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Panasonic S-106ME1E5 Service Manual

Other manuals for S-106ME1E5: Instruction Manual, Service Manual, Service Manual
Manual is about: 2WAY VRF SYSTEM

Summary of S-106ME1E5

  • Page 1

    85464849326000 reference no. Sm830226-00 outdoor unit model no. Class 73 106 140 224 280 e1 high static pressure ducted indoor unit class 22 28 36 45 56 60 73 90 106 140 160 u1 4-way cassette s-160mu1e51 s-140mu1e51 s-106mu1e51 s-73mu1e51 s-160mu1e5 s-140mu1e5 s-106mu1e5 s-73mu1e5 s-140mt1e5 s-106mt...

  • Page 2

    Ii important! Please read before starting this air conditioning system meets strict safety and operating standards. As the installer or service person, it is an important part of your job to install or service the system so it operates safely and efficiently. For safe installation and trouble-free o...

  • Page 3

    Iiii caution • do not touch the air inlet or the sharp aluminum fins of the outdoor unit. You may get injured. • ventilate any enclosed areas when installing or testing the refrigeration system. Escaped refrigerant gas, on contact with fire or heat, can produce dangerously toxic gas. • confirm after...

  • Page 4

    Iii 2. The standards for minimum room volume are as follows. (1) no partition (shaded portion) (2) when there is an effective opening with the adjacent room for ventilation of leaking refrigerant gas (opening without a door, or an opening 0.15% or larger than the respective floor spaces at the top o...

  • Page 5

    Iv precautions for installation using new refrigerant 1. Care regarding tubing 1-1. Process tubing material: use c1220 phosphorous deoxidized copper specified in jis h3300 “copper and copper alloy seamless pipes and tubes.” for tubes of ø22.22 or larger, use c1220 t-1/2h material or h material, and ...

  • Page 6

    V important information regarding the refrigerant used this product contains fluorinated greenhouse gases covered by the kyoto protocol. Do not vent gases into the atmosphere. Refrigerant type: r410a gwp (1) value: 1975 (1) gwp = global warming potential periodical inspections for refrigerant leaks ...

  • Page 7: Contents —

    Vi — contents — section 1: control functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 section 2: outdoor unit repair procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 1. Removing panels . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 8

    Vii section 5. Trouble diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 1. Contents of remote controller switch alarm display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 2. Outdoor unit control panel led display . . . . . . . . . . ....

  • Page 9: 1.  Control Functions

    1 - 1 3way system control functions 1 1. Control functions 1. Introduction 2. Selecting outdoor unit for operation 3. 4. 5. 6. 7. 8. Compressor control output of pcb outdoor fan control indoor units control from the ccu tube refrigerant recovery control oil control 9. 10. 11. 12. 13. Defrost control...

  • Page 10: 1. Introduction

    3way system control functions 1 - 2 1 1. Introduction the 3way system is a system that allows multiple outdoor units to be connected. The outdoor units all contain inverter compressors, and the system does not utilize the sub units that were used in earlier systems. The outdoor unit where the unit n...

  • Page 11

    1 - 3 3way system control functions 1 2. Selecting outdoor unit for operation 2-1. Outdoor unit operating rules all outdoor units in this system contain an inverter compressor. Therefore there is no order of priority for the outdoor units. 2-2. Delayed start of outdoor units 2-3. Outdoor unit stop r...

  • Page 12: 3. Compressor Control

    3way system control functions 1 - 4 1 3. Compressor control 3-1. Compressors mounted in the outdoor units [u-8mf2e8, u-10mf2e8, u-12mf2e8, u-14mf2e8, u-16mf2e8] 8 hp 10 hp 12 hp 14 hp 16 hp installed compressor compressor 1 dc inverter rotary compressor 2 constant speed scroll 10hp 10hp 10hp 10hp 10...

  • Page 13: 3. Compressor Control

    1 - 5 3way system control functions 1 3. Compressor control 3-3. Delay start of each compressor 3-4. Operating frequency range of inverter compressor to decrease the load of power-supply facility, it is possible to delay start of each compressor. 3-5. Forced compressor stop once a compressor stops, ...

  • Page 14: 3. Compressor Control

    3way system control functions 1 - 6 1 3. Compressor control 3-6. Capacity control (roadmap control) 3-6-1. Evaporation temperature adjustment by roadmap control the cooling capacity is adjusted with this control. It prevents freezing of the indoor unit's heat exchanger and the dew to the outside pan...

  • Page 15: 3. Compressor Control

    1 - 7 3way system control functions 1 3. Compressor control condensation temperature area at cooling operation 3-6-2. Condensation temperature adjustment by roadmap control the “b” area’s target temperature is different due to cooling, heating and mixed cooling/heating operation. Target lower temper...

  • Page 16: 3. Compressor Control

    3way system control functions 1 - 8 1 3. Compressor control when operating in cooling mode with the ambient temperature less than 21°c, the unit is set in low ambient temperature cooling mode. During low ambient temperature cooling mode, the heat exchanger capacity control is performed in addition t...

  • Page 17: 3. Compressor Control

    1 - 9 3way system control functions 1 3. Compressor control compressor control table low condensation temp. [tc] high a b c d lo w ev aporation temp. [t e] high up stop slow_up target down a b c not_up not_up evaporation temperature (te) and condensation temperature (tc) areas a, b, c, and d are the...

  • Page 18: 3. Compressor Control

    3way system control functions 1 - 10 1 3. Compressor control (3) increasing/decreasing the heat exchanger capacity (when the outdoor unit heat exchanger is functioning as an evaporator) • primarily when both the evaporation temperature (te) and condensation temperature (tc) are low this occurs when ...

  • Page 19: 3. Compressor Control

    1 - 11 3way system control functions 1 3. Compressor control 3-7. Protection control 3-7-1. Compressor discharge temperature protection discharge temp. The compressor capacity is controlled according to the table below. 3-7-2. Abnormal low pressure protection the compressor capacity is controlled ac...

  • Page 20: 3. Compressor Control

    3way system control functions 1 - 12 1 3. Compressor control 3-7-4. Primary current protection of hic board the fan motor current is included in primary current. Pcb is protected from the power consumption increase of fan motor when the heat exchanger is blocked by frost, etc. Limit current 1 max. C...

  • Page 21: 4. Output of Pcb

    1 - 13 3way system control functions 1 4. Output of pcb 4-1. [dcv, scv, pbv] turn dcv, scv and pbv to on/off. Change the outdoor unit heat exchanger mode and/or control the heat exchanger capacity. Solenoid valve item indication on pcb dcv1 dcv1a dcv2 dcv2a scv1 scv2 pbv1 pbv2 save rcv rbv orvr bpv ...

  • Page 22: 4. Output of Pcb

    3way system control functions 1 - 14 1 4. Output of pcb 4-2. Save valve [save] 4-3. Refrigerant control valve [rcv] this valve turns on for 5 seconds before the inverter compressor starts. After the inverter compressor starts, the valve is on for ten seconds. Then it turns off. The main purpose of t...

  • Page 23: 4. Output of Pcb

    1 - 15 3way system control functions 1 4. Output of pcb 4-4. Refrigerant balance valve [rbv] the main purpose of this valve is to detect the flow of refrigerant (refrigerant volume) on the indoor unit when the outdoor unit heat exchanger is functioning as an evaporator. When the valve determines tha...

  • Page 24: 4. Output of Pcb

    3way system control functions 1 - 16 1 4. Output of pcb 4-6. By-pass valve [bpv] this valve is for pushing the oil in the balance piping into other outdoor unit. 4-7. Refrigerant interception valve [o2] this valve works when the outdoor unit receives signal of the refrigerant leakage from the indoor...

  • Page 25: 4. Output of Pcb

    1 - 17 3way system control functions 1 4. Output of pcb 4-8-3. Expansion valve for heat exchanger control the configuration of the heat exchangers is different depending on the capacity of the outdoor unit. When operating in all cooling or all heating mode, the heat exchangers of which the compresso...

  • Page 26: 4. Output of Pcb

    3way system control functions 1 - 18 1 4. Output of pcb 4-9. Sc circuit electronic control valve [mov4] 4-9-1. Sc control (cooling mode only) during cooling operation, the liquid refrigerant which condenses at the outdoor unit heat exchanger flows into the receiver tank, and sc (sub-cool = supercool...

  • Page 27: 5. Outdoor Fan Control

    1 - 19 3way system control functions 1 5. Outdoor fan control 5-1. Fan mode these outdoor units utilize a dc fan motor that can be controlled in a maximum of 15 steps (15 modes). However, fan modes 14 and 15 can only be used if high static pressure mode has been set. * for information concerning eep...

  • Page 28: 5. Outdoor Fan Control

    3way system control functions 1 - 20 1 5. Outdoor fan control this control is intended to prevent snow from accumulating on stopped fans. When the outdoor unit is stopped, the fan motor is forcibly started by the control for fan crack prevention’s fan mode. 5-1-2. Snow removal control (1) independen...

  • Page 29: 5. Outdoor Fan Control

    1 - 21 3way system control functions 1 5. Outdoor fan control 5-1-3. Silent mode this unit includes 2 types of silent modes. See the table under the section “5-1. Fan mode” for maximum fan mode in silent mode. Selecting the silent mode results in operation that gives priority to reducing noise, beca...

  • Page 30: 5. Outdoor Fan Control

    3way system control functions 1 - 22 1 5. Outdoor fan control 5-2. Fixed initial fan mode for the first 30 seconds after operation starts, the mode is fixed at the initial mode which was calculated from the relationship between the ambient temperature and the outdoor unit horsepower. If the outdoor ...

  • Page 31

    1 - 23 3way system control functions 1 6. Indoor units control from ccu * the meaning of outdoor unit “operating” is functioning as a cooling or heating system at least more than one compressor operating simultaneously. *1 sh control adjusts the difference between the liquid temperature and gas temp...

  • Page 32

    3way system control functions 1 - 24 1 6. Indoor units control from ccu this device connects the solenoid valve kit which is used to switch between indoor unit cooling/heating for 3-way types. In case of special controls, solenoid valve kit performs special operation. For detail, refer to the sectio...

  • Page 33

    1 - 25 3way system control functions 1 6. Indoor units control from ccu indoor unit fan run in the heating mode is stopped from ccu at the following conditions. 6-3-3. Heating mode ccu intervenes in drain pump control of the indoor unit according to the setting in eeprom in the outdoor unit. The dra...

  • Page 34

    3way system control functions 1 - 26 1 6. Indoor units control from ccu eeprom setting in main outdoor unit code: 2b xx setting no. 20 30 40 50 60 20 minutes 30 minutes (factory preset mode) 40 minutes 50 minutes 60 minutes * the drain pump always operates when the indoor unit is thermostat on in co...

  • Page 35

    1 - 27 3way system control functions 1 7. Tube refrigerant recovery control this control is intended to recover refrigerant if refrigerant has accumulated somewhere in the tubing when the units have been stopped for long periods, as well as to compensate for tubing thermal loss during heating start,...

  • Page 36

    3way system control functions 1 - 28 1 7. Tube refrigerant recovery control control when outdoor unit heat exchanger is acting as an evaporator (when all units are in heating mode or at start of mixed operation when heating load is high) * when the above operation is finished, normal operation start...

  • Page 37: 8. Oil Control

    1 - 29 3way system control functions 1 8. Oil control 8-1. Oil level 8-2. Oil level detection 8-3. Self-separator oil recovery control 8-4. Inter outdoor units oil recovery control – utilizing balance tubes * this oil recovery might be performed regardless of oil level according to operating conditi...

  • Page 38: 8. Oil Control

    3way system control functions 1 - 30 1 8. Oil control 8-5-1. Start of system oil recovery control 8-5-2. Simplified flow of system oil recovery control when operating compressor oil level 0 system oil recovery control shall be performed as the flow mentioned below. Surely perform this system control...

  • Page 39: 8. Oil Control

    1 - 31 3way system control functions 1 8. Oil control 8-6. Oil rotation control the oil rotation control system regularly exchanges oil among the outdoor units regardless of oil level. Oil rotation control is performed every one hour with accumulated operation time among the connected multiple outdo...

  • Page 40: 9. Defrost Control

    3way system control functions 1 - 32 1 9. Defrost control eeprom setting in main outdoor unit code: a3 setting no. 20 21 xx 20 21 40 interval of “1” 40 (factory preset mode) 90 never use 41 system employs 1 outdoor unit in the refrigerant system 2 or more outdoor units in the refrigerant system defr...

  • Page 41: 9. Defrost Control

    1 - 33 3way system control functions 1 9. Defrost control 9-3. Frost detection 9-4. Reverse cycle defrost (1) 9-4-1. Start of reverse cycle defrost 9-4-2. Simplified flow of reverse cycle defrost reverse cycle defrost is performed in systems where only 1 outdoor unit is connected to the refrigerant ...

  • Page 42: 9. Defrost Control

    3way system control functions 1 - 34 1 9. Defrost control this reverse cycle defrost process is performed after outdoor units, indoor units and solenoid valve kits are changed to the cooling cycle. Reverse cycle defrost process * 1 outdoor unit operates at maximum horsepower. Valves at all indoor un...

  • Page 43: 9. Defrost Control

    1 - 35 3way system control functions 1 9. Defrost control 9-5. Outdoor unit cycle defrost outdoor unit cycle defrost is performed in systems where 2 or more outdoor units are connected to the refrigerant system. With this defrost method, when 1 outdoor unit operates in defrost mode (heat exchanger o...

  • Page 44: 9. Defrost Control

    3way system control functions 1 - 36 1 9. Defrost control e c→e e→c s c : evaporator operation *1 function when a common use solenoid valve kit is used and there are more than one (1) indoor unit in the cooling mode within the same solenoid valve kit. *2 function when a common use solenoid valve kit...

  • Page 45: 9. Defrost Control

    1 - 37 3way system control functions 1 9. Defrost control indoor unit (expansion valve, solenoid valve kit, fan) *1 function when a common use solenoid valve kit is used and there are more than one (1) indoor unit in the cooling mode within the same solenoid valve kit. *2 function when a common use ...

  • Page 46

    3way system control functions 1 - 38 1 10. Upper current limitation mode (demand control) eeprom setting in main outdoor unit eeprom setting in main outdoor unit code: 1a setting no. Xx 0 0 40 40 45 45 code: 1e setting no. 0 no display 1 information is displayed when input of demand control is set (...

  • Page 47

    1 - 39 3way system control functions 1 10. Upper current limitation mode (demand control) limit value limited ratio against standard value outdoor unit even if the demand control is not performed, upper current limitation is restricted. 10-2. Upper current limitation mode hp = horsepower 8 hp 10 hp ...

  • Page 48: 11. Alarm Information

    3way system control functions 1 - 40 1 11. Alarm information the upper limit discharge temperature is 106°c for all compressors. When the discharge temperature reaches 106°c, that compressor is stopped and restarted. If the same high discharge condition occurs 5 times, then an alarm occurs. After a ...

  • Page 49: 11. Alarm Information

    1 - 41 3way system control functions 1 11. Alarm information 8 hp 10 hp 12 hp 14 hp 16 hp primary current [a] outdoor unit 15.1 description compressor 1 primary current detected over-current higher than values. The fan motor current is included in primary current. Compressor 1 secondary current dete...

  • Page 50: 11. Alarm Information

    3way system control functions 1 - 42 1 11. Alarm information 11-3-1. High-pressure sensor failure the high-pressure switch works when it detects 3.65mpa or more. If one of the high-pressure switches works, whole outdoor units stop and then restart. If the high-pressure switch works after the system ...

  • Page 51: 11. Alarm Information

    1 - 43 3way system control functions 1 11. Alarm information alarm display gas temperature sensor in heat exchanger 1 liquid temperature sensor in heat exchanger 1 exl1 exg1 air temp ambient air temperature suction temperature temp. Sensor at refrigerant gas outlet of dual-tube scg sct exg2 gas temp...

  • Page 52: 12. Backup Operation

    3way system control functions 1 - 44 1 12. Backup operation this system includes a function for automatic backup operation. An alarm is displayed on the remote controller to inform the user that a failure has occurred. When the following alarm occurs, automatic backup operation is engaged. Automatic...

  • Page 53: 12. Backup Operation

    1 - 45 3way system control functions 1 12. Backup operation 12-1-2. Start of automatic backup operation if the above alarms occur, the alarm is displayed on the remote controller etc. Pressing the remote controller button again starts automatic backup mode. When the backup operation is started, oper...

  • Page 54: 12. Backup Operation

    3way system control functions 1 - 46 1 12. Backup operation 12-2. Manual backup operation 12-1-4. Check for blinks when automatic backup setting when operating the automatic backup by setting the outdoor unit eeprom, blink check on the remote controller and centralized control systems is enabled to ...

  • Page 55: 12. Backup Operation

    1 - 47 3way system control functions 1 12. Backup operation all compressors of sub outdoor unit are backed up unit no. 1 main unit ccu function unit no. 2 sub unit unit no. 3 sub unit main outdoor unit sub outdoor unit sub outdoor unit number of setting 2 not necessary not necessary unit no. 1 2 3 m...

  • Page 56: 13. Other Functions

    3way system control functions 1 - 48 1 13. Other functions 13-1. Maintenance function for power supply stop of indoor unit (e06 ignore) the system can continue operation even if outdoor unit cannot communicate with some indoor units. It is necessary to set to eeprom the allowed number of operating i...

  • Page 57: 13. Other Functions

    1 - 49 3way system control functions 1 13. Other functions this system includes a simple function for judging the amount of refrigerant. 13-2-1. Starting refrigerant level judgment mode 13-2-2. Conditions for amount of refrigerant judgment 13-2-3. Outdoor unit pcb led indications in judgment mode 13...

  • Page 58

    3way system control functions 1 - 50 1 14. Detail setting in eeprom of outdoor unit dn item setting no. 04 operation for using snowfall sensor 0=no sensor & control (p) 1=sensor & control 2=no sensor & no control (for detail, refer to 5-1-3) (for detail, refer to 5-1-4) 3=sensor & no control 05 outd...

  • Page 59

    1 - 51 3way system control functions 1 14. Detail setting in eeprom of outdoor unit dn item setting no. Never use the dn code unlisted in the following table. (p) : factory preset mode a3 the minimum operating time 1 until defrosting 20=20min.. 21=21min. ,,,,, 40=40min. (p) (for detail, refer to 9-2...

  • Page 60: – Memo –

    – memo – 1 - 52 sm830226-00̲3way eco-i system.In52 52 sm830226-00̲3way eco-i system.In52 52 2013/02/13 11:52:30 2013/02/13 11:52:30

  • Page 61

    2 - 1 3way system outdoor unit repair procedures 2 2. Outdoor unit repair procedures 1. Removing panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 2-3 2. 3. 2-5 4. 2-5 2-12 5. 6. 2-13 2-14 2-18 7. 8. 9. Discharging compressor oil...

  • Page 62: 1. Removing Panels

    3way system outdoor unit repair procedures 2 - 2 2 1. Removing panels (1) front panel removal (fig.1) • remove the front panel. Be sure to turn off the power before maintenance. When the power is turned off, wait for 5 minutes without any work. Then start working. Caution front panel power outlet pa...

  • Page 63

    2 - 3 3way system outdoor unit repair procedures 2 2. Discharging compressor oil discharged oil can be used for checking the condition of the system. Based on the appearance and color of the discharged oil, a judgment can be made on whether the system is operating normally or not. 2-1. Discharging o...

  • Page 64

    3way system outdoor unit repair procedures 2 - 4 2 2. Discharging compressor oil 2-2. Discharging oil in compressor recover the refrigerant in the outdoor unit following the procedures in “4. Recovering refrigerant.” remove the compressor and discharge the oil in it. Refer to “9. Compressor” for det...

  • Page 65: 3. Backup Operation

    2 - 5 3way system outdoor unit repair procedures 2 3. Backup operation this system includes an emergency automatic backup function that allows the a/c to operate during the period after trouble occurs until repairs are made. However, during repair and at other times, use manual backup operation. 3-1...

  • Page 66: 3. Backup Operation

    3way system outdoor unit repair procedures 2 - 6 2 3. Backup operation after recovery work is completed, wire the communication lines between indoor and outdoor units again. If it not finished yet, an alarm is emitted immediately. Caution (2) adjusting the refrigerant for backup operation during bac...

  • Page 67: 4. Recovering Refrigerant

    2 - 7 3way system outdoor unit repair procedures 2 4. Recovering refrigerant the following equipment and tools are required: jumper wire with clips, adjustable wrench, set of manifold gauge valves specially designed for refrigerant r410a only, vacuum pump, refrigerant recovery unit, pre-purged refri...

  • Page 68: 4. Recovering Refrigerant

    3way system outdoor unit repair procedures 2 - 8 2 4. Recovering refrigerant 4-2. Refrigerant recovery procedures (indoor unit) the flowchart below shows the refrigerant recovery procedures you must follow when replacing or repairing the indoor unit due to trouble in the refrigerant circuit. Start 4...

  • Page 69: 4. Recovering Refrigerant

    2 - 9 3way system outdoor unit repair procedures 2 4. Recovering refrigerant (2) if the remote controller (cz-rtc2) is not available for maintenance of the outdoor unit 1 determine the outdoor unit where the unit no. Setting (sw5) (3p dip switch) (blue) on the outdoor unit control pcb is set to no. ...

  • Page 70: 4. Recovering Refrigerant

    3way system outdoor unit repair procedures 2 - 10 2 4. Recovering refrigerant 4-2-3. Refrigerant recovery procedures (2): indoor unit with no ball valve equipped refrigerant in all indoor units and the refrigerant tubing circuit can be pumped into the outdoor unit. The maximum refrigerant storage ca...

  • Page 71: 4. Recovering Refrigerant

    2 - 11 3way system outdoor unit repair procedures 2 4. Recovering refrigerant 4-3. Recovery of refrigerant from entire system (1) turn off power to the entire outdoor system. (2) short-circuit the ap pins (cn24) on the outdoor control pcb of all outdoor units, then supply power to the outdoor units....

  • Page 72

    3way system outdoor unit repair procedures 2 - 12 2 5. Checking for leakage after repair high-pressure outlet port (for ø7.94mm-dia connector) low-pressure outlet port (for ø7.94mm-dia connector) liquid tube service port (for ø7.94mm-dia connector) discharge tube service port (for ø7.94mm-dia connec...

  • Page 73: 6. Evacuating System

    2 - 13 3way system outdoor unit repair procedures 2 6. Evacuating system manifold gauge lo hi low-pressure outlet port (for ø7.94mm-dia connector) high-pressure outlet port (for ø7.94mm-dia connector) liquid tube service port (for ø7.94mm-dia connector) discharge tube service port (for ø7.94mm-dia c...

  • Page 74: 7. Charging Compressor Oil

    3way system outdoor unit repair procedures 2 - 14 2 7. Charging compressor oil (dpr : cv6230817937) nipple packless valve (receiver-tank: cv6380152988) fig. 8 7-1. If refrigerant has already been charged to outdoor unit be sure to use an exclusive oil-charging tank for charging compressor oil. Prior...

  • Page 75: 7. Charging Compressor Oil

    2 - 15 3way system outdoor unit repair procedures 2 7. Charging compressor oil when the predetermined amount of oil has been charged into the oil-charging tank, immediately close the lower valve. Next, run the vacuum pump until the system pressure reaches lower than -101kpa(-755 mmhg, 5 torr). Close...

  • Page 76: 7. Charging Compressor Oil

    3way system outdoor unit repair procedures 2 - 16 2 7. Charging compressor oil next follow the instructions in “4-2-1. Cooling operation (for all units)” at the outdoor unit where oil will be charged, and start cooling operation at all units. When the operating conditions have stabilized, perform st...

  • Page 77: 7. Charging Compressor Oil

    2 - 17 3way system outdoor unit repair procedures 2 7. Charging compressor oil 7-3. Charging additional compressor oil (after replacing compressor) the rated amount of oil is pre-charged in the compressors as given below: when replacing a faulty compressor, be sure to first measure the amount of rem...

  • Page 78

    3way system outdoor unit repair procedures 2 - 18 2 8. Pumping out refrigerant from outdoor unit the hoses may be subject to internal pressure from the refrigerant inside the out- door unit. Check that the manifold gauge valves are fully closed beforehand. A schrader-type push-to-release valve is pr...

  • Page 79

    2 - 19 3way system outdoor unit repair procedures 2 8. Pumping out refrigerant from outdoor unit (8) short-circuit the vacuum application pin on the outdoor unit control pcb of the unit to be repaired. Then turn on the outdoor unit power. When the vacuum application pin is short-circuited and the po...

  • Page 80

    3way system outdoor unit repair procedures 2 - 20 2 8. Pumping out refrigerant from outdoor unit while closing the valves, the rise in discharge temperature or another factor may cause a protective device to activate, stopping the operation of the outdoor unit. If this occurs, immediately fully clos...

  • Page 81: 9. Compressor

    2 - 21 3way system outdoor unit repair procedures 2 9. Compressor 9-1. Compressor trouble diagnosis and check methods generally, compressor failures can be classified into the following categories. (1) mechanical trouble (a) locking (intrusion of foreign objects, galling, etc.) (b) pressure rise fai...

  • Page 82: 9. Compressor

    3way system outdoor unit repair procedures 2 - 22 2 9. Compressor 9-2. Replacing the compressor(s) 9-2-1. Replacing only the failed compressor (1) if backup operation is required, follow the instructions in “3. Backup operation” and engage backup operation. (2) follow the instructions in “9-3. Remov...

  • Page 83: 9. Compressor

    2 - 23 3way system outdoor unit repair procedures 2 9. Compressor 9-2-2. Replacing all compressors in a failed unit (1) follow the instructions in “2. Discharging compressor oil” and drain the oil from the oil separator in the failed unit. Measure the amount of drained oil. (2) if backup operation i...

  • Page 84: 9. Compressor

    3way system outdoor unit repair procedures 2 - 24 2 9. Compressor 9-2-3. Replacing all compressors in a system (1) follow the instructions in “2. Discharging compressor oil” and drain the oil from the oil separators in all out- door units. Measure the amount of drained oil. (2) follow the instructio...

  • Page 85: 9. Compressor

    2 - 25 3way system outdoor unit repair procedures 2 9. Compressor 9-2-4. Dry core cleaning if burning or other failures occur repeatedly at compressors within the same system, in many cases the cause is acid, sludge, carbon, or other substances that remain in the refrigeration cycle as the result of...

  • Page 86: 9. Compressor

    3way system outdoor unit repair procedures 2 - 26 2 9. Compressor (16) after evacuating all nitrogen gas from the tubing, apply vacuum to all outdoor units where dry cores were removed until the pressure is –101kpa (–755 mmhg, 5 torr) or less. (17) installation: refer to the “information for the per...

  • Page 87: 9. Compressor

    2 - 27 3way system outdoor unit repair procedures 2 9. Compressor 9-3. Removing compressors when removing and installing compressors, use sufficient caution to ensure that moisture or other substances do not enter the refrigerant tubing system. 9-3-1. Removing compressors (for all models) (1) after ...

  • Page 88: 9. Compressor

    3way system outdoor unit repair procedures 2 - 28 2 9. Compressor 9-3-2. Removing constant-speed compressors (for 12, 14 and 16 horse power models) (1) (2) (3) (5) (6) tube-with-flare-nut (8) pull the compressor toward you. (4) after retrieving refrigerant from the system, perform nitrogen gas repla...

  • Page 89

    3 - 1 3way system outdoor unit maintenance remote controller 3 3. Outdoor unit maintenance remote controller 1. Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 2. Functions . . . . . . . . . . . . . . . . . . . ...

  • Page 90: 1. Overview

    3way system outdoor unit maintenance remote controller 3 - 2 3 1. Overview outdoor unit maintenance remote controller (cz-rtc2) for 3way system nabout the outdoor unit maintenance remote controller the outdoor unit utilizes nonvolatile memory (eeprom) on its pcb. This allows eeprom data to replace t...

  • Page 91: 2. Functions

    3 - 3 3way system outdoor unit maintenance remote controller 3 2. Functions nfunctions on the ordinary display (1) functions: button operations can be used to perform the following functions. • start/stop of all indoor units • switching between cooling and heating • test run of all indoor units • do...

  • Page 92

    3way system outdoor unit maintenance remote controller 3 - 4 3 3. Ordinary display controls and functions nfunctions on the ordinary display • connect the special service checker wiring to the outdoor unit pcb. The connection is shown in the figure below. L if the communications line in the inter-un...

  • Page 93

    3 - 5 3way system outdoor unit maintenance remote controller 3 3. Ordinary display controls and functions fig. 1 l all units start/stop (fig. 1) the (on/off operation) button can be used to start and stop all the indoor units. • the led turns on when 1 or more indoor units is operating. • the led bl...

  • Page 94

    3way system outdoor unit maintenance remote controller 3 - 6 3 3. Ordinary display controls and functions ndisplay (functions) • use the temperature setting and buttons to change the item code. Item code item remarks outdoor unit alarm alarm code display no. Of connected indoor units quantity unit n...

  • Page 95

    3 - 7 3way system outdoor unit maintenance remote controller 3 3. Ordinary display controls and functions (3) xx-yy r.C. Displays the outdoor unit sub-bus address which is currently selected. Xx = outdoor system address on main bus line (1 – 30) yy = outdoor unit sub-bus address (1 – 8). “1” appears...

  • Page 96

    3way system outdoor unit maintenance remote controller 3 - 8 3 3. Ordinary display controls and functions n concerning the 7-segment, 4-digit display remote controller timer display the connected unit nos. Are displayed as shown below, using the 7-segment 4-digit ( ) display and the colon. 1 2 7 12 ...

  • Page 97

    3 - 9 3way system outdoor unit maintenance remote controller 3 4. Monitoring operations display the indoor unit and outdoor unit sensor temperatures. Press and hold the (check) button and buttons simultaneously for 4 seconds or longer to switch to temperature monitor mode. During temperature monitor...

  • Page 98

    3way system outdoor unit maintenance remote controller 3 - 10 3 4. Monitoring operations ndisplay of unit no. 1 (main unit) dn description remarks intake temp. °c e1 °c e2 °c e3 °c indoor unit discharge temp. °c discharge temp. Setting °c indoor unit electronic control valve position step discharge ...

  • Page 99

    3 - 11 3way system outdoor unit maintenance remote controller 3 5. Outdoor unit alarm history monitor • displays outdoor unit alarms only. Does not display indoor unit alarms. • check the indoor unit alarm histories separately using the indoor unit remote controllers or other control device. Press a...

  • Page 100

    3way system outdoor unit maintenance remote controller 3 - 12 3 6. Mode settings n setting mode 1 press and hold the (check) button and (ventilation) button simultaneously for 4 seconds or longer. Use the temperature setting and buttons to change the item code. The item codes and setting data are sh...

  • Page 101

    3 - 13 3way system outdoor unit maintenance remote controller 3 6. Mode settings n setting mode 2 press and hold the (check) button, button, and button simultaneously for 4 seconds or longer. Use the temperature setting and buttons to change the item code. The item codes and setting data are shown i...

  • Page 102: – Memo –

    – memo – 3 - 14 5/a9#;'%1k5;56'/a5.

  • Page 103

    4 3way system remote controller functions 4 - 1 4. Remote controller functions 1. Simple settings function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 2. Detailed settings function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 104: 1. Simple Settings Function

    3way system remote controller functions 4 - 2 1. Simple settings function 4 this allows the filter lifetime, operating mode priority change, central control address, and other settings to be made for an individual or group- control indoor unit to which the remote controller used for simple settings ...

  • Page 105: 1. Simple Settings Function

    3way system remote controller functions 4 - 3 1. Simple settings function 4 list of simple setting items item code item setting data no. Description filter sign on time (fitlter life time) 0000 not displayed 0001 150 hours 0002 2,500 hours 0003 5,000 hours 0004 10,000 hours 0005 use the filter cloggin...

  • Page 106

    3way system remote controller functions 4 - 4 2. Detailed settings function 4 this allows the system address, indoor unit address, and other settings to be made for the individual or group-control indoor unit to which the remote controller used for detailed settings is connected. When detailed setti...

  • Page 107

    3way system remote controller functions 4 - 5 2. Detailed settings function 4 the flap swings during the operation under "setting the flap separately". At this time, the unselected flaps are moved to the position 1 . (refer to fig.3) * setting data “ ” (refer to fig.3) flap position 1 5 7 press the ...

  • Page 108

    3way system remote controller functions 4 - 6 2. Detailed settings function 4 list of detailed setting items item code item setting data no. Description no. Description no. Description type 0001 4-way casstte (60×60) (u1, y1) 0002 2-way cassette (l1) 0003 1-way cassette (d1) 0005 low silhouette duct...

  • Page 109

    3way system remote controller functions 4 - 7 2. Detailed settings function 4 item code item setting data no. Description (1b) forced thermostat on time 0000 5 minutes 0001 4 minutes cooling discharge temperature shift –010 –10°c –009 –9°c –008 –8°c 0010 10°c heating discharge temperature shift –010...

  • Page 110

    3way system remote controller functions 4 - 8 2. Detailed settings function 4 item code item setting data no. Description automatic drain pump operation 0000 no forced operation 0001 forced operation for 1 minute 0060 continuous operation ventilation fan operation 0000 none 0001 ventilation fan oper...

  • Page 111

    3way system remote controller functions 4 - 9 2. Detailed settings function 4 item code item setting data no. Description fan tap setting (fan tap change in order to prevent drop in air discharge caused by filter installation) dc fan tap operating mode purpose 0000 standard standard (setting at shipm...

  • Page 112

    3way system remote controller functions 4 - 10 2. Detailed settings function 4 simple setting items item code item description 01 filter sign on time setting (filter lifetime) changes the indoor unit filter lifetime when a high-performance filter or other optional product is installed. 02 degree of filt...

  • Page 113

    3way system remote controller functions 4 - 11 2. Detailed settings function 4 item code item description 03 central control address set when using a central control device. Used when setting the central control address manually from the remote controller. 04 operating mode priority change note (1) ...

  • Page 114

    3way system remote controller functions 4 - 12 2. Detailed settings function 4 when the operating mode at the priority remote controller is changed, the operating modes of other remote controllers change as shown below. Mode change at priority remote controller operating modes at other remote contro...

  • Page 115

    3way system remote controller functions 4 - 13 2. Detailed settings function 4 item code item description 10 unit type set when the indoor unit eeprom memory is replaced during servicing. 11 indoor unit capacity 12 system (outdoor unit) address these are not set at the time of shipping from the fact...

  • Page 116

    3way system remote controller functions 4 - 14 2. Detailed settings function 4 item code item description 1f (upper limit) 20 (lower limit) change to the remote control temperature setting range cooling this setting changes the temperature range (upper limit and lower limit) which is set from the re...

  • Page 117

    3way system remote controller functions 4 - 15 2. Detailed settings function 4 (continued from previous page) item code item description 3c heat exchanger temperature for cold air discharge the heat exchanger temperature control point for prevention of cold air discharge during heating operation can...

  • Page 118

    3way system remote controller functions 4 - 16 2. Detailed settings function 4 3way system remote controller functions 2. Detailed settings function selecting the dc fan motor tap (when setting from the pcb) 4-way cassette type stop the system before performing these steps. Open the electrical compo...

  • Page 119

    3way system remote controller functions 4 - 17 3. Remote controller servicing functions 4 the remote controller includes a number of servicing functions. Use these as needed for test runs and inspections. List of servicing functions functions description button operation reset operation unit status ...

  • Page 120

    3way system remote controller functions 4 - 18 3. Remote controller servicing functions 4 test run function operates the unit with the thermostat forced on. Press and hold the button for 4 seconds or longer. “test” appears on the remote controller lcd display (fig. 3). Start operation. Press the but...

  • Page 121

    3way system remote controller functions 4 - 19 3. Remote controller servicing functions 4 n sensor temperature display function (displayed regardless of whether unit is operating or stopped) the procedure below displays the sensor temperatures from the remote controller, indoor unit, and outdoor uni...

  • Page 122

    3way system remote controller functions 4 - 20 3. Remote controller servicing functions 4 indoor unit sensors 02 03 04 05 06 07 intake temp. E1 e2 e3 discharge temp. Discharge temp. Setting 08 position of indoor unit electronic control valve outdoor unit sensors unit no.1 unit no.2 unit no.3 0a 2a 4...

  • Page 123: 5.  Trouble Diagnosis

    5 5 - 1 3way system trouble diagnosis 5. Trouble diagnosis 1. Contents of remote controller switch alarm display . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 2. Outdoor unit control panel led display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 3. Remote contr...

  • Page 124

    5 5 - 2 3way system trouble diagnosis 1. Contents of remote controller switch alarm display on: blinking: off: possible cause of malfunction wired remote control display wireless remote controller receiver display operation timer standby for heating serial communication errors mis-setting remote con...

  • Page 125

    5 5 - 3 3way system trouble diagnosis 1. Contents of remote controller switch alarm display on: blinking: off: possible cause of malfunction wired remote control display wireless remote controller receiver display operation timer standby for heating outdoor thermistor is either open or damaged. Comp...

  • Page 126

    5 5 - 4 3way system trouble diagnosis 2. Outdoor unit control panel led display ( : on : blinking : off) led (red) display meaning 1 2 after the power is turned on (and automatic address setting is not in progress), no communication with the indoor units in that system is possible. (both on) after p...

  • Page 127

    5 5 - 5 3way system trouble diagnosis 3. Remote controller servicing functions sensor temperature display function (displayed both when unit is running and stopped) use the following check procedure to display the sensor temperatures from the remote controller, indoor unit, and outdoor unit sensors ...

  • Page 128

    5 5 - 6 3way system trouble diagnosis 3. Remote controller servicing functions sensor temperature relationship table location where sensor is installed sensor address sensor type sensor address sensor type indoor unit remote controller temperature discharge temperature sensor discharge temperature s...

  • Page 129: 4. 3Way Alarm Codes

    5 5 - 7 3way system trouble diagnosis 4. 3way alarm codes with types 8hp and 10hp, the inv compressor is compressor 1. With types 12hp, 14hp and 16hp, the inv compressor is compressor 1, and the constant-speed compressors (ac1) are compressors 2. Page alarm meaning alarm code 5-8 5-8 5-8 5-9 5-9 5-9...

  • Page 130: 4. 3Way Alarm Codes

    5 5 - 8 3way system trouble diagnosis 4. 3way alarm codes e06 alarm alarm code e06 alarm meaning outdoor unit failed to receive serial communication signals from indoor unit. Alarm conditions outdoor unit failed to receive serial communication signals from indoor unit. Probable cause (1) the indoor ...

  • Page 131: 4. 3Way Alarm Codes

    5 5 - 9 3way system trouble diagnosis 4. 3way alarm codes e24 alarm alarm code e24 alarm meaning outdoor unit failed to receive communication from other outdoor unit. Alarm conditions after initial communications were completed, communications from an outdoor unit stopped. Probable cause (1) after i...

  • Page 132: 4. 3Way Alarm Codes

    5 5 - 10 3way system trouble diagnosis 4. 3way alarm codes e25 alarm alarm code e25 alarm meaning outdoor unit address setting failure (duplication) alarm conditions communication by inter-outdoor unit control wiring was received that contained the same address as that unit 5 times or more within 3 ...

  • Page 133: 4. 3Way Alarm Codes

    5 5 - 11 3way system trouble diagnosis 4. 3way alarm codes f04, f05 alarm alarm code f04, f05 alarm meaning compressor 1 discharge temperature sensor trouble, compressor 2 discharge temperature sensor trouble. Alarm conditions (1) discharge temp. Of 100°c or higher was detected 30 minutes or more af...

  • Page 134: 4. 3Way Alarm Codes

    5 5 - 12 3way system trouble diagnosis 4. 3way alarm codes check (3) leakage from the discharge tube check valve trouble: although the other compressor is operating and this compressor is stopped, the discharge temperature of this compressor rises together with the temperature of the other compresso...

  • Page 135: 4. 3Way Alarm Codes

    5 5 - 13 3way system trouble diagnosis 4. 3way alarm codes f08 alarm alarm code f08 alarm meaning outdoor air temperature sensor trouble alarm conditions (1) a/d step is 10 steps or less (short circuit). (2) a/d step is 1014 steps or more (open circuit) probable cause (1) sensor malfunction (includi...

  • Page 136: 4. 3Way Alarm Codes

    5 5 - 14 3way system trouble diagnosis 4. 3way alarm codes f16 alarm alarm code f16 alarm meaning high-pressure sensor malfunction alarm conditions high-pressure sensor disconnected or open circuit high-pressure sensor detected over 3.6mpa continuously for 30 minutes while outdoor units stopped. Hig...

  • Page 137: 4. 3Way Alarm Codes

    5 5 - 15 3way system trouble diagnosis 4. 3way alarm codes f17 alarm alarm code f17 alarm meaning low-pressure sensor trouble alarm conditions (2) sensor open circuit probable cause (2) pcb malfunction check (1) sensor short circuit (1) sensor malfunction (including connector) (1) measure the sensor...

  • Page 138: 4. 3Way Alarm Codes

    5 5 - 16 3way system trouble diagnosis 4. 3way alarm codes h11, h12 alarm alarm code h11, h12 alarm meaning h12: constant speed compressor 2 lock current alarm h11: constant speed compressor 2 overcurrent alarm alarm conditions h11: during operation, when the compressor current value exceeds the fol...

  • Page 139: 4. 3Way Alarm Codes

    5 5 - 17 3way system trouble diagnosis 4. 3way alarm codes h03, h13 alarm alarm code h03, h13 alarm meaning h03 : compressor 1 ct sensor disconnected or short-circuit h13 : compressor 2 ct sensor disconnected or short-circuit alarm conditions compressor 1: compressor 2: when the compressor 1(inv) is...

  • Page 140: 4. 3Way Alarm Codes

    5 5 - 18 3way system trouble diagnosis 4. 3way alarm codes h06 alarm alarm code h06 alarm meaning abnormal decrease of low-pressure alarm conditions probable cause (1) low-pressure sensor failure (1) low-pressure sensor failure (1) replacement of low-pressure sensor (2) correct malfunction of refrig...

  • Page 141: 4. 3Way Alarm Codes

    5 5 - 19 3way system trouble diagnosis 4. 3way alarm codes h08, h27 alarm alarm code h08, h27 alarm meaning trouble (open circuit) with the oil sensor (connection) at compressor 1 and compressor 2 alarm conditions this alarm occurs when a connector connection (pins 1 and 2 for compressor 1, pins 4 a...

  • Page 142: 4. 3Way Alarm Codes

    5 5 - 20 3way system trouble diagnosis 4. 3way alarm codes l10 alarm alarm code l10 alarm meaning outdoor unit capacity not set alarm conditions the outdoor unit capacity has not been set, or the setting is not allowed by the system. Probable cause this alarm occurs because the capacity has not been...

  • Page 143: 4. 3Way Alarm Codes

    5 5 - 21 3way system trouble diagnosis 4. 3way alarm codes l17 alarm alarm code l17 alarm meaning outdoor unit model mismatch alarm conditions this alarm occurs when a unit other than r410a refrigerant model is connected. Probable cause (1) a unit that uses r407c refrigerant, or a r22 model unit, wa...

  • Page 144: 4. 3Way Alarm Codes

    5 5 - 22 3way system trouble diagnosis 4. 3way alarm codes p03, p17 alarm alarm code p03, p17 alarm meaning p03 : compressor 1 discharge temperature trouble p17 : compressor 2 discharge temperature trouble alarm conditions compressor 1 : pre-trip stops when the temperature exceeds 106°c. Compressor ...

  • Page 145: 4. 3Way Alarm Codes

    5 5 - 23 3way system trouble diagnosis 4. 3way alarm codes p04 alarm alarm code p04 alarm meaning high-pressure switch activated. Alarm conditions the operation of the electronic circuit in the high-pressure switch may short-circuit the terminal depending on the pressure. A pressure of 3.8 mpa or ab...

  • Page 146: 4. 3Way Alarm Codes

    5 5 - 24 3way system trouble diagnosis 4. 3way alarm codes p14 alarm alarm code alarm meaning alarm conditions probable cause check and correction example notes p14 o 2 sensor operation (1) 1-1 system configuration is an o 2 sensor being used? If “yes”, see “3-1”. If “no”, see “2-1”. If “yes”, see “...

  • Page 147: 4. 3Way Alarm Codes

    5 5 - 25 3way system trouble diagnosis 4. 3way alarm codes p22 alarm alarm code alarm meaning alarm conditions probable cause p22 fan motor trouble fan motor start failure, fan motor hall ic input failure possible causes are a hall ic input circuit failure and a fan hic failure. Check check the fan ...

  • Page 148

    5 5 - 26 3way system trouble diagnosis 5. Blinking inspection display currently the blinking inspection display can be displayed only on the wired remote controller and system remote controller. Blinking inspection display (1) (automatic backup) alarm code (blinking inspection display) alarm meaning...

  • Page 149

    5 5 - 27 3way system trouble diagnosis 5. Blinking inspection display blinking inspection display (2) (compressor magnet sw seizing detection) alarm code (blinking inspection display) alarm meaning compressor magnet sw seizing detected status: although an outdoor unit exists where the outdoor unit f...

  • Page 150: 6. Inspection of Parts

    5 5 - 28 3way system trouble diagnosis 6. Inspection of parts disconnect the cn3 connector (3p, wht) from the outdoor unit control panel. Measure the resistance between socket pins 1 and 3. The resistance is ok if the result is 0 Ω. Disconnect the cn4 connector (3p, red) from the outdoor unit contro...

  • Page 151: 7. Test  Pin

    5 5 - 29 3way system trouble diagnosis 7. Test pin when the test pin on the outdoor unit control pcb is short-circuited, each part can be operated individually. After turning off the main unit power, short circuit the test pin (cn022, wht), then turn the power back on. Output is performed in the seq...

  • Page 152

    5 5 - 30 3way system trouble diagnosis 8. Symptom: thermostat in off continues or cycles off & on too frequently 1-1 adjust setting temperature 1-2 yes no connect correctly 1-3 yes no 1 check if the sensors are connected correctly. Are all connection made properly? Room temp. (ta) in yellow, heat ex...

  • Page 153

    201302 sm830226-00̲3way eco-i system.In1 1 sm830226-00̲3way eco-i system.In1 1 2013/02/13 16:50:58 2013/02/13 16:50:58.