation)
Communication failure between outdoor units 4
(Automatic address memory data failure under combined installation)
Communication failure between outdoor units 5
(Insufficient number of connected dependent units under combined installation)
Communication failure between outdoor units 6
(Automatic address setting time out under combined installation)
When the error is detected, the display shows as follows.
Error Error code
244
TROUBLESHOOTING
4)
Monitor Mode
Monitor mode monitors various input/output status and stored data such as temperature or running hours.
Use this mode by selecting the code number with [UP] or [DOWN] switch.
Refer to P235 and after, [Code List for Each Mode] for available code numbers.
Function of each switch
Switch Display contents of functions / 7-segment LEDs
[UP] switch
Changes code number. The code number increases.
(00 → 01 → ··· → 7A → 7b → ··· → FE → FF → 00 → ··· )
[DOWN] switch
[INDOOR UNIT] switch
[MODE] switch
[CLEAR] switch
Changes code number. The code number decreases.
(FF → FE → ··· → 54 → 53 → ··· → 01 → 00 → FF → ··· )
Selects indoor unit. (Ascending order of indoor unit registration. Code No.
E8 ~ FF.)
(Indoor unit of the earliest registration → ··· → latest registration → earliest registration → ··· )
Switches the mode. The mode proceeds to command mode by pressing the switch for 1 second.
Not used
[SET] switch
Simultaneous pressing of
[SET] + [CLEAR] switches
Not used
Switches the mode. The mode proceeds to check mode by pressing the switches simultaneously for 2 seconds.
※ Refer to P234, [Method of switching modes] regarding switching condition.
245
TROUBLESHOOTING
5)
Command Mode
Command mode changes a part of operation status such as engine indicated speed during GHP operation, and conducts system operation check. Normally, use this mode with the procedure shown below.
1. Select command
1) Select the code number with [UP] or [DOWN] switch. Select the indoor unit with [INDOOR UNIT] switch.
2) Proceed to "2. During command setting" with [SET] switch.
2. During command setting
1) Change the setting data with [UP] or [DOWN] switch and [SET] switch.
2) Command process is determined with [SET] switch. After determined, it proceeds to 1. Select command.
※ Underlined items may be unnecessary depending on the code number.
※ Refer to P235 and after, [Code List for Each Mode] for available code numbers.
Function of each switch
Switch
[UP] switch
[DOWN] switch
[INDOOR UNIT] switch
[MODE] switch
[CLEAR] switch
[SET] switch
Simultaneous pressing of
[UP] + [DOWN] switches
Display contents of functions / 7-segment LEDs
1. Select command
Changes code number. The code number increases.
(00 → 01 → ··· → 7A → 7b → ··· → FE → FF → 00 → ··· )
2. During command setting
Changes the rated value. Increases the rated value.
※ Refer to P248 and after, [Operational Procedure / Display Contents] operation method of each code for details.
1. Select command
Changes code number. The code number decreases.
(FF → FE → ··· → 54 → 53 → ··· → 01 → 00 → FF → ··· )
2. During command setting
Changes the rated value. Decreases the rated value.
※ Refer to P248 and after, [Operational Procedure / Display Contents] operation method of each code for details.
1. Select command, 2. During command setting
Selects indoor unit. (Ascending order of indoor unit registration.Code No.
E8 ~ FF.)
(Indoor unit of the earliest registration → ··· → latest registration → all indoor units → earliest registration → ··· )
1. Select command, 2. During command setting
Switches the mode. The mode proceeds to running hours display mode by pressing the switch for 1 second.
2. During command setting
Cancels the setting data.
(Switches: 2. During command setting → 1. Select command)
1. Select command
Starts the command setting.
(Switches: 1. Select command → 2. During command setting)
2. During command setting
Changes the digit to be set during command setting.
Determines the setting data.
(Switches: 2. During command setting → 1. Select command)
※ Refer to P248 and after, [Operational Procedure / Display Contents] operation method of each code for details.
2. During command setting
Switches between forced setting / automatic setting.
※ Refer to P248 and after, [Operational Procedure / Display Contents] operation method of each code for details.
246
TROUBLESHOOTING
6)
Check Mode
Check mode overwrites various stored data such as running hours, and checks operation of various parts.
Normally, use this mode with the procedure shown below.
1. Select command
1) Select the code number with [UP] or [DOWN] switch. Select the dip switch number or other with [INDOOR
UNIT] switch.
2) Proceed to "2. During command setting" with [SET] switch.
2. During command setting
1) Change the setting data with [UP] or [DOWN] switch and [SET] switch.
2) Command process is determined with [SET] switch. After determined, it proceeds to 1. Select command.
※ Underlined items may be unnecessary depending on the code number.
※ Refer to P235 and after, [Code List for Each Mode] for available code numbers.
Function of each switch
Switch
[UP] switch
[DOWN] switch
[INDOOR UNIT] switch
[MODE] switch
[CLEAR] switch
[SET] switch
Simultaneous pressing of
[UP] + [DOWN] switches
Display contents of functions / 7-segment LEDs
1. Select command
Changes code number. The code number increases.
(00 → 01 → ··· → 7A → 7b → ··· → FE → FF → 00 → ··· )
2. During command setting
Changes the rated value. Increases the rated value.
※ Refer to P248 and after, [Operational Procedure / Display Contents] operation method of each code for details.
1. Select command
Changes code number. The code number decreases.
(FF → FE → ··· → 54 → 53 → ··· → 01 → 00 → FF → ··· )
2. During command setting
Changes the rated value. Decreases the rated value.
※ Refer to P248 and after, [Operational Procedure / Display Contents] operation method of each code for details.
1. Select command
Changes the dip switch number, etc.
※ Refer to P248 and after, [Operational Procedure / Display Contents] operation method of each code for details.
1. Select command, 2. During command setting
Switches the mode. The mode proceeds to running hours display mode by pressing the switch for 1 second.
2. During command setting
Cancels the setting data.
(Switches: 2. During command setting → 1. Select command)
1. Select command
Starts the command setting.
(Switches: 1. Select command → 2. During command setting)
2. During command setting
Changes the digit to be set during command setting.
Determines the setting data.
(Switches: 2. During command setting → 1. Select command)
※ Refer to P248 and after, [Operational Procedure / Display Contents] operation method of each code for details.
2. During command setting
Switches between forced setting / automatic setting.
※ Refer to P248 and after, [Operational Procedure / Display Contents] operation method of each code for details.
247
TROUBLESHOOTING
7)
Operational Procedure / Display Contents
Operation for each code number after mode/code number selection is shown below.
Code No. / functions
Operational procedure / display contents
Command mode, check mode
D Ⅲ communication forced master setting is set. This setting makes automatic address setting time shorter.
Command mode and check mode have the same function.
Method of forced master setting
Select command (Initial display)
00
D Ⅲ communication forced master setting
↓
Press [SET] switch
During command setting
※ [CLEAR] switch enables the system to proceed to command selection.
↓
Press [SET] switch for 2 seconds
Return to select command (setting is completed)
Forced master setting process is completed
248
TROUBLESHOOTING
Code No. / functions
Operational procedure / display contents
01
Re-wiring recognition setting
Command mode, check mode
Indoor / outdoor unit re-wiring recognition is set.
Only indoor unit re-wiring recognition during automatic address setting is available in command mode.
Example) Method of indoor unit re-wiring recognition setting
Select command (Initial display)
Indoor unit re-wiring recognition Outdoor unit re-wiring recognition
Switching with [INDOOR UNIT] switch
→
←
↓ Press [SET] switch for 0.5 seconds
During command setting
※ [CLEAR] switch enables the system to proceed to command selection.
↓
Press [SET] switch for 2 seconds
Return to select command (setting is completed)
Re-wiring recognition setting process is completed
"End" display disappears by changing the command to another one or switching indoor/ outdoor unit.
※ After re-wiring recognition, the system conducts automatic address of indoor/outdoor units again as when the power is turned ON.
249
TROUBLESHOOTING
Code No. / functions
Operational procedure / display contents
Monitor mode
Displays cooling pump down operation (code No. 03) / heating pump-down operation (code No. 04).
In the case of operation mode "Cooling" and status "Pump down in progress"
Operation mode Status
Operation modes are as follows
C : Cooling
H : Heating
Status are as follows
Pd : Pump down in progress oFF : Pump down OFF
In the case of operation mode "Heating" and status "Pump down OFF"
03
Cooling pump down operation
Command mode
Programs cooling pump down operation (code No. 03) / heating pump-down operation (code No. 04) operation setting. With this setting, outdoor actuator is set to cooling/heating pump down operation mode.
※ Cooling pump down operation is available in "During cooling/operation control" only.
※ Heating pump down operation is available in "During heating/operation control" only.
Example) Method of cooling pump down operation setting
Select command (Initial display)
In the case of change
"Cooling pump down OFF → ON"
In the case of change
"Cooling pump down ON → OFF"
04
Heating pump down operation
↓ Press [SET] switch ↓ Press [SET] switch
During command setting
※ [CLEAR] switch enables the system to proceed to command selection.
→
←
Switching with [UP] or [DOWN] switch
↓
Press [SET] switch
↓
Press [SET] switch
Return to select command (setting is completed)
Cooling pump down operation setting Completed
Cooling pump down operation starts.
Cooling pump down operation is stopped.
250
TROUBLESHOOTING
Code No. / functions
Operational procedure / display contents
Monitor mode
Displays status of refrigerant recovery [vacuuming] setting.
When refrigerant recovery setting is in progress
Refrigerant recovery [vacuuming] display
LED 4 shows "V" (looks like inverted 4).
It is always displayed.
Refrigerant recovery Status
Status are as follows rtn: Refrigerant recovery setting in progress oFF: Refrigerant recovery setting OFF
When refrigerant recovery setting is OFF
06
Refrigerant recovery
[vacuuming] setting
Command mode
Programs refrigerant recovery [vacuuming] setting.
※ Refrigerant recovery [vacuuming] is available "During system stop (outdoor units stopped and all remote controllers OFF)" only. After setting, outdoor unit operation is prohibited.
Method of refrigerant recovery [vacuuming] operation setting
Select command (Initial display)
In the case of change "OFF → Set" In the case of change "During setting → Cancel"
↓ Press [SET] switch
During command setting
↓ Press [SET] switch
→
←
Switching with [UP] or [DOWN] switch
→
←
↓ Press [SET] switch ↓ Press [SET] switch
Return to select command (setting is completed)
Refrigerant recovery [vacuuming] setting Completed
Set to refrigerant recovery [vacuuming] status.
Refrigerant recovery [vacuuming] setting is cancelled.
251
TROUBLESHOOTING
Code No. / functions
Operational procedure / display contents
Monitor mode
Displays status of forced defrosting.
When forced defrosting is in progress
Defrosting Status
Display of defrosting
LED 4 shows "d" (looks like inverted 4).
It is always displayed.
Status are as follows
Frc : Forced defrosting in progress oFF : Force defrosting OFF
When force defrosting is OFF
07
Forced defrosting
Command mode
Programs forced defrosting setting.
※ Forced defrosting is available in "During heating/operation control" only.
Method of forced defrosting setting
Select command (Initial display)
In the case of change
"Force defrosting OFF → set"
In the case of change
"Forced defrosting in progress → cancel"
↓ Press [SET] switch
During command setting
↓ Press [SET] switch
→
←
Switching with [UP] or [DOWN] switch
→
←
↓
Press [SET] switch
↓
Press [SET] switch
Return to select command (setting is completed) Forced defrosting setting Completed
Forced defrosting starts.
Forced defrosting is cancelled.
252
TROUBLESHOOTING
Code No. / functions
Operational procedure / display contents
Monitor mode
Displays status of the energy saving test operation.
When energy saving test operation is in progress
Energy save Status
Display of energy save
"E" is always displayed.
Status are as follows tSt : Energy saving test operation in progress oFF : Energy saving test operation OFF
When energy saving test operation is OFF
08
Energy saving test operation
Command mode
Programs energy saving test operation setting.
※ Energy saving test operation is available "During system stop (outdoor units stopped and all remote controllers OFF)" only. If the outdoor unit starts operation during energy saving test operation, energy saving test operation is terminated.
Method of energy saving test operation setting
Select command (Initial display)
In the case of change
"Test operation OFF → start"
In the case of change
"Test operation in progress → cancel"
↓
Press [SET] switch
During command setting
↓
Press [SET] switch
→
←
Switching with [UP] or [DOWN] switch
→
←
↓
Press [SET] switch
↓
Press [SET] switch
Return to select command (setting is completed)
Energy saving test operation setting Completed
Energy saving test operation starts.
Energy saving test operation is cancelled.
※ Energy saving test operation is finished automatically in 10 minutes.
253
TROUBLESHOOTING
Code No. / functions
Operational procedure / display contents
Monitor mode
Retrofit setting status is displayed.
When status is standard specification
Status
Std : Standard specification rEn : Retrofit specification
09
Retrofit check Status
When status is retrofit specification
254
TROUBLESHOOTING
Code No. / functions
Operational procedure / display contents
Monitor mode
Displays engine coolant refilling status.
When engine coolant refilling is in progress
Engine coolant refilling status are as follows on : Engine coolant refilling in progress oFF : Engine coolant refilling OFF
When engine coolant refilling is OFF
OA
Engine coolant refilling
Check mode
Programs engine coolant refilling setting. With this setting, the outdoor engine coolant pump operates for 5 minutes.
Method of engine coolant refilling setting
Select command (Initial display)
In the case of chaneg
"Refilling OFF → start"
In the case of change
"Refilling in progress → cancel"
↓ Press [SET] switch ↓ Press [SET] switch
During command setting
※ [CLEAR] switch enables the system to proceed to command selection.
→
←
Switching with [UP] or [DOWN] switch
↓
Press [SET] switch
↓
Press [SET] switch
Return to select command (setting is completed)
Engine coolant refilling setting Completed
Engine coolant refilling starts.
Engine coolant refilling is cancelled.
11
Actual engine speed
Monitor mode
Displays actual engine speed.
When actual engine speed is 1,242 rpm (min
-1
)
255
TROUBLESHOOTING
Code No. / functions
Operational procedure / display contents
Monitor mode
Displays indicated engine speed (code No. 12) / apparent engine speed (code No. 13).
When indicated engine speed is 1,200 rpm (min -1 )
Command mode
Switches between forced setting and automatic setting (cancelling forced setting) of indicated engine speed (code No. 12) / apparent engine speed (code No. 13).
Example) Method of apparent engine speed setting
Select command (Initial display)
During automatic operation During forced setting (2,200 → 2,050 rpm (min -1 ))
12
Indicated engine speed
13
Apparent engine speed
↓ Press [SET] switch
During command setting
Automatic setting Forced setting
↓ Press [SET] switch
→
←
Switch by pressing [UP] + [DOWN] switches simultaneously for 1 second
↓
Change data with [UP] or
[DOWN] switch
(changes by 50 rpm (min
-1
))
↓
Press [SET] switch
↓
Press [SET] switch
Return to select command (setting is completed)
Apparent engine speed setting Completed
Automatic setting is completed.
Forced setting is completed.
※ Forced setting is automatically cancelled in 10 minutes.
※ This function is not available when the engine is not running.
※ Only one of the engine speeds (indicated, apparent, total apparent) may be forced at one time.
256
TROUBLESHOOTING
Code No. / functions
Operational procedure / display contents
Monitor mode
Displays 1/10 of total apparent engine speed.
When total apparent engine speed is 10,350 rpm (min -1 )
Command mode
Switches between forced setting and automatic setting (cancelling forced setting) of total apparent engine speed.
Method of total apparent engine speed setting
Select command (Initial display)
During automatic operation During forced setting (9,000 → 10,450 rpm (min
-1
))
14
Total apparent engine speed
↓
Press [SET] switch
During command setting
Automatic setting
↓
Press [SET] switch
Forced setting
→
←
Switch by pressing [UP] + [DOWN] switches simultaneously for 1 second
↓
Change data with [UP] or
[DOWN] switch
(changes by 50 rpm (min
-1
))
↓ Press [SET] switch ↓ Press [SET] switch
Return to select command (setting is completed)
Total apparent engine speed setting Completed
Automatic setting is completed.
Forced setting is completed.
※ Displays 1/10 of total apparent engine speed.
※ Forced setting is automatically cancelled in 10 minutes.
※ This function is not available when the engine is not running.
※ Only one of the engine speeds (indicated, apparent, total apparent) may be forced at one time.
257
TROUBLESHOOTING
Code No. / functions
Operational procedure / display contents
Monitor mode
Displays engine throttle valve open position (code No. 15) / fuel gas flow control valve open position
(code No. 16).
When fuel gas flow control valve open position is 238 steps
Check mode
Programs forced setting of engine throttle valve open position (code No. 15) / fuel gas flow volume control valve open position (code No. 16).
Example) Method of engine throttle valve open position setting
Select command (Initial display)
During automatic operation During forced setting (110 → 294 steps)
15
Engine throttle valve open position
16
Fuel gas flow control valve open position
↓ Press [SET] switch
During command setting
Automatic setting Forced setting
↓ Press [SET] switch
→
←
Switch by pressing [UP] + [DOWN] switches simultaneously for 1 second
↓
Change the flashing digit data with [UP] or [DOWN] switch.
Switch by pressing [UP] +
[DOWN] switches simultaneously for 1 second
↓ Press [SET] switch (Flashing digit moves to the right)
↓
Change the flashing digit data with [UP] or [DOWN] switch.
(with digit up/down)
↓ Press [SET] switch (Flashing digit moves to the right)
258
Code No. / functions
TROUBLESHOOTING
Operational procedure / display contents
↓
Change the flashing digit data with [UP] or [DOWN] switch.
(with digit up/down)
(Continued)
15
Engine throttle valve open position
16
Fuel gas flow control valve open position
↓ Press [SET] switch
(all digits start flashing)
↓
Press [SET] switch
↓
Press [SET] switch
Return to select command (setting is completed)
Engine throttle valve open position setting Completed
Automatic setting is completed.
Forced setting is completed.
17
Engine spark advance angle
Monitor mode
Displays engine spark advance angle.
When engine spark advance angle is 8.6°
259
TROUBLESHOOTING
Code No. / functions
Operational procedure / display contents
Monitor mode
Displays engine coolant pump flow volume.
When engine coolant pump flow volume is 80 %
Check mode
Programs forced setting of engine coolant pump flow volume.
Method of engine coolant pump flow volume setting
Select command (Initial display)
During automatic operation During forced setting (100 → 94 %)
18
Engine coolant pump flow volume
↓ Press [SET] switch
During command setting
Automatic setting Forced setting
↓ Press [SET] switch
→
←
Switch by pressing [UP] + [DOWN] switches simultaneously for 1 second
↓
Change the flashing digit data with [UP] or [DOWN] switch.
Switch by pressing [UP] +
[DOWN] switches simultaneously for 1 second
↓ Press [SET] switch (Flashing digit moves to the right)
↓
Change the flashing digit data with [UP] or [DOWN] switch.
(with digit up/down)
↓
Press [SET] switch (Flashing digit moves to the right)
↓
Change the flashing digit data with [UP] or [DOWN] switch.
(with digit up/down)
260
Code No. / functions
TROUBLESHOOTING
Operational procedure / display contents
↓ Press [SET] switch
(all digits start flashing)
(Continued)
18
Engine coolant pump flow volume
↓
Press [SET] switch
↓
Press [SET] switch
Return to select command (setting is completed)
Engine coolant pump flow volume setting Completed
Automatic setting is completed.
Forced setting is completed.
※ Forced setting is automatically cancelled in 10 minutes.
261
TROUBLESHOOTING
Code No. / functions
Operational procedure / display contents
Monitor mode
Displays actuators output status.
When output 3 (starter transformer) is ON
Output status are as follows on : Output ON oF : Output OFF
When output 12 (reversing valve) is OFF
20
Actuators output status/ individual actuating
※ The [INDOOR UNIT] switch changes displayed actuator output. By pressing ON, display toggles as follow [output 1] → [output 2] → ··· → [output 20] → [output 1] → ···.
※ Output number - output table (common to monitor mode and check mode)
Output No.
1
2
3
Output name
Main side output permission
Engine side output permission
Starter transformer
6
7
4
5
Electromagnetic gas valve 1
Electromagnetic gas valve 2
Starter
Ignition circuit drive signal
8
9
-
Compressor clutch 2
10
Electromagnetic compressor capacity valve 2
※ 1. Unit with drain heater kit only
14
15
16
17
18
19
Output No.
11
12
13
Output name
Hot gas bypass valve
Reversing valve
Electromagnetic compressor capacity valve 1
Compressor heaters 1, 2
Engine oil pan heater ※ 1
Exhaust water drain heaters 1, 2 ※ 1
-
-
-
20 -
262
TROUBLESHOOTING
Code No. / functions
Operational procedure / display contents
Check mode
Conducts single forced actuator operation.
※ To drive the starter, turn ON " ① Main side output permission", " ② Engine side output permission", and " ③ Starter transformer" in order. Then turn ON " ⑥ Starter".
※ To drive the starter, turn ON " ① Main side output permission", " ② Engine side output permission" Then turn ON " ④⑤ Electromagnetic gas valve".
Example) Method of forced activation of starter setting
Select command (Initial display) Displays output status of the designated number
↓ Press the [INDOOR UNIT] switch 5 times
Select command Select starter
(Continued)
20
Actuators output status/ individual actuating
↓
Press [SET] switch
During command setting
→
←
↓ Press [SET] switch
ON/OFF changes with [UP] or [DOWN] switch
↓ Press [SET] switch
Return to select command (setting is completed)
Forced activation of starter setting Completed
Starter output is OFF.
Starter output is ON.
※ Forced setting is automatically cancelled in 3 minutes. (Starter is cancelled in 5 seconds)
263
TROUBLESHOOTING
Code No. / functions
Operational procedure / display contents
Monitor mode
Displays outdoor fan motor 1 speed (code No. 25) / outdoor fan motor 2 speed (code No. 26)
When outdoor fan motor 2 speed is 628 rpm (min -1 )
Command mode, check mode
Programs forced setting of outdoor fan motor 1 speed (code No. 25) / outdoor fan motor 2 speed
(code No. 26).(available up to 1,200 rpm (min -1 ))
Example) Method of outdoor fan motor 1 speed setting
Select command (Initial display)
During automatic operation During forced setting (1,155 → 898 rpm (min -1 ))
25
Outdoor fan motor 1 speed
26
Outdoor fan motor 2 speed
↓ Press [SET] switch
During command setting
Automatic setting Forced setting
↓ Press [SET] switch
→
←
Switch by pressing [UP] + [DOWN] switches simultaneously for 1 second
↓ Change the flashing digit data with [UP] or [DOWN] switch.
Switch by pressing [UP] +
[DOWN] switches simultaneously for 1 second
↓ Press [SET] switch (Flashing digit moves to the right)
↓
Change the flashing digit data with [UP] or [DOWN] switch.
(with digit up/down)
↓
Press [SET] switch (Flashing digit moves to the right)
264
Code No. / functions
TROUBLESHOOTING
Operational procedure / display contents
↓ Press [SET] switch (all digits start flashing)
(Continued)
25
Outdoor fan motor 1 speed
26
Outdoor fan motor 2 speed
↓
Change the flashing digit data with [UP] or [DOWN] switch.
(with digit up/down)
↓ Press [SET] switch
(all digits start flashing)
↓ Press [SET] switch ↓ Press [SET] switch
Return to select command (setting is completed)
Outdoor fan motor 1 speed setting Completed
Automatic setting is completed.
Forced setting is completed.
※ Forced setting is automatically cancelled in 10 minutes.
↓
Change the flashing digit data with [UP] or [DOWN] switch.
(with digit up/down)
265
TROUBLESHOOTING
Code No. / functions
Operational procedure / display contents
Monitor mode
Displays subcooling valve open position (code No. 28) / outdoor heat exchanger liquid flow control valve open position (code No. 29) / sub heat exchanger liquid flow control valve open position (code
No. 2A) / oil bypass control valve open position (code No. 2c).
When sub heat exchanger liquid flow control valve open position is 432 steps
28
Subcooling valve open position
Command mode, check mode
Programs forced setting of subcooling valve open position (code No. 28) / outdoor heat exchanger liquid flow control valve open position (code No. 29) / sub heat exchanger liquid flow control valve open position (code No. 2A) / oil bypass control valve open position (code No. 2c).
(available range between 0 ~ 500 steps)
Example) Method of outdoor heat exchanger liquid flow control valve open position setting
Select command (Initial display)
During automatic operation During forced setting (110 → 327 steps)
29
Outdoor heat exchanger liquid flow control valve open position
↓ Press [SET] switch
During command setting
Automatic setting Forced setting
↓ Press [SET] switch
2A
Sub heat exchanger liquid flow control valve open position
→
←
Switch by pressing [UP] + [DOWN] switches simultaneously for 1 second
Switch by pressing [UP] +
[DOWN] switches simultaneously for 1 second
↓
Change the flashing digit data with [UP] or [DOWN] switch.
2c
Oil bypass control valve open position
↓ Press [SET] switch (Flashing digit moves to the right)
↓
Change the flashing digit data with [UP] or [DOWN] switch.
(with digit up/down)
↓
Press [SET] switch (Flashing digit moves to the right)
266
Code No. / functions
TROUBLESHOOTING
Operational procedure / display contents
↓
Change the flashing digit data with [UP] or [DOWN] switch.
(with digit up/down)
(Continued)
28
29
2A
2c
↓ Press [SET] switch (Flashing digit moves to the right)
↓
Press [SET] switch
↓
Press [SET] switch
Return to select command (setting is completed)
Outdoor heat exchanger liquid flow control valve open position setting Completed
Automatic setting is completed.
Forced setting is completed.
※ When in command mode, forced setting is automatically cancelled in 10 minutes.
267
TROUBLESHOOTING
Code No. / functions
Operational procedure / display contents
Monitor mode
Displays abnormal engine speed avoidance control status with "ON" or "OFF".
When control to avoid abnormal refrigerant high pressure is in progress
Abnormal engine speed avoidance control status are as follows on : Control in progress oF : Control off
When control to avoid abnormal engine coolant temperature is OFF
30
Apparent engine speed control to avoid abnormality
※ The [INDOOR UNIT] switch changes displayed engine speed control to avoid abnormality. By pressing ON, display toggles as follow [abnormal refrigerant high pressure avoidance control] → [abnormal refrigerant low pressure avoidance control] → ··· → [abnormal engine coolant temperature avoidance control] → [abnormal refrigerant high pressure avoidance control] → ···.
※ Abnormal engine speed avoidance control status table
Avoidance No.
Abnormality to be avoided
Apparent engine speed control to avoid abnormality 1
Apparent engine speed control to avoid abnormality 2
Apparent engine speed control to avoid abnormality 3
Apparent engine speed control to avoid abnormality 4
Abnormal refrigerant high pressure
Abnormal refrigerant low pressure
Abnormal compressor discharge pipe temperature
-
Apparent engine speed control to avoid abnormality 5
Apparent engine speed control to avoid abnormality 6
Apparent engine speed control to avoid abnormality 7
Apparent engine speed control to avoid abnormality 8
Emergency avoidance of abnormal high pressure or refrigerant
-
-
Abnormal engine coolant temperature
268
TROUBLESHOOTING
Code No. / functions
Operational procedure / display contents
Monitor mode
Displays motor-operated valve control status for abnormality avoidance with "ON" or "OFF".
During avoidance of freezing of the sub heat exchanger liquid flow control valve.
Motor-operated valve control status for abnormality avoidance are as follows on : Control in progress oF : Control off
When control to avoid abnormal outdoor heat exchanger liquid flow control valve intake temperature is off
31
Motoroperated valve control to avoid abnormality
※ The [INDOOR UNIT] switch changes displayed motor-operated valve control status for abnormality avoidance. By pressing ON, display toggles as follow [Avoidance of freezing of the sub heat exchanger liquid flow control valve] → [Avoidance of abnormal intake temperature of the outdoor heat exchanger liquid flow control valve] → · · · → [—] → [—]
→ ··· → [Avoidance of freezing of the sub heat exchanger liquid flow control valve] → ···.
※ Motor-operated valve control status for abnormality avoidance table
Avoidance No.
Abnormality to be avoided
Motor-operated valve control to avoid abnormality 1
Motor-operated valve control to avoid abnormality 2
Motor-operated valve control to avoid abnormality 3
Motor-operated valve control to avoid abnormality 4
Freezing of the sub heat exchanger liquid flow control valve
Abnormal intake temperature of the outdoor heat exchanger liquid flow control valve
-
-
269
TROUBLESHOOTING
Code No. / functions
Operational procedure / display contents
Monitor mode
Displays protection operation status with "ON" or "OFF".
When compressor protection control is in progress
Protection operation status on: During protect operation oF: Protection operation OFF
When defrosting operation is OFF
32
Protection operation status
※ The [INDOOR UNIT] switch changes displayed protection operation status. By pressing ON, display toggles as follows [compressor protect control] → [—] → · · · → [—] →
[defrosting operation] → [compressor protect control] → · · ·.
※ Protection operation status table
Protection operation No.
Protection operation 1
Protection operation 2
Protection operation name
Compressor protection control
-
Protection operation 3
Protection operation 4
Protection operation 5
Protection operation 6
Protection operation 7
Protection operation 8
-
-
-
-
-
Defrosting operation
270
TROUBLESHOOTING
Code No. / functions
Operational procedure / display contents
Monitor mode
Displays outdoor unit input status with "ON" or "OFF".
When output monitor of electromagnetic gas valve is ON
Outdoor unit input status on : Input ON oF : Input OFF
When refrigerant high pressure switches 1 and 2 is OFF
33
Outdoor unit input status
※ The [INDOOR UNIT] switch changes displayed outdoor unit input status. By pressing
ON, display toggles as follow [engine oil pressure switch] → ··· → [oil level switch] →
[engine oil pressure switch] → ···.
※ Outdoor unit input status table
Input No.
Outdoor unit input 1
Outdoor unit input 2
Outdoor unit input name
Engine oil pressure switch
-
Outdoor unit input 3
Outdoor unit input 4
Outdoor unit input 5
Electromagnetic gas valves 1, 2 output monitor
Rrefrigerant high pressure switches 1, 2 (compressor)
Oil level switch
40
Refrigerant high pressure 1
Monitor mode
Displays refrigerant high pressure 1.
When refrigerant high pressure 1 is 1.96 MPa
※ Pressure is shown in MPa. To convert it to psi, use the following formula. psi = MPa x 145.04
41
Refrigerant low pressure
Monitor mode
Displays refrigerant low pressure.
When refrigerant low pressure is 0.32 MPa
※ Pressure is shown in MPa. To convert it to psi, use the following formula. psi = MPa x 145.04
271
TROUBLESHOOTING
Code No. / functions
Operational procedure / display contents
Monitor mode
Displays selected temperature. (Refer to code number table below)
When compressor intake temperature 1 is 12 ℃
49
4A
46
47
44
45
42
43
4d
50
4b
4c
51
When engine compartment temperature is -5 ℃
4d
50
51
49
4A
4b
4c
※ Code number table (excerpt from the code number list)
Code No.
Temperature data name ※ 1
42
43
Refrigerant high pressure 1 equivalent temperature (
Refrigerant low pressure equivalent temperature (
℃
℃ )
)
44
45
46
47
Compressor intake temperature (
Accumulator outlet temperature (
℃
℃
)
)
Compressor 1 discharge pipe temperature (
Compressor 2 discharge pipe temperature (
℃
℃
)
)
Outdoor heat exchanger vapor pipe temperature (
Outdoor heat exchanger liquid temperature (
Outdoor liquid pipe temperature (
Sub heat exchanger liquid temperature (
Outside air temperature ( ℃
Engine coolant temperature (
)
Engine compartment temperature (
℃
℃
)
℃
)
℃
)
℃
)
℃
)
)
※ 1 : Temperature is shown in Celsius (C). To convert it to Fahrenheit (F), use the following formula. F = C x 9/5 + 32
53
Engine exhaust air temperature
(unit with deodorant kit only)
Monitor mode
Displays engine exhaust air temperature.
When engine exhaust air temperature is 579 ℃
※ Temperature is shown in Celsius (C). To convert it to Fahrenheit (F), use the following formula. F = C x 9/5 + 32
272
TROUBLESHOOTING
Code No. / functions
54
Starter voltage
Operational procedure / display contents
Monitor mode
Displays starter voltage.
When starter voltage is 8.7 V
55
Igniter voltage
Monitor mode
Displays igniter voltage.
When igniter voltage is 13.1 V
56
Starter transformer voltage
Monitor mode
Displays starter transformer voltage.
When starter transformer voltage is 10.7 V
273
TROUBLESHOOTING
Code No. / functions
Operational procedure / display contents
Monitor mode
Displays engine running hours (code No. 60) / last periodical inspection time (code No. 61) / compressor 1 running hours (code No. 62) / compressor 2 running hours (code No. 63) in hours.
When compressor 1 running hours are 17,824 hours
Alternately displayed
→
←
60
Engine running hours
61
Last periodical inspection time
62
Compressor 1 running hours
Check mode
Programs forced setting of engine running hours (code No. 60) / last periodical inspection time (code
No. 61) / compressor 1 running hours (code No. 62) / compressor 2 running hours (code No. 63) by 10 hours. (available up to 50,000 hours)
Example) Method of engine running hours setting
Select command
In the case of change 2,345 → 14,970 hours
↓ Press [SET] switch
During command setting
↓
Less than 10 hours are dropped
Digit of 10,000 hours is flashing
Change the flashing digit data with [UP] or [DOWN] switch.
63
Compressor 2 running hours
↓
Press [SET] switch (Flashing digit moves to the right)
Digit of 1,000 hours is flashing
↓ Change the flashing digit data with [UP] or [DOWN] switch. (with digit up/down)
↓
Press [SET] switch (Flashing digit moves to the right)
Digit of 100 hours is flashing
↓
Change the flashing digit data with [UP] or [DOWN] switch. (with digit up/down)
274
Code No. / functions
TROUBLESHOOTING
Operational procedure / display contents
(Continued)
60
Engine running hours
61
Last periodical inspection time
62
Compressor 1 running hours
63
Compressor 2 running hours
↓
Digit of 10 hours is flashing
↓ Change the flashing digit data with [UP] or [DOWN] switch. (with digit up/down)
↓
Press [SET] switch (Flashing digit moves to the right)
Press [SET] switch (all digits start flashing)
↓
Press [SET] switch
Return to select command (setting is completed)
Engine running hours setting Completed
Forced setting is completed.
275
TROUBLESHOOTING
Code No. / functions
Operational procedure / display contents
Monitor mode
Displays the number of starter on/off times (code No. 68) / the number of engine on/off times (code
No. 69) / the number of compressor 1 on/off times (code No. 6A) / the number of compressor 2 on/ off times (code No. 6b) in times.
When the number of starter on/off times is 254,019 times
Alternately displayed
→
←
68
Number of starter on/off times
Check mode
Programs forced setting of the number of starter on/off times (code No. 68) / the number of engine on/off times (code No. 69) / the number of compressor 1 on/off times (code No. 6A) / the number of compressor 2 on/off times (code No. 6b) by 100 times. (available up to 300,000 times)
Example) Method of number of compressor 1 on/off times setting
Select command
In the case of change 123,456 → 50,000 times
Less than 100 times are dropped
69
Number of engine on/off times
↓
Press [SET] switch
During command setting
6A
Nubmer of compressor 1 on/off times
↓
Digit of 100,000 times is flashing
Change the flashing digit data with [UP] or [DOWN] switch.
6b
Nubmer of compressor 2 on/off times
↓
Press [SET] switch (Flashing digit moves to the right)
Digit of 10,000 times is flashing
↓
Change the flashing digit data with [UP] or [DOWN] switch. (with digit up/down)
↓ Press [SET] switch (Flashing digit moves to the right)
Digit of 1,000 times is flashing
↓
Change the flashing digit data with [UP] or [DOWN] switch. (with digit up/down)
276
Code No. / functions
TROUBLESHOOTING
Operational procedure / display contents
(Continued)
68
Number of starter on/off times
69
Number of engine on/off times
6A
Nubmer of compressor 1 on/off times
6b
Nubmer of compressor 2 on/off times
↓
↓
↓
Press [SET] switch (Flashing digit moves to the right)
Digit of 100 times is flashing
Change the flashing digit data with [UP] or [DOWN] switch. (with digit up/down)
Press [SET] switch (all digits start flashing)
↓ Press [SET] switch
Return to select command (setting is completed)
Nubmer of compressor 1 on/off times setting Completed
Forced setting is completed.
70
Serial code
Monitor mode
Alternately displays the first 4 digits and last 4 digits of the serial code.
When serial code is A105CF82
Alternately displayed
→
←
71
Model code
Monitor mode
Model code is displayed on LED 2 and 1.
When model code is E1
277
TROUBLESHOOTING
Code No. / functions
Operational procedure / display contents
Monitor mode
OEM code is displayed on LED 1.
In the case of AISIN brand / DAIKIN indoor unit
72
OEM code
※ OEM code table
OEM code
A-d d-d
Corresponding brand / indoor unit
AISIN brand / DAIKIN indoor unit
DAIKIN brand / DAIKIN indoor unit
Monitor mode
Model type is displayed on LED 1.
When model type is multi zone type
73
Model type
※ Model type table
Model type code c
Model type
Multi zone type
74
Outdoor unit series and capacity
Monitor mode
Outdoor unit series and capacity are displayed.
In the case of 15 TON
Otdoor unit series Otdoor unit capacity
Outdoor unit series
15 TON : Upper "-"
8 TON : Lower "-"
Outdoor unit capacity
15 TON : 71.0
8 TON : 45.0
In the case of 8 TON
278
TROUBLESHOOTING
Code No. / functions
Operational procedure / display contents
Monitor mode
Additional function is displayed with "ON" or "OFF".
When it is with cold district specification
Additional function with/ without are as follows on : With additional function oF: Without additional function
When it is without high power
75
Additional function
※ The [INDOOR UNIT] switch changes displayed additional function.By pressing ON, display toggles as follows [cold district specification] → [-] → · · · → [15 TON] → [hi-power type] →
[-] → · · · → [cold district specification] → · · ·.
※ Additional function table
Additional function No.
1
2
3
4
5
6
Additional function contents
Cold district specification
-
-
15 TON
Hi-power type
7
8 -
-
-
279
TROUBLESHOOTING
Code No. / functions
Operational procedure / display contents
78
Main microcomputer programming version
Monitor mode
Displays main microcomputer programming version.
When main microcomputer programming version is 15
79
Engine microcomputer programming version
Monitor mode
Displays engine microcomputer programming version.
When engine microcomputer programming version is 1
7A
IF microcomputer programming version
Monitor mode
Displays IF microcomputer programming version.
When IF microcomputer programming version is 22
280
TROUBLESHOOTING
Code No. / functions
Operational procedure / display contents
Monitor mode
Displays periodical inspection status.
Before periodical inspection time
Remaining time until next periodical inspection is displayed
(In this case, periodical inspection alert will be sent
1,134 hours later.)
On or after periodical inspection time
"oVEr" is displayed
7b
Periodical inspection
Check mode
Reset periodical inspection
Select command (Initial display) Displays the periodical inspection status
OR
↓ Press and hold [SET] switch (for 0.5 seconds)
During command setting
↓ Press and hold [SET] switch (for 2 seconds)
Return to select command (setting is completed)
Periodical inspection reset Completed
Reset is completed.
"End"display disappears when other command is selected
281
TROUBLESHOOTING
Code No. / functions
Operational procedure / display contents
Monitor mode
Displays EEPROM dip switch 1 status (code No. 80) / EEPROM dip switch 2 status (code No. 81)
/ EEPROM dip switch 3 status (code No. 82) / EEPROM dip switch 4 status (code No .83) /
EEPROM dip switch 5 status (code No. 84) / EEPROM dip switch 6 status (code No. 85).
In the case of EEPROM dip switch 3 status "Pin 4 ON"
Pin status are as follows on : ON oF : OFF
In the case of EEPROM dip switch 4 status "Pin 1 OFF"
80
EEPROM dip switch 1
81
EEPROM dip switch 2
82
EEPROM dip switch 3
※ The [INDOOR UNIT] switch changes displayed EEPROM dip switch. By pressing ON, display toggles as follow [pin 1] → [pin 2] → ··· → [pin 8]
Check mode
Programs each pin of EEPROM dip switches.
(EEPROM dip switches 4 ~ 6 set programming is not available.)
Example) Method of pin 5 of EEPROM dip switch setting
Select command (Initial display) Displays pin 1 status
→ [pin 1] → ···.
83
EEPROM dip switch 4
84
EEPROM dip switch 5
↓
Press the [INDOOR UNIT] switch 4 times
Select command Select pin 5
85
EEPROM dip switch 6
(monitor mode only)
↓ Press [SET] switch
During command setting
→
←
ON/OFF changes with [UP] or [DOWN] switch
↓ Press [SET] switch ↓ Press [SET] switch
Return to select command (setting is completed) Pin 5 setting Completed
Pin 5 is ON.
Pin 5 is OFF.
282
TROUBLESHOOTING
Code No. / functions
Operational procedure / display contents
98
Tc set value
Monitor mode
Displays Tc set value (code No. 98) / Te set value (code No. 99) / heating indoor SC target set value
(code No. 9c). (display range : -20 ~ 60 ℃ )
When Tc set value is -1 ℃
99
Te set value
9c
Heating indoor SC target set value
When heating indoor SC target set value is 12 ℃
When heating indoor SC target set value is not set
※ Temperature is shown in Celsius (C). To convert it to Fahrenheit (F), use the following formula.
F = C x 9/5 + 32
9A
Electronic expansion valve open position of the indoor unit whose is stopped in heating mode
Monitor mode
Displays electronic expansion valve open position of the indoor unit whose is stopped in heating mode (code No. 9A) / electronic expansion valve open position of the indoor unit whose temperature control is stopped in heating mode (code No. 9b). (display range : 0 ~ 250 step)
When electronic expansion valve open position of the indoor unit whose is stopped in heating mode is set at 110 steps
When electronic expansion valve open position of the indoor unit whose temperature control is stopped in heating mode is set at 140 steps
9b
Electronic expansion valve open position of the indoor unit whose temperature control is stopped in heating mode
When electronic expansion valve open position of the indoor unit whose temperature control is stopped in heating mode is not set
283
TROUBLESHOOTING
Code No. / functions
Operational procedure / display contents
Monitor mode
Displays heating hot start high pressure value. (display range : 1.00 ~ 3.50 MPa)
When heating hot start high pressure value is 2.86 MPa
9d
Heating hot start high pressure value
When heating hot start high pressure value is not set
※ Pressure is shown in MPa. To convert it to psi, use the following formula. psi = MPa x 145.04
Monitor mode
Displays error log.
In the case of error log 2 (previous)
Alternately displayed
→
← b0~b9
Error log
(latest ~ 9 times ago)
Monitor code Engine running hours when an error occurred (10 hours)
Error main code
※ Code number table (excerpt from the code number list)
Code No.
Error log contents b0 b1
Error log 1 (latest)
Error log 2 (previous) b2 b3 b4 b5
Error log 3 (2 times ago)
Error log 4 (3 times ago)
Error log 5 (4 times ago)
Error log 6 (5 times ago) b6 b7 b8 b9
Error log 7 (6 times ago)
Error log 8 (7 times ago)
Error log 9 (8 times ago)
Error log 10 (9 times ago)
Error sub code
284
TROUBLESHOOTING
Code No. / functions
Operational procedure / display contents c0
Address under combined installation
Monitor mode
Displays address under combined installation
In the case of master outdoor unit
Address under combined installation
0 : Master outdoor unit
1 : Dependent outdoor unit 1
2 : Dependent outdoor unit 2 c1
Number of connected units under combined installation
(Number of outdoor units)
Monitor mode
Displays number of connected units under combined installation.
(Total number of master and dependent outdoor units is displayed. 1 is displayed when there is no dependent unit.)
When the number of dependent outdoor units is 1 d0
EX4 address
Monitor mode
Displays outdoor unit address (EX4 address) used for D Ⅲ communication.
When the EX4 adress is 0 d1
Number of connected indoor units
Monitor mode
Displays the number of connected indoor units in the same refrigerant system that were set with automatic address.
When the number of connected indoor units is 27.
d2
Number of connected
BS units
Monitor mode
Displays the number of connected BS units in the same refrigerant system that were set with automatic address.
※ BS unit is used for simultaneous cooling/heating operation.
When the number of connected BS units is 14.
285
TROUBLESHOOTING
Code No. / functions
Operational procedure / display contents d3
Number of
D Ⅲ outdoor units
Monitor mode
Displays the number of connected terminals in the same D Ⅲ net that were set with automatic address.
※ This data is displayed only when EX4 address is 0 in the code No. d0.
When 16 indoor units are connected in D Ⅲ net d4
Number of
D Ⅲ outdoor units
Monitor mode
Displays the number of connected outdoor units in same D Ⅲ net that were set with automatic address. (including itself)
※ This data is displayed only when EX4 address is 0 in the code No. d0.
When 7 outdoor units (including itself) are connected in D Ⅲ net d5
Number of
D Ⅲ BS units
Monitor mode
Displays the number of connected BS units in same D Ⅲ net set with automatic address.
※ BS unit is used for simultaneous cooling/heating operation.
※ This data is displayed only when EX4 address is 0 in the code No. d0.
When connected number of BS units is 8 in D Ⅲ net d6
Number of
D Ⅲ zones
Monitor mode
Displays the number of connected zones in the same D Ⅲ net set with automatic address.
※ This data is displayed only when EX4 address is 0 in the code No. d0.
When 6 zones are connected in the same D Ⅲ net
286
TROUBLESHOOTING
Code No. / functions
Operational procedure / display contents
Monitor mode
Displays air net address number.
When air net address is 105
Check mode
Programs forced setting of air net address number.
(Setting range of air net address number is 0 ~ 63.)
Method of air net address number setting
Select command (Initial display)
When the address is not set In the case of address change "49 → 22" d9
Air net address number
↓ Press [SET] switch
During command setting
Automatic setting Forced setting
↓ Press [SET] switch
→
←
Switch by pressing [UP] + [DOWN] switches simultaneously for 1 second
↓
Change the flashing digit data with [UP] or [DOWN] switch.
Switch by pressing [UP] +
[DOWN] switches simultaneously for 1 second
↓
Press [SET] switch (Flashing digit moves to the right)
↓
Change the flashing digit data with [UP] or [DOWN] switch.
(with digit up/down)
↓
Press [SET] switch
(all digits start flashing)
↓ Press [SET] switch ↓ Press [SET] switch
Return to select command (setting is completed) Air net address setting Completed
Address clear is completed.
Address setting is completed.
287
TROUBLESHOOTING
Code No. / functions
Operational procedure / display contents
Monitor mode
Displays setting status of cooling/heating collective address number (code no. dA) / low noise address number (code No. db).
In the case of cooling/heating collective address setting status "Pin 4 ON"
Setting status are as follows on : ON oF : OFF
When low noise address No. 1 pin is OFF
※ The [INDOOR UNIT] switch changes displayed pin number. By pressing ON, display toggles as follow [pin 1] → [pin 2] → ··· → [pin 5] → [pin 1] → ···.
dA
Cooling/ heating collective address number
Check mode
Programs cooling/heating collective address number (code No. dA) and low noise address number
(code No. db) for each pin.
Example) Method of cooling/heating collective address pin 5 setting
Select command (Initial display) Displays pin 1 status db
Low noise address number
↓
Press the [INDOOR UNIT] switch 4 times
Select command Select pin 5
↓ Press [SET] switch
During command setting
→
←
ON/OFF changes with [UP] or [DOWN] switch
↓
Press [SET] switch ↓ Press [SET] switch
Return to select command (setting is completed) Pin 5 setting Completed
Pin 5 is ON.
Pin 5 is OFF.
288
TROUBLESHOOTING
Code No. / functions
Operational procedure / display contents
Monitor mode
Shows current method of indoor unit number display.
When indoor unit number is displayed by air net address
Method of indoor unit number display
Air : Air net address cnt : Order of indoor unit registration
Command mode
Switches the method of indoor unit number display.
Method of indoor unit number display setting
Select command (Initial display)
In the case of method of indoor unit number display change "By air net address → By the order of indoor unit registration"
In the case of method of indoor unit number display change "By the order of indoor unit registration → By air net address"
E0
Switching of indoor unit number display
↓
Press [SET] switch
Select command
↓
Press [SET] switch
→
←
ON/OFF changes with [UP] or [DOWN] switch
↓
Press [SET] switch
↓
Press [SET] switch
Return to select command (setting is completed)
Method of indoor unit number display setting Completed
Setting for display by the order of indoor unit registration is completed.
Setting for display by air net address is completed.
289
TROUBLESHOOTING
Code No. / functions
Operational procedure / display contents
Monitor mode
Displays forced setting status of indoor electronic expansion valve open position in shutdown status (code No. E8) / temperature control is OFF (code No. E9) / temperature control is ON
(code No. EA).
Indoor expansion valve open position forced setting in stopping : When the setting of indoor unit No. 13 is 160 steps
Alternately displayed?
E8
Indoor electronic expansion valve open position forced setting in shutdown status
→
←
Indoor electronic expansion valve open position forced setting during thermostat OFF :
When the setting of idoor unit No. 6 is automatic
Alternately displayed
→
←
E9
Indoor electronic expansion valve open position forced setting when temperature control is OFF
EA
Indoor electronic expansion valve open position forced setting when temperature control is ON
※
※
The [INDOOR UNIT] switch selects indoor unit. Each time the switch is pressed, indoor unit registration order goes up by 1. After the last registered indoor unit, it goes back to the first registered unit.
Indoor unit number display is changeable between "air net address" and "registration order" with code No. E0. (In the case of "air net address", only last 2 digits are displayed.)
Command mode
Programs forced setting/cancel of indoor electronic expansion valve open position.
Example) Method of indoor electronic expansion valve open position when temperature control of indoor unit No. 46
Select command (Initial display) Displays indoor unit No. 0 setting
Alternately displayed?
↓
→
←
Select the indoor unit with [INDOOR UNIT] switch
Select command Select indoor unit No. 46
Alternately displayed?
→
←
※ The [INDOOR UNIT] switch selects indoor unit. Each time the switch is pressed, indoor unit registration order goes up by 1. After the last registered unit, it goes to all indoor unit selection. After all indoor unit selection, it goes back to the first registered unit.
290
TROUBLESHOOTING
Code No. / functions
Operational procedure / display contents
(Continued)
E8
Indoor electronic expansion valve open position forced setting in shutdown status
E9
Indoor electronic expansion valve open position forced setting when temperature control is OFF
[ Display when all indoor units are selected ]
Alternately displayed?
→
←
Display of all indoor
※ After this, LED 6 and 5 display code number and indoor unit number alternately.
In this figure, code number is displayed.
↓ Press [SET] switch
During command setting
During automatic setting During forced setting "64 → 1,248 steps"
→
←
Switch by pressing [UP] + [DOWN] switches simultaneously for 1 second
↓
Change the setting data with [UP] or [DOWN] switch
(by 32 steps)
Switch by pressing [UP] +
[DOWN] switches simultaneously for 1 second
EA
Indoor electronic expansion valve open position forced setting when temperature control is ON
↓
Press [SET] switch
↓
Press [SET] switch
Return to select command (setting is completed)
Indoor electronic expansion valve open position when temperature control setting
Completed
Automatic setting is completed Forced setting is completed
※ Forced setting of indoor electronic expansion valve is automatically cancelled in 10 minutes
291
TROUBLESHOOTING
Code No. / functions
Operational procedure / display contents
Monitor mode
Displays forced setting status of indoor fan air volume in shutdown status (code No. Eb) / when temperature control is OFF (code No. Ec) / when temperature control is ON (code No. Ed).
Indoor fan air volume forced setting during thermostat OFF : When the setting of indoor unit
No. 35 is fan air volume 1
Alternately displayed
→
←
Indoor fan air volume forced setting during thermostat ON : When the setting of indoor unit
No. 2 is automatic
Alternately displayed
Eb
Indoor fan air volume forced setting in shutdown status
Ec
Indoor fan air volume forced setting when temperature control is OFF
Ed
Indoor fan air volume forced setting when temperature control is ON
→
←
※ The [INDOOR UNIT] switch selects indoor unit. Each time the switch is pressed, indoor unit registration order goes up by 1. After the last registered indoor unit, it goes back to the first registered unit.
※ Indoor unit number display is changeable between "air net address" and "registration order" with code No. E0. (In the case of "air net address", only last 2 digits are displayed.)
Indoor fan air volume displays are as follows
0 : Stop
1 : Very low
2 : Low
3 : High
5 : Very high
Auto : Automatic
Command mode
Programs forced setting/cancel of indoor fan air volume.
Example) Method of indoor fan air volume in shutdown status of indoor unit No. 19
Select command Displays indoor unit No. 40 setting
Alternately displayed?
→
←
↓ Select the indoor unit with [INDOOR UNIT] switch
Select command Select indoor unit No. 19
Alternately displayed?
→
←
※ The [INDOOR UNIT] switch selects indoor unit. Each time the switch is pressed, indoor unit registration order goes up by 1. After the last registered unit, it goes to all indoor unit selection. After all indoor unit selection, it goes back to the first registered unit.
292
TROUBLESHOOTING
Code No. / functions
Operational procedure / display contents
(Continued)
Eb
Indoor fan air volume forced setting in shutdown status
Ec
Indoor fan air volume forced setting when temperature control is OFF
Ed
Indoor fan air volume forced setting when temperature control is ON
[ Display when all indoor units are selected ]
Alternately displayed
→
←
Display of all indoor unit selection
※ After this, LED 6 and 5 display code number and indoor unit number alternately.
In this figure, code number is displayed.
↓
Press [SET] switch
During command setting
During automatic setting During forced setting (0 → 3)
→
←
Switch by pressing [UP] + [DOWN] switches simultaneously for 1 second
↓
Change the setting data with [UP] or [DOWN] switch
(0 ~ 3, 5)
Switch by pressing [UP] +
[DOWN] switches simultaneously for 1 second
↓ Press [SET] switch ↓ Press [SET] switch
Return to select command (setting is completed)
Indoor fan air volume in shutdown status setting Completed
Automatic setting is completed.
Forced setting is completed.
※ Forced setting of indoor fan air volume is automatically cancelled in 10 minutes
293
TROUBLESHOOTING
Code No. / functions
Operational procedure / display contents
F8
Indoor electronic expansion valve actual open position
Monitor mode
Displays indoor electronic expansion valve actual open position.
When the open position of indoor unit No. 3 is 470 steps
Alternately displayed
→
←
※ The [INDOOR UNIT] switch selects indoor unit. Each time the switch is pressed, indoor unit registration order goes up by 1. After the last registered indoor unit, it goes back to the first registered unit.
※ Indoor unit number display is changeable between "air net address" and "registration order" with code No. E0. (In the case of "air net address", only last 2 digits are displayed.)
Monitor mode
Displays remote controller unit No. / remote controller code.
In the case of "indoor unit No. 22: remote controller unit No. 8, remote controller code c, and fixed as master"
Alternately displayed
F9
Remote controller unit
No. / Remote controller code
→
←
Fixed as master
Remote controller code
Remote controller unit No.
Fixed as master
Remote controller code
Remote controller unit No.
※ Remote controller code : A ~ F is displayed.
※ Fixed as master : When the remote controller is fixed as the master controller, "c" is displayed.
※ Remote controller unit number : 0 ~ 15 is displayed.
※ The [INDOOR UNIT] switch selects indoor unit. Each time the switch is pressed, indoor unit registration order goes up by 1. After the last registered indoor unit, it goes back to the first registered unit.
※ Indoor unit number display is changeable between "air net address" and "registration order" with code No. E0. (In the case of "air net address", only last 2 digits are displayed.)
294
TROUBLESHOOTING
Code No. / functions
Operational procedure / display contents
FA
Indoor unit air net address number
Monitor mode
Displays indoor unit air net address number
When air net address of indoor unit No. 34 is No. 158
Alternately displayed?
→
←
※ The [INDOOR UNIT] switch selects indoor unit. Each time the switch is pressed, indoor unit registration order goes up by 1. After the last registered indoor unit, it goes back to the first registered unit.
※ Indoor unit number display is "registration order".
Fb
Indoor unit capacity
Monitor mode
Displays indoor unit capacity.
When ndoor unit capacity of indoor unit No. 55 is 28.0 kW
Alternately displayed?
→
←
※ The [INDOOR UNIT] switch selects indoor unit. Each time the switch is pressed, indoor unit registration order goes up by 1. After the last registered indoor unit, it goes back to the first registered unit.
※ Indoor unit number display is changeable between "air net address" and "registration order" with code No. E0. (In the case of "air net address", only last 2 digits are displayed.)
※ Capacity is shown in kW. To convert it to BTU/h use the following formula.
BTU/h = kW x 3,412
295
TROUBLESHOOTING
Code No. / functions
Operational procedure / display contents
Fc
Indoor heat exchanger vapor pipe temperature
Monitor mode
Displays status of indoor heat exchanger vapor pipe temperature (code No. Fc) / indoor heat exchanger liquid pipe temperature (code No. Fd) / indoor intake air temperature (code No. FE).
When indoor heat exchanger vapor pipe temperature of inddor unit No. 91 is -3 ℃
Alternately displayed
→
←
Fd
Indoor heat exchanger liquid pipe temperature
FE
Indoor intake air temperature
When indoor unit intake temperature of indoor unit No. 7 is 24 ℃
Alternately displayed?
→
←
※ The [INDOOR UNIT] switch selects indoor unit. Each time the switch is pressed, indoor unit registration order goes up by 1. After the last registered indoor unit, it goes back to the first registered unit.
※ Indoor unit number display is changeable between "air net address" and "registration order" with code No. E0. (In the case of "air net address", only last 2 digits are displayed.)
※ Temperature is shown in Celsius (C). To convert it to Fahrenheit (F), use the following formula. F = C x 9/5 + 32
296
TROUBLESHOOTING
Code No. / functions
Operational procedure / display contents
Monitor mode
Displays indoor unit operation status.
When operation status of indoor unit No. 14 is temperature setting 27 ℃ in cooling
Alternately displayed
→
←
FF
Indoor unit operation status /
Collective test operation
Operation mode
Temperature control Set temperature
Operation mode
Temperature control Set temperature
Temperature control
During temperature control : o
During temperature control request : _
No temperature control request : Blank
Operation mode
Cooling : C
Heating : H
Dry : d
Fan : F
Stop : S
Temperature settings
Cooling : Temperature setting
Heating : Temperature setting
Dry : Temperature setting
Fan : --
Stop : --
※ The [INDOOR UNIT] switch selects indoor unit. Each time the switch is pressed, indoor unit registration order goes up by 1. After the last registered indoor unit, it goes back to the first registered unit.
※ Indoor unit number display is changeable between "air net address" and "registration order" with code No. E0. (In the case of "air net address", only last 2 digits are displayed.)
※ Temperature is shown in Celsius (C). To convert it to Fahrenheit (F), use the following formula. F = C x 9/5 + 32
297
TROUBLESHOOTING
Code No. / functions
Operational procedure / display contents
(Continued)
FF
Indoor unit operation status /
Collective test operation
Command mode
Programs test operation setting. (Simultaneous operation or stop of all indoor units is possible)
Method of test operation setting
Select command (Initial display)
In the case of change "Test operation stopped → Cooling test operation"
Display modes are as follows
Hcr : During heating test operation
Ccr : During cooling test operation oFF : Test operation is stopped
↓ Press [SET] switch
Selecting command
↓
Switching with [UP] or [DOWN] switch
Changeable modes are as follows
↑ UP
↓
Press [SET] switch for 1 second
Hcr : Heating test operation
Ccr : Cooling test operation oFF : Stop test operation
↓ DOWN
Return to select command (setting is completed) Test operationsetting Completed
Cooling test operation starts.
298
6. Protection Devices
8 TON
FRONT SIDE
TROUBLESHOOTING
Engine coolant temperature sensor
Engine oil pressure switch
REAR SIDE
Oil level switch
Figure 1 Engine and related parts
299
TROUBLESHOOTING
PANEL SIDE
Outdoor liquid pipe temperature sensor
Accumulator outlet temperature sensor
ENGINE SIDE
Outdoor heat exchanger liquid temperature sensor
Sub heat exchanger liquid temperature sensor
Outdoor heat exchanger vapor temperature sensor
Refrigerant high pressure sensor 1
Refrigerant low pressure sensor
Compressure discharge pipe temperature sensor 1
Refrigerant high pressure switch 1
Compressure discharge pipe temperature sensor 2
Compressure intake temperature sensor
Figure 2 Refrigerant system
300
Eelectric leakage breaker
ENLARGE
Figure 3 In control box
Radiator cap
TROUBLESHOOTING
Outside air temperature sensor
Figure 4 Overhead view
301
Engine compartment temperature sensor
(attached to the 1F top panel)
TROUBLESHOOTING
15 TON
FRONT SIDE
Engine coolant temperature sensor
Engine oil pressure switch
Oil level switch
Figure 1 Engine and related parts
302
TROUBLESHOOTING
PANEL SIDE
Outdoor liquid pipe temperature sensor
Refrigerant high pressure switch 1
Accumulator outlet temperature sensor
ENGINE SIDE
Outdoor heat exchanger liquid temperature sensor
Sub heat exchanger liquid temperature sensor
Outdoor heat exchanger vapor temperature sensor
Refrigerant low pressure sensor
Compressure discharge pipe temperature sensor 1
Refrigerant high pressure sensor 1
Refrigerant high pressure switch 2
Compressure discharge pipe temperature sensor 2
Compressure intake temperature sensor 1
Figure 2 Refrigerant system
303
TROUBLESHOOTING
Eelectric leakage breaker
ENLARGE
Figure 3 In control box
Radiator cap
Outside air temperature sensor
Figure 4 2F
Engine compartment temperature sensor
(attached to the 1F top panel)
304
TROUBLESHOOTING
7. Standard Operation Data
8 TON
Engine speed
Number of compressors
Compressor intake pressure
Compressor intake temperature rpm (min
-
℉ ( ℃ )
-1 psi (MPa)
Compressor discharge pressure psi (MPa)
)
Compressor discharge temperature
Number of outdoor fans
℉ (
-
℃ )
Outdoor heat exchanger liquid flow control valve open position
Sub heat exchanger liquid flow control valve open position
Subcooling valve open position
Electromagnetic compressor capacity valve 1
Electromagnetic compressor capacity valve 2
OCR valve open position
Engine coolant temperature ℉ ( stp stp stp
-
stp
℃ )
15 TON
Rated cooling
1700 (1700)
2
133 (0.92)
64 (18)
365 (2.52)
138 (59)
2
0
Overloaded cooling
(outside air 115 ℉ (46 ℃ )
1500 (1500)
2
146 (1.01)
77 (25)
463 (3.19)
163 (73)
2
0
Rated heating
1750 (1750)
2
113 (0.78)
63 (17)
392 (2.70)
160 (71)
2
125
0
462
OFF
OFF
349
158 (70)
0
500
OFF
OFF
349
165 (74)
122
68
OFF
OFF
201
144 (62)
Engine speed
Number of compressors
Compressor intake pressure
Compressor intake temperature rpm (min
-
℉ ( ℃ )
-1 psi (MPa)
Compressor discharge pressure psi (MPa)
)
Compressor discharge temperature
Number of outdoor fans
℉ (
-
℃ )
Outdoor heat exchanger liquid flow control valve open position
Sub heat exchanger liquid flow control valve open position
Subcooling valve open position
Electromagnetic compressor capacity valve 1
Electromagnetic compressor capacity valve 2
OCR valve open position
Engine coolant temperature ℉ ( stp stp stp
-
stp
℃ )
Rated cooling
2000 (2000)
2
119 (0.82)
66 (19)
425 (2.93)
167 (75)
2
0
0
198
OFF
OFF
449
165 (74)
305
Overloaded cooling
(outside air 115 ℉ (46 ℃ )
1100 (1100)
2
154 (1.06)
81 (27)
473 (3.26)
165 (74)
2
0
0
500
OFF
OFF
447
162 (72)
Rated heating
1950 (1950)
2
110 (0.76)
57 (14)
408 (2.81)
160 (71)
2
165
220
40
OFF
OFF
425
145 (63)
TROUBLESHOOTING
8. Wiring Diagram of the Outdoor Unit
8 TON
̪ Electronic expansion valve is 5 cores (without brown) or
6 cores (with brown).
18'8
̪
5%'8
̪
1'8
̪
5'8
̪
*.
59
1+.
.8.
+.6
%2
6
%2
6
%2
5 6*.
6*) 516 #6 25.
25*
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4$T$N1;9 ԣԡԠԢԜԞ
%0
4$T$N1;9
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4$T$N1;9 ԧԥԨԪԤԦ
2%$
%0
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49;$N
%0
Ԙԙ
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Heat exchanger compartment
(/
ITQWPFKPI
Unit with drain heater kit only
Engine compartment
+P1WV
%QOOWPK
ECVKQP
1WV1WV
%QOOWPK
ECVKQP
E/G
OPH
Engine compartment
Engine oil pan heater
(unit with drain heater kit only)
C/P2
OEV
DH
Exhaust water drain heater
(unit with drain heater kit only)
SOT
C/P S Compressor intake temperature sensor PSH1
C/P T1
C/P T2
HLSW1
ILT
C/P H1
C/P H2
SCEV
AOT
Compressor discharge pipe temperature sensor 1
Compressor discharge pipe temperature sensor 2
Refrigerant high pressure switch 1
Outdoor liquid pipe temperature sensor
Compressor heater 1
Compressor heater 2
Subcooling valve
Accumulator outlet temperature sensor
SEV
THG
OLP
PSL
OIL-LVL
WP
E/G R
Compressor clutch
Outdoor heat exchanger liquid flow control valve
Sub heat exchanger liquid temperature sensor
Refrigerant high pressure sensor 1
Sub heat exchanger liquid flow control valve
Outdoor heat exchanger vapor temperature sensor
Engine oil pressure switch
Refrigerant low pressure sensor
Oil level switch
Engine coolant pump
Engine compartment temperature sensor
4PV
C/P V1
C/P V2
BV
E/G E
THL
TB1
TB2
FUEL
WT
OVEV
Reversing valve
Electromagnetic compressor capacity valve 1
Electromagnetic compressor capacity valve 2
Hot gas bypass valve
Exhaust water drain heater
(unit with deodorant kit only)
Outdoor heat exchanger liquid temperature sensor
Terminal block 1 (for power supply)
Terminal block (for communication)
Fuel gas flow control valve
Engine coolant temperature sensor
Oil bypass control valve
306
1WVUKFG
(WGN
ICUDQZ
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EMC-PCB IG1
IG2
IG3
WB(G2)
STM
STR
TR2
MAIN-PCB
PWR-PCB
Ignition coil 1
Ignition coil 2
Ignition coil 3
Engine speed sensor
Throttle valve
Starter
Transformer 2
Control box
Main PCB
Power supply PCB
KR-PCB
DCBL-PCB
C
ENK-PCB
DB
RY1
TR1
L
EMC PCB
Cold district PCB
(unit with drain heater kit only)
DCBL PCB
Electrolysis condenser
(Not use)
Diode bridge
Starter relay
Transformer 1
Reactor
IGN
IF-PCB
Igniter
Communication control
PCB
ELB Eelectric leakage breaker
Heat exchanger compartment
FM1
FM2
Fan motor 1
Fan motor 2
THO
GV1
GV2
Outside air temperature sensor
Fuel box
Electromagnetic gas valve 1
Electromagnetic gas valve 2
307
TROUBLESHOOTING
15 TON
̪ Electronic expansion valve is 5 cores (without brown) or
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Unit with drain heater kit only
C/P T1
C/P T2
C/P V1
Engine compartment
Compressor discharge pipe temperature sensor 1
Compressor discharge pipe temperature sensor 2
Electromagnetic compressor capacity valve 1
C/P2
OEV
SEV
SOT
C/P V2
AOT
Electromagnetic compressor capacity valve 2
Accumulator outlet temperature sensor
THG
THL
SCEV
PSL
HLSW1 Refrigerant high pressure switch 1 OIL-LVL
HLSW2 Refrigerant high pressure switch 2 FUEL
PSH1
Subcooling valve
Refrigerant low pressure sensor
OLP
BV
C/P S
Refrigerant high pressure sensor 1 C/P H1
Compressor intake temperature sensor
C/P H2
WP
Heat exchanger compartment
(/
Compressor clutch
Outdoor heat exchanger liquid flow control valve
Sub heat exchanger liquid flow control valve
Sub heat exchanger liquid temperature sensor
Outdoor heat exchanger vapor temperature sensor
Outdoor heat exchanger liquid temperature sensor
Engine oil pressure switch
Hot gas bypass valve
Oil level switch
Fuel gas flow control valve
Compressor heater 1
Compressor heater 2
Engine coolant pump
ITQWPFKPI
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TB1
TB2
IG1
IG2
IG3
IG4
OVEV
DH
E/G
OPH
E/G E
E/G R
Oil bypass control valve
Exhaust water drain heater
(unit with drain heater kit only)
Engine oil pan heater
(unit with drain heater kit only)
Exhaust water drain heater
(unit with deodorant kit only)
Engine compartment temperature sensor
Outdoor liquid pipe temperature sensor
Terminal block 1 (for power supply)
Terminal block (for communication)
Ignition coil 1
Ignition coil 2
Ignition coil 3
Ignition coil 4
308
1WVUKFG
(WGN
ICUDQZ
%QPVTQNDQZ
56/
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Unit with drain heater kit only
#TTCPIGOGPVKPVJGEQPVTQNDQZ
NOTE) The status of contact point shown in the diagram is when the system is shut down.
IGN
4PV
WT
WB(G2)
WB(Ne)
STM
STR
MAIN-PCB
PWR-PCB
Igniter
Reversing valve
Engine coolant temperature sensor
Engine speed sensor (G2)
Engine speed sensor (Ne)
Throttle valve
Starter
Control box
Main PCB
Power supply PCB
EMC-PCB
KR-PCB
DCBL-PCB
C
ENK-PCB
DB
RY1
TR1
TR2
EMC PCB
Cold district PCB
(unit with drain heater kit only)
DCBL PCB
Electrolysis condenser
(Not use)
Diode bridge
Starter relay
Transformer 1
Transformer 2
L
ELB
Reactor
Eelectric leakage breaker
IF-PCB Communication control PCB
Heat exchanger compartment
FM1
FM2
THO
Fan motor 1
Fan motor 2
Outside air temperature sensor
Fuel box
GV1
GV2
Electromagnetic gas valve 1
Electromagnetic gas valve 2
309
TECHNICAL DATA FOR REPAIR
TECHNICAL DATA FOR REPAIR
1. Engine System
Compression system
Ignition system
Fuel system
Item
Compression
Valve clearance
Each cylinder
Compression limit
When the engine is hot
When the engine is cold
Ignition timing
Spark plug electrode clearance
Spark plug tightening torque
Air/Fuel ratio (O
2 meter)
Fuel gas pressure
Type
8 TON
Engine oil
Standard amount
15 TON
Engine oil pressure
Standard value
203 psi (1.4 MPa) or higher
160 psi (1.1 MPa)
0.014 ± 0.002 inch (0.35 ± 0.05 mm)
0.010 ± 0.002 inch (0.25 ± 0.05 mm)
17 ± 3°/1,200 rpm (min -1 )
0.016 ~ 0.039 inch (0.4 ~ 1.0 mm)
15 ~ 22 lb·ft (20 ~ 30 N·m)
3 ~ 10 % / 2,400 rpm (min -1 )
0.15 ~ 0.36 psi (1.0 ~ 2.5 kPa)
AISIN Gas Engine Oil L-10000G
7.93 gal (30 L)
(B level -3/8 ~ 0 inch (-10 ~ 0 mm))
8.45 gal (32 L)
(A level -3/8 ~ 0 inch (-10 ~ 0 mm))
21.8 ~ 72.5 psi (150 ~ 500 kPa)
(in 1,800 rpm (min
-1
))
#1
#2
#3
#1 ~ 4
5.7 ± 2.2 k Ω
4.6 ± 1.8 k Ω
3.5 ± 1.3 k Ω
1.9 ~ 5.0 k Ω
Electric resistance
High voltage cable
8 TON
Engine throttle valve
15 TON
Connector [1]-[2],
[2]-[3],
[4]-[5],
[5]-[6]
Connector [1]-[3],
[4]-[6]
Engine oil pressure switch
Oil level switch
Electromagnetic gas valves 1, 2
Starter
Starter pinion coil
Fuel gas flow control valve
Connector [1]-[2],
[2]-[4],
[5]-[7],
[7]-[8]
Connector [1]-[4],
[5]-[8]
Engine speed sensor
8 TON
Ignition coil
15 TON
120 Ω (77 ℉ (25 ℃ ))
240 Ω (77 ℉ (25 ℃ ))
Less than 1 Ω , 1 M Ω or more
Less than 1 Ω , 1 M Ω or more
21 Ω
0.01 Ω (68 ℉ (20 ℃ ))
0.24 Ω (68 ℉ (20 ℃ ))
120 Ω (77 ℉ (25 ℃ ))
240 Ω (77 ℉ (25 ℃ ))
1,100 ± 150 Ω (68 ℉ (20 ℃ ))
2.8 Ω
1.85 Ω
310
Remark
8 TON only
Primary coil
TECHNICAL DATA FOR REPAIR
Electric resistance
Compressor belt tension
Item
Engine oil pan heater
Exhaust water drain heater
Replacement
Inspection
8 TON
15 TON
8 TON
15 TON
8 TON
15 TON
Standard value
833 Ω
On the PCB
(combined value)
Drain filter
Drain hose
On the PCB
(combined value)
421
833
851
476
Ω
Ω
Ω
Ω
Sonic
Drain filter
Drain hose
667
225 ~ 270 lbf
(1,000 ~ 1,200 N)
Ω
1,667 Ω
Mechanical 155 lbf (690 N)
Sonic
Mechanical
Sonic
Mechanical
Sonic
Mechanical
301 ~ 346 lbf
(1,340~1,540 N)
202 lbf (900 N)
180 ~ 216 lbf
(800 ~ 960 N)
124 lbf (550 N)
241 ~ 277 lbf
(1,070~1,230 N)
162 lbf (720 N)
Remark
Unit with drain heater kit only
※
※ Measure the belt tension with a sonic belt tension gauge. Tension values for a mechanical belt tension gauge on the chart are reference values.
8 TON 15 TON Setting for sonic belt tension gauge
Unit mass
Number of ribs
Span 212 mm
17 g / rib•m
8 pieces
242 mm
311
TECHNICAL DATA FOR REPAIR
2. Refrigerant System
Indoor unit temperature difference
(Intake-Discharge)
Flare nuts tightening torque
Item
Nominal outer diameter
In cooling
In heating
Refrigerant permissible piping length and height difference between indoor and outdoor units
Refrigerant line size
Permissible piping length
(Equivalent length / Actual length)
Permissible height difference between indoor and outdoor units
Outdoor unit installed above indoor units
Outdoor unit installed below indoor units
Liquid line
8 TON
15 TON
Vapor line
8 TON
15 TON
1/4 inch (6.35 mm)
3/8 inch (9.52 mm)
1/2 inch (12.70 mm)
5/8 inch (15.88 mm)
3/4 inch (19.05 mm)
Standard value Remark
Δ T=18 ~ 27 ℉ (10 ~ 15 ℃ )
Δ T=27 ~ 36 ℉ (15 ~ 20 ℃ )
It's vary according to the envitonmental conditions or indoor units.
The values are only for reference.
623/541 ft (190/165 m)
164 ft (50 m)
131 ft (40 m)
1/2 inch (
5/8 inch (
Φ
Φ
12.7 mm)
15.9 mm)
1-1/8 inch ( Φ 28.6 mm)
1-1/4 inch ( Φ 31.8 mm)
10.4 ~ 13.3 lb·ft
(14 ~ 18 N·m)
25.2 ~ 31.0 lb·ft
(34 ~ 42 N·m)
36.3 ~ 45.1 lb·ft
(49 ~ 61 N·m)
50.3 ~ 60.7 lb·ft
(68 ~ 82 N·m)
74.0 ~ 88.8 lb·ft
(100 ~ 120 N·m)
(Brazing)
Outdoor heat exchanger liquid flow control valve registance value
Sub heat exchanger liquid flow control valve registance value
Connector
[red]-[white],
[red]-[orange],
[brown]-[yellow],
[brown]-[blue]
Connector
[white]-[orange],
[yellow]-[blue]
Refrigerant high pressure switches 1,2 registance value
Subcooling valve registance value
Oil bypass control valve registance value
Connector
[red]-[white],
[red]-[orange],
[brown]-[yellow],
[brown]-[blue]
Connector
[white]-[orange],
[yellow]-[blue]
Compressor clutch 2 registance value
Hot gas bypass valve registance value
Reversing valve registance value
Electromagnetic compressor capacity valves 1,2 registance value
312
8 TON 46 ± 4 Ω
15 TON 34.3 ± 4.3 Ω
When the electronic expansion valve is 5 cores (without brown), substitute red core for brown core.
8 TON 92 ± 8 Ω
15 TON 68.6 ± 8.6 Ω
Less than1 Ω ,
1 M Ω or more
2 : 15 TON only
46 ± 4 Ω
92 ± 8 Ω
4 Ω ± 20 %
1,050 Ω
950 Ω
1,050 Ω
When the electronic expansion valve is 5 cores (without brown), substitute red core for brown core.
TECHNICAL DATA FOR REPAIR
Item
Compressor heaters 1, 2 registance value
Type
Refrigerant oil
Additional refilling amount of the refrigerant oil when repairing the refrigerant system
Standard amount
When doing refrigerant pump down
When recovering refrigerant
When recovering refrigerant vapor
When accumulator is replaced
When oil separator is replaced
Standard value
1.67 k Ω ± 7 %
NL10
1.06 gal (4 L)
0 gal (0 cm 3 )
0.11 gal (400 cm
0.11 gal (400 cm
3
3
0.26 gal (1,000 cm
)
)
3
0.53 gal (2,000 cm 3 )
)
When other part is replaced
(except compressor)
Type
Refrigerant gas Standard amount
8 TON
15 TON
Additional refilling amount of the refrigerant when repairing the refrigerant system
Measured value
R410A
25.4 lbs (11.5 L)
37.5 lbs (17.0 L)
※ 1
※ Additional refilling amount of the refrigerant when repairing the refrigerant system
(Calcuate using theformula indicated below)
Refilling amount (lbs)
= (l
1
x 0.237) + (l
2
x 0.168) + (l
3
x 0.114) + (l
4
x 0.074) + (l
5
x 0.036) + (l
6
x 0.015)
Remark
Refilling of refrigerant oil at the time of installation is not necessary.
When replacing the parts that do not contain the refrigerant oil inside such as discharge pipes, expansion valves, or dryer filters.
When the compressor
(including dryer filter) is replaced, you must supply refrigerant oil into the compressor unit separately.
(For details, refer to
P116 and after)
If the other parts are replaced together, total of refilling amount required for each replaced part must be added.
Refilling amount (kg)
= (l
1
x 0.353) + (l
2
x 0.250) + (l
3
x 0.170) + (l
4
x 0.110) + (l
5
x 0.054) + (l
6
x 0.022) l
1
=Liquid piping Φ 7/8 inch total length (ft) l
2
=Liquid piping Φ 3/4inch total length (ft) l
3
=Liquid piping Φ 5/8 inch total length (ft) l
4
=Liquid piping Φ 1/2 inch total length (ft) l
5
=Liquid piping Φ 3/8 inch total length (ft) l
6
=Liquid piping Φ 1/4 inch total length (ft) l
1
=Liquid piping Ф 22.22 mm total length (m) l
2
=Liquid piping Ф 19.05 mm total length (m) l
3
=Liquid piping Ф 15.88 mm total length (m) l
4
=Liquid piping Ф 12.70 mm total length (m) l
5
=Liquid piping Ф 9.52 mm total length (m) l
6
=Liquid piping Ф 6.35 mm total length (m)
NOTE) When more than one indoor unit is connected, add 2.2 lbs (1 kg) more refrigerant to the above-mentioned formula.
[When more than one indoor unit is connected]
Refilling amount (lbs)
= (l
1
x 0.237) + (l
2
x 0.168) + (l
3
x 0.114) + (l
4
x 0.074) + (l
5
x 0.036) + (l
6
x 0.015) + 2.2
Refilling amount (kg)
= (l
1
x 0.353) + (l
2
x 0.250) + (l
3
x 0.170) + (l
4
x 0.110) + (l
5
x 0.054) + (l
6
x 0.022) + 1.0
313
TECHNICAL DATA FOR REPAIR
3. Engine Coolant System
Thermostat valve
Engine coolant
Engine coolant additive
Engine coolant pump
Item
140 ℉ (60 open
℃ )
Starts opening at
Opened fully at
Thermostat valve lift amount
158 ℉ (70 ℃ ) open
Starts opening at
Opened fully at
Type
Color
Thermostat valve lift amount
8 TON
Amount
15 TON
Volume concentration
Specified refilling amount
Type
Resistance value
8 TON
15 TON
8 TON
15 TON
Standard value
140
163
0.33 inch (8.5 mm)
158
181
℉
℉
℉
℉
(60
(73
(70
(83
℃
℃
℃
℃ )
)
)
)
0.33 inch (8.5 mm)
Remark
AISIN Coolant S
Green
14.99 l (15 L)
26.01 l (26 L)
50 vol% (engine coolant : 0.55, water : 0.45)
AISIN Coolant additive
10.1 ~ 11.8 fl oz. (300 ~ 350 cm 3 )
15.6 ~ 17.2 fl oz. (460 ~ 510 cm 3 )
16 ~ 25 Ω
10 ~ 18 Ω
Including engine coolant in the reserve tank
-4 ℉ (-20 ℃ ) antifreezing solution
314
TECHNICAL DATA FOR REPAIR
4. Thermistor Characteristics
Outdoor unit
Engine coolant temperature sensor resistance value
Temperature
122 ℉ (50 ℃ )
176 ℉ (80 ℃ )
212 ℉ (100 ℃ )
230 ℉ (110 ℃ )
Outside air temperature sensor resistance value
Engine compartment temperature sensor resistance value
Outdoor heat exchanger liquid temperature sensor resistance value
Outdoor heat exchanger vapor temperature sensor resistance value
Sub heat exchanger liquid temperature sensor resistance value
Outdoor liquid pipe temperature sensor resistance value
Compressor intake temperature sensor resistance value
Accumulator outlet temperature sensor resistance value
Compressor discharge pipe temperature sensor resistance value
Engine exhaust air temperature sensor resistance value
(unit with deodorant kit only)
Temperature
14 ℉ (-10 ℃ )
32 ℉ (0 ℃ )
50 ℉ (10 ℃ )
68 ℉ (20 ℃ )
86 ℉ (30 ℃ )
104 ℉ (40 ℃ )
122 ℉ (50 ℃ )
131 ℉ (55 ℃ )
140 ℉ (60 ℃ )
149 ℉ (65 ℃ )
158 ℉ (70 ℃ )
167 ℉ (75 ℃ )
Temperature
32 ℉ (0 ℃ )
68 ℉ (20 ℃ )
122 ℉ (50 ℃ )
176 ℉ (80 ℃ )
212 ℉ (100 ℃ )
248 ℉ (120 ℃ )
Temperature
392 ℉ (200 ℃ )
572 ℉ (300 ℃ )
752 ℉ (400 ℃ )
932 ℉ (500 ℃ )
1,112 ℉ (600 ℃ )
1,292 ℉ (700 ℃ )
1,472 ℉ (800 ℃ )
Standard value
17.6 k Ω
6.1 k Ω
3.3 k Ω
2.5 k Ω
Standard value
23.7 k Ω
15.0 k Ω
9.8 k Ω
6.5 k Ω
4.4 k Ω
3.1 k Ω
2.2 k Ω
1.9 k Ω
1.6 k Ω
1.4 k Ω
1.2 k Ω
1.0 k Ω
Standard value
182.9 k Ω
70.4 k Ω
20.2 k Ω
7.0 k Ω
3.7 k Ω
2.1 k Ω
Standard value
371.1 k Ω
52.6 k Ω
11.5 k Ω
3.53 k Ω
1.38 k Ω
0.64 k Ω
0.34 k Ω
315

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