PUHZ-SHW230YKA SERVICE MANUAL R410A. September 2012 SPLIT-TYPE, AIR TO WATER HEAT PUMP. No. OCH534. [Service Ref.] [Model name] CONTENTS

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1 SPLIT-TYPE, AIR TO WATER HEAT PUMP September 202 No. SERVICE MANUAL R40A [Model name] PUHZ-SHW230YKA [Service Ref.] PUHZ-SHW230YKA Note: This manual describes only service data of the outdoor unit. Refer to Technical manual of ATW, I/F and FTC. RoHS compliant products have <G> mark on the spec name plate. CTENTS. SAFETY PRECAUTI SPECIFICATIS DATA OUTLINES AND DIMENSIS WIRING DIAGRAM WIRING SPECIFICATIS REFRIGERANT SYSTEM DIAGRAM TROUBLESHOOTING DISASSEMBLY PROCEDURE PARTS CATALOG (OCB534) PUHZ-SHW230YKA

2 SAFETY PRECAUTI -. ALWAYS OBSERVE FOR SAFETY Before obtaining access to terminal, all supply circuits must be disconnected. Preparation before the repair service. Prepare the proper tools. Prepare the proper protectors. Provide adequate ventilation. After stopping the operation of the air conditioner, turn off the power-supply beaker. Discharge the condenser before the work involving the electric parts. Precautions during the repair service. Do not perform the work involving the electric parts with wet hands. Do not pour water into the electric parts. Do not touch the refrigerant. Do not touch the hot or cold areas in the refrigerating cycle. When the repair or the inspection of the circuit needs to be done without turning off the power, exercise great caution not to touch the live parts. -2. CAUTIS RELATED TO NEW REFRIGERANT Cautions for units utilizing refrigerant R40A Do not use refrigerant other than R40A. If other refrigerant (R22 etc.) is used, chlorine in refrigerant can cause deterioration of refrigerant oil etc. Use a vacuum pump with a reverse flow check valve. Vacuum pump oil may flow back into refrigerant cycle and that can cause deterioration of refrigerant oil etc. Use the following tools specifically designed for use with R40A refrigerant. The following tools are necessary to use R40A refrigerant. Tools for R40A Gauge manifold Vacuum pump adaptor Charge hose Gas leak detector Torque wrench Handle tools with care. Electronic refrigerant charging scale If dirt, dust or moisture enters into refrigerant cycle, that can cause deterioration of refrigerant oil or malfunction of compressor. Do not use a charging cylinder. If a charging cylinder is used, the composition of refrigerant will change and the efficiency will be lowered. Charge refrigerant from liquid phase of gas cylinder. If the refrigerant is charged from gas phase, composition change may occur in refrigerant and the efficiency will be lowered. Use the specified refrigerant only. Never use any refrigerant other than that specified. Doing so may cause a burst, an explosion, or fire when the unit is being used, serviced, or disposed of. Correct refrigerant is specified in the manuals and on the spec labels provided with our products. We will not be held responsible for mechanical failure, system malfunction, unit breakdown or accidents caused by failure to follow the instructions. Ventilate the room if refrigerant leaks during operation. If refrigerant comes into contact with a flame, poisonous gases will be released. 2

3 [] Cautions for service () Perform service after recovering the refrigerant left in unit completely. (2) Do not release refrigerant in the air. (3) After completing service, charge the cycle with specified amount of refrigerant. [2] Additional refrigerant charge When charging directly from cylinder Check that cylinder for R40A on the market is syphon type. Charging should be performed with the cylinder of syphon stood vertically. (Refrigerant is charged from liquid phase.) Unit Gravimeter [3] Service tools Use the below service tools as exclusive tools for R40A refrigerant. No. Tool name Specifications Gauge manifold Only for R40A Use the existing fitting specifications. (UNF/2) Use high-tension side pressure of 5.3 MPa G or over. 2 Charge hose Only for R40A Use pressure performance of 5.09 MPa G or over. 3 Electronic scale 4 Gas leak detector Use the detector for R34a, R407C or R40A. 5 Adaptor for reverse flow check Attach on vacuum pump. 6 Refrigerant charge base 7 Refrigerant cylinder Only for R40A Top of cylinder (Pink) Cylinder with syphon 8 Refrigerant recovery equipment 3

4 -3. CAUTIS FOR REFRIGERANT PIPING WORK Tools for R40A (The following table shows whether conventional tools can be used or not.) Tools and materials Use R40A tools Can R22 tools be used? Can R407C tools be used? Gauge manifold Charge hose Gas leak detector Refrigerant recovery equipment Refrigerant cylinder Safety charger Tool exclusive for R40A Tool exclusive for R40A Tool for HFC refrigerant Tool exclusive for R40A Tool exclusive for R40A Tool exclusive for R40A Charge valve Vacuum pump Bender Pipe cutter Welder and nitrogen gas cylinder Refrigerant charging scale Vacuum gauge or thermistor vacuum gauge and vacuum valve Charging cylinder Air purge, refrigerant charge and operation check Gas leak check Refrigerant recovery Refrigerant charge Prevent compressor malfunction when charging refrigerant by spraying liquid refrigerant Prevent gas from blowing out when detaching charge hose Vacuum drying and air purge Bend the pipes Cut the pipes Weld the pipes Charge refrigerant Check the degree of vacuum. (Vacuum valve prevents back flow of oil and refrigerant to thermistor vacuum gauge) Refrigerant charge Tool exclusive for R40A Tools for other refrigerants can be used if equipped with adapter for reverse flow check Tools for other refrigerants can be used Tools for other refrigerants can be used Tools for other refrigerants can be used Tools for other refrigerants can be used Tools for other refrigerants can be used Tool exclusive for R40A : Prepare a new tool. (Use the new tool as the tool exclusive for R40A.) : Tools for other refrigerants can be used under certain conditions. : Tools for other refrigerants can be used. (Usable if equipped with adapter for reverse flow) (Usable if equipped with adapter for reverse flow) 4

5 2 SPECIFICATIS 2-. SPECIFICATI PUHZ-SHW230YKA <Reference data> Plate heat exchanger (MWA2-38PA) *2pcs [connected in parallel] Nominal water flow L/min 65.9 Rating conditions Nominal operating condition Heating Capacity kw 23.0 Heating (A2/W35) (A7/W35) Outside air temperature (Dry-bulb) + 2 C COP 3.65 Outside air temperature (Wet-bulb) + C Power input kw 6.3 Water temperature (inlet/outlet) + 30 C/+ 35 C Heating Capacity kw 23.0 Heating (A2/W45) (A7/W45) COP 2.77 Outside air temperature (Dry-bulb) + 2 C Power input kw 8.29 Outside air temperature (Wet-bulb) + C Heating Capacity kw 23.0 Water temperature (inlet/outlet) + 40 C/+ 35 C (A2/W35) Heating (A7/W35) COP 2.37 Outside air temperature (Dry-bulb) + 7 C Power input kw 9.69 Outside air temperature (Wet-bulb) + 6 C Heating Capacity kw 23.0 Water temperature (inlet/outlet) + 30 C/+ 35 C (A2/W45) COP 2.02 Heating (A7/W45) Power input kw.4 Outside air temperature (Dry-bulb) + 7 C Nominal water flow L/min 57.3 Outside air temperature (Wet-bulb) + 6 C Water temperature (inlet/outlet) + 40 C/+ 45 C Cooling Capacity kw (A35/W7) Cooling (A35/W7) EER 2.22 Outside air temperature (Dry-bulb) + 35 C Power input kw 9.0 Outside air temperature (Wet-bulb) + 24 C Cooling Capacity kw Water temperature (inlet/outlet) + 2 C/+ 7 C (A35/W8) EER 3.55 Cooling (A35/W8) Power input kw 5.64 Outside air temperature (Dry-bulb) + 35 C Outside air temperature (Wet-bulb) + 24 C Water temperature (inlet/outlet) + 23 C/+ 8 C Note: "COP" and "Power input" in the above table are the values that do NOT contain the "pump input (based on EN 45)". 5

6 2--2. Outdoor unit Model name PUHZ-SHW230YKA Running current Heating(A7/W35) A 9.6 Cooling(A35/W7) A 3.7 Power factor Heating(A7/W35) % 95 Cooling(A35/W7) % 95 Power supply (phase, cycle, voltage) 3 phase, 50 Hz, 400 V Max. current A 25.0 Breaker size A 32 Outer casing Galvanized plate External fi nish Munsell 3Y 7.8/. Refrigerant control Liner expansion valve Compressor Hermetic scroll Model ANB66FJNMT Motor output kw 4.7 Start type Inverter Protection devices HP switch LP switch Discharge thermo Comp. surface thermo Oil (Model) L.7 (FV50S) Crankcase heater W Heat exchanger Air Plate fi n coil Water Plate heat exchanger Fan Fan (drive) No. Propeller fan 2 Fan motor output kw Air fl ow m³/min 40 (CFM) (4,940) Defrost method Reverse cycle *¹ Noise level (SPL) Heating db 59 *² Cooling db 58 *² Dimensions Width mm (in.) 050 (4-5/6) Depth mm (in.) *³ (3+-3/6) Height mm (in.) 338 (52-/6) Weight kg (lbs) 48 (327) Refrigerant R40A Quantity kg (lbs) 7. (5.7) Guaranteed operating Heating C -25 ~ +35 range (Outdoor) Cooling C -5 * 4 ~ +46 Outlet water temp. Heating C +60 (Max. in heating, Min. in cooling) Cooling C +5 Nominal return water Heating C +0 ~ +59 temperature range Cooling C +8 ~ +28 Water fl ow rate range L/min 28.7 ~ 68.9 Maximum outlet water temperature Maximum outlet water temperature [ C] Ambient temperature [ C] * Hot gas with 4-way valve *2 at distance of m from outdoor unit *3 grill *4 With the optional air outlet guide, the operation at -5 outdoor temperature is possible. 6

7 3 DATA 3-. Addition of refrigerant At time of shipping Total piping length (one way) Amount of additional refrigerant charge (kg) 30 m and less 3-40 m 4-50 m 5-60 m 6-70 m 7-80 m For single combination ( indoor unit) For twin / triple / quadruple combination (2-4 indoor units) 7. kg No additional charge necessary.4 kg 2.8 kg 0.9 kg.8 kg 4.2 kg 5.6 kg 7.0 kg Calculate the amount of additional refrigerant charge using formula provided below. When length exceeds 50 m for twin / triple / quadruple combination When the total length of the piping exceeds 50 m, calculate the amount of additional charge based on the following requirements. Note: If the calculation produces a negative number (i.e. a minus charge), of if calculation results in an amount that is less than the Additional charage amount for 50 m, perform the additional charge using the amount shown in Additional charge amount for 50 m. Amount of additional charge = Main piping: Liquid line size ø2.7 overall length 0.7 Main piping: Branch piping: Branch piping: Liquid line size Liquid line size Liquid line size + ø9.52 overall length ø9.52 overall length ø6.35 overall length 0.4 (Gas line: ø25.4) (Gas line: ø5.88) (kg) (kg) (m) 0.7 (kg/m) (m) 0.4 (kg/m) (m) 0.05 (kg/m) (m) 0.02 (kg/m) Additional charge amount for 50 meters.8 kg <Limits of refrigerant piping installation> Max. m Indoor unit Outdoor unit Main piping Branch piping Multi distribution pipe (option) Outdoor unit : SHW230 Water heat exchanger Water heat exchanger 2 Water heat exchanger 3 A: ø m B: ø m C: ø m D: ø m Main piping ø9.52 is A = 65 m Branch piping ø9.52 is B + C + D = 5 m Therefore, the amount of additional charge is: = 5.6 (kg) (Fractions are rounded up) 3-2. NOISE CRITERI CURVES MICROPHE m UNIT.5m GROUND 7 PUHZ-SHW230YKA OCTAVE BAND SOUND PRESSURE LEVEL, db (0 db = μbar) APPROXIMATE THRESHOLD OF HEARING FOR CTINUOUS NOISE MODE SPL(dB) COOLING 58 HEATING 59 LINE BAND CENTER FREQUENCIES, Hz NC-70 NC-60 NC-50 NC-40 NC-30 NC-20

8 3-3. Standard operation data Reference data (connect to Plate HEX) Mode Total Electrical circuit Refrigerant circuit Water conditions (MWA2-38PA) o 2 pcs [connected in parallel] Cooling (A35/W7) Heating (A7/W35) Capacity W 20,000 23,000 Input kw Outdoor unit PUHZ-SHW230YKA Phase, Hz 3, 50 Voltage V 400 Current A Discharge pressure MPa Suction pressure MPa Discharge temperature ºC Condensing temperature ºC Suction temperature ºC 8 8 Evaporating temperature ºC 6 2 Evaporator inlet temperature ºC 7 Evaporator outlet temperature ºC 6 Condenser inlet temperature ºC 65 Condenser outlet temperature ºC 34 Flow volume L/min Outlet water temperature ºC 7 35 Outdoor conditions Intake air temperature D.B. ºC 35 7 W.B. ºC 24 6 Piping length : Main 2.5m, Branch 2.5m / 2.5m The unit of pressure has been changed to MPa based on international SI system. The conversion factor is: (MPa) = 0.2 (kgf/cm²) 3-4. CAPACITY CORRECTI (Refrigerant piping length) Cooling and heating capacity is lowered according to the piping length. Capacity can be obtained by referring to the following capacity curves. Corrected pipe length (m) = actual pipe length (m) + number of bends 0.3 (m) Cooling Heating SHW230 Capacity ratio [%] SHW Corrected pipe length [m] 8

9 4 OUTLINES AND DIMENSIS PUHZ-SHW230YKA Unit: mm FREE SPACE (Around the unit) 2 SERVICE SPACE 3 FOUNDATI BOLTS 4 PIPING-WIRING DIRECTIS The diagram below shows a basic example. Explanation of particular details are given in the installation manuals etc. Dimensions of space needed for service access are shown in the below diagram. Please secure the unit firmly with 4 foundation (M0) bolts. (Bolts and washers must be purchased locally.) Over 50 <Foundation bolt height> Piping and wiring connections can be made from 4 directions: FRT,Right,Rear and Below. FOUNDATI Over 500 Less than 30 FREE Over Over 0mm Over 0mm 0 Service space Over 500 Over 000mm Over 50mm Example of Notes Refrigerant GAS pipe connection (attached JOINT)ø25.4(Brazing locally) Refrigerant LIQUID pipe connection (FLARE) ø 9.52(3/8F) * Indication of STOP VALVE connection location. *2 (FLARE)ø 9.05(3/4F) 2 Piping Knockout Hole Details Power supply wiring hole (ø40knockout) Front trunking hole (Knockout) Power supply wiring hole (ø27knockout) Right piping hole (Knockout) Power supply wiring hole (ø27knockout) Power supply wiring hole (ø40knockout) Right trunking hole (Knockout) Power supply wiring hole (ø27knockout) Power supply wiring hole (ø40knockout) Rear trunking hole (Knockout) ø92 ø92 73 Front piping hole (Knockout) Rear piping hole (Knockout) ø Bottom piping hole (Knockout) Drain hole (5-ø33) Side Air Intake Rear Air Intake 600 Installation Feet Air Discharge 050 Earth terminal 2-U Shaped notched holes (Foundation Bolt M0) Oval holes (Foundation Bolt M0) Rear Air Intake Side Air Intake Handle for moving Handle for moving Handle for moving Terminal connection Left Power supply wiring Right Indoor/Outdoor wiring Service panel Handle for moving Brazing * 450 *,*2 : Air intake 2 Front piping cover Rear piping cover 9

10 5 WIRING DIAGRAM PUHZ-SHW230YKA SYMBOL NAME SYMBOL NAME SYMBOL NAME TB Terminal Block<Power Supply> FUSE, FUSE2 Fuse<T5AL250V> SW6 Switch<Model Select> TB2 Terminal Block<Indoor/Outdoor> CY, CY2 Capacitor SW7 Switch<Function Switch> MC Motor for Compressor P. B. Power Circuit Board SW8 Switch<Function Switch> MF,MF2 Fan Motor SC-U/V/W Connection Terminal<U/V/W-Phase> SW9 Switch<Function Switch> 2S4 Solenoid Valve (Four-Way Valve) TB-L/L2/L3 Connection Terminal<L/L2/L3-Power supply> SWP Switch<Pump Down> 63H High Pressure Switch TB-P Connection Terminal CN3 Connector<Emergency Operation> 63L Low Pressure Switch TB-P2 Connection Terminal LED, LED2 LED<Operation Inspection Indicators> 63HS High Pressure Sensor TB-C Connection Terminal F3, F4 Fuse<T6.3AL250V> TH3 Thermistor<Liquid> TB-N Connection Terminal SV Connector<Connection for Option> TH4 Thermistor<Discharge> X52A 52C Relay SS Connector<Connection for Option> TH6 TH7 Thermistor<2-Phase Pipe> Thermistor<Ambient> N. F. LI/LI2/LI3/NI Noise Filter Circuit Board Connection Terminal<L/L2/L3/NI-Power supply> CNM CNMNT Connector<Connection for Option> Connector<Connection for Option> TH32 Thermistor<Suction> LO/LO2/LO3 Connection Terminal<L/L2/L3-Power supply> CNVMNT Connector<Connection for Option> TH34 Thermistor<Comp. Surface> GD,GD2 Connection Terminal<Ground> CNDM Connector<Connection for Option> LEV-A, LEV-B, LEV-C Electronic Expansion Valve C. B. Controller Circuit Board CN3S Connector<Connection for Option> ACL4 Reactor SW Switch<Forced Defrost, Defect History Record CN5 Connector<Connection for Option> DCL Reactor Reset, Refrigerant Address> X5, X52, X54 Relay CB, CB2 Main Smoothing Capacitor SW4 Switch<Test Operation> RS Rush Current Protect Resistor SW5 Switch<Function Switch, Model Select> MF MS 3~ MF2 MS 3~ C. B. 2 CNS (WHT) 3 CNDC (PNK) 3 CNF 7(WHT) CNF2 7 (WHT) 63H TRANS 63L CNAC (WHT) TH32 TH7TH6 TH3 TH4 t t t t t TH32 TH7/6 TH3 TH4 (BLK) (RED) (WHT) (WHT) 3 63H (YLW) CN2 (WHT) 7 F3 F4 3 63L (RED) HS TH34 (WHT) (RED) LED2 63HS TH34 LED t 2 LEV-A 5 LEV-A (WHT) CN4 (WHT) 2 X52 M LEV-B 5 LEV-B (RED) X54 M 2S4 3 3 SV /CH (GRN) (GRY) 5 5 LEV-C (BLU) LEV-C M CNVMNT CNMNT (WHT) (WHT) CNM 4 (WHT) X5 3 SS (WHT) SW5 SW8 SW4 SWP * * SW6 SW CN3 SW7 SW9 CN3S (WHT) CNDM (WHT) CN5 (WHT) * WHT FUSE RED FUSE2 7 P. B. 7 2S4 WHT RED 2 2 CN2 (WHT) 2 CN4 (WHT) 2 CN5 (RED) SC-W SC-V SC-U TB-L3 BLK BLK WHT RED W V U MC MS 3~ TB-L2 WHT TB-L RED CY CY2 BLK X52A TB2 S YLW RS RED BLK TB-P TB-P2 TB-C TB-N INDOOR UNIT S2 S3 BRN ORN DCL RED CB WHT CB2 BLK 2 POWER SUPPLY 3N~ 400V 50Hz TB RED L WHT L2 BLK L3 BLU N GRN/YLW N. F. LI LI 2 LI 3 NI CNAC (WHT) 3 CNCT (RED) 2 CNAC2 3 (RED) LO LO 2 LO3 RED WHT BLK * MODEL SELECT The black square( )indicates a switch position. MODEL SW6 OFF Y SW5-6 *2 OFF *2 SW5 - to 5 : Function Switch. GD GD2 CNDC (PNK) 3 3 CNL (BLU) BLK BLK 2 WHT WHT ACL4 *3 Ambient temp. of ZUBADAN Flash Injection becomes effective. The black square( )indicates a switch position. Ambient temp. 3 C or less (lnitial setting) OFF SW9-3.4 *4 234 *4 SW9- to 2 : Function Switch Ambient temp. 0 C or less OFF SW9-3.4 *4 234 Ambient temp. SW9-3.4 *4 Ambient temp. SW9-3.4 *4 3 C or less 0 OFF C or less OFF 234

11 6 WIRING SPECIFICATIS S S2 S3 A B L L2 L3 N S S2 S3 C A Indoor unit B Outdoor unit C Remote controller D Main switch (Breaker) E Earth D For Power E For Power D B E A C E A E A Note: When multiple indoor units (Hydro boxes) are connected to the outdoor unit, wire the PCB of either one of the indoor unit and the outdoor unit (S,S2,S3). It is impossible to connect the PCBs of multiple indoor units to the outdoor unit. FIELD ELECTRICAL WIRING (power wiring specifications) Outdoor unit model SHW230Y Outdoor unit power supply 3N~ (3 ph 4-wires), 50 Hz, 400 V Outdoor unit input capacity Main switch (Breaker) * 32 A Outdoor unit power supply 5 Min. 4 Indoor unit-outdoor unit *2 Cable length 50m:3 4 (Polar)/ Cable length 80m:3 6 (Polar) Wiring Wire No. size (mm 2 ) Circuit rating Indoor unit-outdoor unit earth *2 Min. 2.5 Remote controller-indoor unit * (Non-polar) Outdoor unit L-N (single) Outdoor unit L-N, L2-N, L3-N (3 phase) *4 AC 230 V Indoor unit-outdoor unit S-S2 *4 AC 230 V Indoor unit-outdoor unit S2-S3 *4 DC 24 V Remote controller-indoor unit *4 DC 2 V *. A breaker with at least 3.0 mm contact separation in each poles shall be provided. Use earth leakage breaker (NV). Make sure that the current leakage breaker is one compatible with higher harmonics. Always use a current leakage breaker that is compatible with higher harmonics as this unit is equipped with an inverter. The use of an inadequate breaker can cause the incorrect operation of inverter. *2. Max. 80 m Total Max. including all indoor/indoor connection is 80 m. Use one cable for S and S2 and another for S3 as shown in the picture. *3. The 0 m wire is attached in the remote controller accessory. *4. The fi gures are NOT always against the ground. S3 terminal has DC 24 V against S2 terminal. However between S3 and S, these terminals are NOT electrically insulated by the transformer or other device. Notes:. Wiring size must comply with the applicable local and national code. 2. Power supply cords and Indoor/Outdoor unit connecting cords shall not be lighter than polychloroprene sheathed flexible cord. (Design IEC 57) 3. Use an earth wire which is longer than the other cords so that it will not become disconnected when tension is applied. Caution: Be sure to install N-line. Without N-line, it could cause damage to the unit. Power supply Isolator 3 poles isolator S A-Control S2 Outdoor Unit S3 S S2 S3 A-Control Indoor Unit Warning: In case of A-control wiring, there is high voltage potential on the S3 terminal caused by electrical circuit design that has no electrical insulation between power line and communication signal line. Therefore, please turn off the main power supply when servicing. And do not touch the S, S2, S3 terminals when the power is energized. If isolator should be used between indoor unit and outdoor unit, please use 3-pole type. Turn on the main power when the ambient temperature is - 20 C or higher. In below - 20 C condition, it needs at least 4hr stand by to operate in order to warm the electrical parts.

12 INDOOR-OUTDOOR CNECTING CABLE (SHW230) Cross section of cable Wire size (mm 2 ) Number of wires Polarity L (m)*6 Round Clockwise : S-S2-S3 (30) *Pay attention to stripe of yellow and green *2 Flat Not applicable Not applicable (Because center wire has no cover finish) *5 Flat From left to right : S-Open-S2-S3 (8).5 4 *3 Round Clockwise : S-S2-S3-Open (30) *Connect S nad S3 to the opposite angle *4 * :Power supply cords of appliances shall not be lighter than design IEC or 227 IEC. *2 :In case that cable with stripe of yellow and green is available. *3 :In case of regular polarity connection (S-S2-S3), wire size is.5 mm 2. *4 :In case of regular polarity connection (S-S2-S3). *5 :In the flat cables are connected as this picture, they can be used up to 30 m. (3C Flat cable 2) S S2 S3 *6 :Mentioned cable length is just a reference value. It may be different depending on the condition of installation, humidity or materials, etc. Be sure to connect the indoor-outdoor connecting cables directly to the units (no intermediate connections). Intermediate connections can lead to communication error if water enters the cables and causes insufficient insulation to ground or a poor electrical contact at the intermediate connection point. 2

13 7 REFRIGERANT SYSTEM DIAGRAM PUHZ-SHW230YKA <Reference> System example: Plate HEX (MWA2 * 2pcs) + FTC (TH/2) Joint pipe (Brazing) Ball valve REV/V P-sensor Heat exchanger Thermistor TH7 (Ambient) Thermistor TH6 (2-phase pipe) Thermistor TH (Outlet water) Water OUT Plate HEX Water IN Plate HEX Thermistor TH2 (Liquid pipe) Refrigerant GAS pipe connection ( inch) Refrigerant LIQUID pipe connection (3/8 inch) Strainer #50 Charge plug (Low pressure) LEV-B Strainer #00 Power receiver Strainer #00 Strainer #00 Charge plug (High pressure) L/P SW Muffler COMP H/P SW Thermistor TH32 (Suction) Thermistor TH4 (Discharge) Thermistor TH34 (Comp.surface) Injection port Strainer #00 LEV-A Thermistor TH3 (Liquid) Distributor Strainer #00 Strainer #00 Stop valve (with service port) Strainer #00 LEV-C HIC Refrigerant flow in cooling Refrigerant flow in heating Symbol Part name Detail COMP Compressor DC inverter scroll compressor (Mitsubishi Electric Corporation) H/P SW High pressure switch (63H) For protection (OFF: 4.5MPa) L/P SW Low pressure switch (63L) For protection (OFF: -0.03MPa) REV/V Reversing (4-way) valve (2S4) Change the refrigerant circuit (Heating / Cooling) and for Defrosting Charge plug Charge plug High pressure / Low pressure / For production test use P-Sensor Pressure sensor (63HS) For calculation of the condensing temperature from high pressure LEV-A Linear expansion valve -A Heating:Secondary LEV Cooling:Primary LEV LEV-B Linear expansion valve -B Heating:Primary LEV Cooling:Secondary LEV LEV-C Linear expansion valve -C For HIC (heating only) TH32 Suction temperature thermistor For LEV control TH3 Liquid temperature thermistor Heating:Evaporating temperature Cooling:Sub cool liquid temperature TH4 Discharge temperature thermistor For LEV control and for compressor protection TH6 2-phase pipe temperature thermistor Outdoor 2-phase pipe temperature TH7 Ambient temperature thermistor For fan control and for compressor frequency control TH34 Comp. surface temperature thermistor For protection Power Receiver Power Receiver For accumulation of refrigerant HIC Heat interchange circuit For high heating capacity Plate HEX Plate Heat Exchanger MWA2-38PA (MITSUBISHI) <Reference> TH Outlet water temperature thermistor For fl ow temp. controller System example TH2 Liquid pipe temperature thermistor For fl ow temp. controller 3

14 8 TROUBLESHOOTING 8-. TROUBLESHOOTING <Error code display by self-diagnosis and actions to be taken for service (summary)> Present and past error codes are logged and displayed on the control board of outdoor unit. Actions to be taken for service, which depends on whether or not the trouble is reoccurring at service, are summarized in the table below. Check the contents below before investigating details. Unit conditions at service Error code Actions to be taken for service (summary) The trouble is reoccurring. The trouble is not reoccurring. Displayed Not displayed Logged Not logged Judge what is wrong and take a corrective action according to 8-3. Self-diagnosis action table. Conduct troubleshooting and ascertain the cause of the trouble. Consider the temporary defects such as the work of protection devices in the refrigerant circuit including compressor, poor connection of wiring, noise and etc. Recheck the symptom, and check the installation environment, refrigerant amount, weather when the trouble occurred, matters related to wiring and etc. 2 Reset error code logs and restart the unit after fi nishing service. 3 There is no abnormality in electrical component, controller board, and etc. Re-check the abnormal symptom. 2 Conduct troubleshooting and ascertain the cause of the trouble. 3 Continue to operate unit for the time being if the cause is not ascertained. 4 There is no abnormality concerning of parts such as electrical component, controller board, and etc. 4

15 8-2. CHECK POINT UNDER TEST RUN Before test run After installation of outdoor unit, piping work and electric wiring work, re-check that there is no water leakage, loosened connections and incorrect polarity. Measure impedance between the ground and the power supply terminal block (L, N) on the outdoor unit by 500 V Megger and check that it is.0 M or over. Turn on power supply 2 hours before test run in order to protect compressor. Make sure to read operation manual before test run. (Especially items to secure safety.) Warning: Do not use the system if the insulation resistance is less than.0 MΩ. Caution: Do not carry out this test on the control wiring (low voltage circuit) terminals. ERROR CODE Self-check Turn on the power. 2 Press [CHECK] button twice. 3 Press [CHECK] button twice to fi nish self-check. A CHECK button B IC : Interface or FTC unit OC : Outdoor unit C Check code Check code Symptom P Flow water (TH) sensor error P2 Refrigerant liquid Pipe (TH2) sensor error P6 Freezing/Overheating protection operation P9 Actual tank temp. (TH5) sensor error Fb FTC unit control system error (memory error, etc.) E0~E5 Signal transmission failure between remote controller and FTC. E6~EF Signal transmission failure between outdoor unit and FTC. No trouble generated in the past. FFFF No corresponding unit U*, F* Outdoor unit failure. Refer to the outdoor unit wiring diagram. TEMP. /OFF For description of each LED (LED~5) provided on the FTC, refer to the following table. LED (Power for microprocessor) Indicates whether control power is supplied. Make sure that this LED is always lit. LED 2 (Power for remote controller) Indicates whether power is supplied to the remote controller. This LED lights only in the case of the FTC unit which is connected to the outdoor unit refrigerant address 0. LED 3 (Communication between FTC and outdoor unit) Indicates state of communication between the FTC and outdoor unit. Make sure that this LED is always blinking. LED 4 LED 5 5

16 8-3. SELF-DIAGNOSIS ACTI TABLE <Abnormalities detected when the power is turned on> Error Code Abnormal point and detection method Case Judgment and action No voltage is supplied to terminal Check following items. block (TB) of outdoor unit. a) Power supply breaker is a) Power supply breaker turned off. b) Contact failure or disconnection of power supply terminal c) Open phase (L or N phase) 2 Electric power is not charged to power supply terminal of outdoor power circuit board. a) Contact failure of power supply terminal b) Open phase on the outdoor power circuit board b) Connection of power supply terminal block (TB) c) Connection of power supply terminal block (TB) 2 Check following items. a) Connection of power supply terminal block (TB) b) Connection of terminal on outdoor power circuit board None 3 Electric power is not supplied to outdoor controller circuit board. a) Disconnection of connector (CNDC) 4 Disconnection of reactor (DCL) 5 Disconnection of outdoor noise filter circuit board or parts failure in outdoor noise filter circuit board 6 Defective outdoor power circuit board 7 Defective outdoor controller circuit board 3 Check connection of the connector (CNDC) on the outdoor controller circuit board. Check connection of the connector CNDC on the outdoor noise filter. Refer to Check connection of reactor. (DCL) 5 a) Check connection of outdoor noise filter circuit board. b) Replace outdoor noise filter circuit board. Refer to Replace outdoor power circuit board. 7 Replace controller board (When items above are checked but the units can not be repaired). F3 F5 F9 63L connector open Abnormal if 63L connector circuit is open for 3 minutes continuously after power supply. 63L: Low-pressure switch 63H connector open Abnormal if 63H connector circuit is open for 3 minutes continuously after power supply. 63H: High-pressure switch 2 connector open Abnormal if both 63H and 63L connector circuits are open for three minutes continuously after power supply. 63H: High-pressure switch 63L: Low-pressure switch Disconnection or contact failure of 63L connector on outdoor controller circuit board 2 Disconnection or contact failure of 63L 3 63L is working due to refrigerant leakage or defective parts. 4 Defective outdoor controller circuit board Disconnection or contact failure of 63H connector on outdoor controller circuit board 2 Disconnection or contact failure of 63H 3 63H is working due to defective parts. 4 Defective outdoor controller circuit board Disconnection or contact failure of connector (63H,63L) on outdoor controller circuit board. 2 Disconnection or contact failure of 63H, 63L 3 63H and 63L are working due to defective parts. 4 Defective outdoor controller board. Check connection of 63L connector on outdoor controller circuit board. Refer to Check the 63L side of connecting wire. 3 Check refrigerant pressure. Charge additional refrigerant. Check continuity by tester. Replace the parts if the parts are defective. 4 Replace outdoor controller circuit board. Check connection of 63H connector on outdoor controller circuit board. Refer to Check the 63H side of connecting wire. 3 Check continuity by tester. Replace the parts if the parts are defective. 4 Replace outdoor controller circuit board. Check connection of connector (63H,63L) on outdoor controller circuit board. Refer to Check the 63H and 63L side of connecting wire. 3 Check continuity by tester. Replace the parts if the parts are defective. 4 Replace outdoor controller circuit board. 6

17 Error Code Abnormal point and detection method Case Judgment and action EA Eb Miswiring of Interface unit/flow temp. controller-outdoor unit connecting wire. Outdoor controller circuit board can automatically check the number of connected Interface unit/flow temp. controller. Abnormal if the number cannot be checked automatically due to miswiring of Interface unit/flow temp. controlleroutdoor unit connecting wire and etc. after power is turned on for 4 minutes. 2. Abnormal if outdoor controller circuit board recognizes excessive number of Interface unit/flow temp. controller. Miswiring of Interface unit/flow temp. controller-outdoor unit connecting wire (converse wiring or disconnection) Outdoor controller circuit board can automatically set the unit number of Interface unit/flow temp. controller. Abnormal if the Interface unit/flow temp. controller number cannot be set within 4 minutes after power on because of miswiring (converse wiring or disconnection) of Interface unit/flow temp. controller-outdoor unit connecting wire. Contact failure or miswiring of Interface unit/flow temp. controlleroutdoor unit connecting wire Diameter or length of Interface unit/flow temp. controller-outdoor unit connecting wire is out of specified capacity. Excessive number of Interface unit/flow temp. controller is connected to outdoor unit. (2 units or more) Defective transmitting receiving circuit of outdoor controller circuit board Defective transmitting receiving circuit of Interface/Flow temp. controller board Noise has entered into power supply or Interface/Flow temp. controller-outdoor unit connecting wire. Contact failure or miswiring of Interface unit/flow temp. controller-outdoor unit connecting wire Diameter or length of Interface unit/flow temp. controller-outdoor unit connecting wire is out of specified capacity. Defective transmitting receiving circuit of outdoor controller circuit board Defective transmitting receiving circuit of Interface/Flow temp. controller board Noise has entered into power supply or Interface unit/flow temp. controller-outdoor unit connecting wire. Check disconnection or looseness or polarity of Interface unit/flow temp. controller-outdoor unit connecting wire of Interface unit/flow temp. controller and outdoor units. Check diameter and length of Interface unit/ Flow temp. controller-outdoor unit connecting wire. Total wiring length: 80 m (Including wiring connecting each Interface unit/flow temp. controller unit and between Interface unit/flow temp. controller and outdoor unit) Also check if the connection order of flat cable is S, S2, S3. Check the number of Interface unit/flow temp. controller that is connected to outdoor unit. (If EA is detected.) ~ Turn the power off once, and on again to check. Replace outdoor controller circuit board or Interface/Flow temp. controller board if abnormality occurs again. Check transmission path, and remove the cause. The descriptions above, -, are for EA, Eb and EC. EC Start-up time over The unit cannot finish start-up process within 4 minutes after power on. Contact failure of Interface unit /Flow temp. controller-outdoor unit connecting wire Diameter or length of Interface unit/flow temp. controlleroutdoor unit connecting wire is out of specified capacity. Noise has entered into power supply or Interface unit/flow temp. controller-outdoor unit connecting wire. EE Incorrect connection The outdoor unit does not receive the signals of I/F or FTC. A device other than Interface unit or Flow temp. controller unit is connected to the unit. Connect I/F or FTC to the unit. * This model is only for the air-to-water system. Not applicable to the air-to-air system. 7

18 <Abnormalities detected while unit is operating> Error Code Abnormal point and detection method Case Judgment and action High pressure (High-pressure switch ~6 Check indoor unit and repair defectives. 63H operated) Abnormal if high-pressure switch 63H operated ( w ) during compressor operation. w 4.5 MPa U 63H: High-pressure switch Short cycle of indoor unit 2 Clogged filter of indoor unit 3 Decreased airflow caused by dirt of indoor fan 4 Dirt of indoor heat exchanger 5 Locked indoor fan motor 6 Malfunction of indoor fan motor 7 Defective operation of stop valve (Not full open) 8 Clogged or broken pipe 9 Locked outdoor fan motor 0 Malfunction of outdoor fan motor Short cycle of outdoor unit 2 Dirt of outdoor heat exchanger 3 Decreased airflow caused by defective inspection of outside temperature thermistor (It detects lower temperature than actual temperature.) 4 Disconnection or contact failure of connector (63H) on outdoor controller board 5 Disconnection or contact failure of 63H connection 6 Defective outdoor controller board 7 Defective action of linear expansion valve 8 Malfunction of fan driving circuit 7 Check if stop valve is fully open. 8 Check piping and repair defect. 9~2 Check outdoor unit and repair defect. 3 Check the detected temperature of outside temperature thermistor on LED display. (SW2 on A-Control Service Tool : Refer to 8-8.) 4~6 Turn the power off and check F5 is displayed when the power is turned again. When F5 is displayed, refer to Judgment and action for F5. 7 Check linear expansion valve. Refer to Replace outdoor controller board. U2 High discharging temperature () Abnormal if discharge temperature thermistor (TH4) exceeds 25: or 0: continuously for 5 minutes. Abnormal if discharge temperature thermistor (TH4) exceeds 0: or more continuously for 30 seconds after 90 seconds have passed since the defrosting operation started. (2) Abnormal if discharge superheat (Cooling: TH4 T63HS / Heating: TH4 T63HS) exceeds 70: continuously for 0 minutes. High comp. surface temperature Abnormal if comp. surface temperature (TH34) exceeds 25:. In the case of high comp. surface temperature error, compressor does not restart unless the thermistor (TH34) becomes less than 95:. Overheated compressor operation caused by shortage of refrigerant 2 Defective operation of stop valve 3 Defective thermistor 4 Defective outdoor controller board 5 Defective action of linear expansion valve 6 Clogging with foreign objects in refrigerant circuit w Clogging occur in the parts which become below freezing point when water enters in refrigerant circuit. 7 In the case of the unit does not restart: Detection temp. of thermistor (TH34) ] 95: Check intake superheat. Check leakage of refrigerant. Charge additional refrigerant. 2 Check if stop valve is fully open. 34 Turn the power off and check if U3 is displayed when the power is turned on again. When U3 is displayed, refer to Judgement and action for U3. 5 Check linear expansion valve. Refer to After recovering refrigerant, remove water from entire refrigerant circuit under vacuum more than hour. U3 Open/short circuit of discharge temperature thermistor (TH4)/ Comp. surface temperature thermistor (TH34) Abnormal if open (3: or less) or short (27: or more) is detected during compressor operation. (Detection is inoperative for 0 minutes of compressor starting process and for 0 minutes after and during defrosting.) Disconnection or contact failure of connector (TH4/TH34) on the outdoor controller circuit board 2 Defective thermistor 3 Defective outdoor controller circuit board Check connection of connector (TH4/TH34) on the outdoor controller circuit board. Check breaking of the lead wire for thermistor (TH4/TH34). Refer to Check resistance value of thermistor (TH4/ TH34) or temperature by microprocessor. (Thermistor/TH4, TH34: Refer to 8-4.) (SW2 on A-Control Service Tool: Refer to 8-8.) 3 Replace outdoor controller board. 8

19 Error Code Abnormal point and detection method Case Judgment and action U4 Open/short of outdoor unit thermistors (TH3, TH32, TH6, TH7, and TH8) Abnormal if open or short is detected during compressor operation. Open detection of thermistors TH3, TH32 and TH6 is inoperative for 0 seconds to 0 minutes after compressor starting and 0 minutes after and during defrosting. W Check which unit has abnormality in its thermistor by switching the mode of SW2. (PAC-SK52ST) (Refer to 8-7.) W Heatsink thermistor(th8) is in the power module. Disconnection or contact failure of connectors Outdoor controller circuit board: TH3, TH32, TH7/6 ( Outdoor power circuit board: ) CN3 2 Defective thermistor 3 Defective outdoor controller circuit board Check connection of connector (TH3, TH32, TH7/6) on the outdoor controller circuit board. Check connection of connector (CN3) on the outdoor power circuit board. Check breaking of the lead wire for thermistor (TH3, TH32, TH6,TH7,TH8). Refer to Check resistance value of thermistor (TH3, TH32, TH6,TH7,TH8) or check temperature by microprocessor. (Thermistor/TH3,TH6,TH7,TH32,TH8: Refer to 8-5.) (SW2 on A-Control Service Tool: Refer to 8-8.) 3 Replace outdoor controller circuit board. Thermistors Symbol Name Open detection Short detection TH3 Thermistor <Liquid> -40 C or below 90 C or above TH32 Thermistor <Suction> -40 C or below 90 C or above TH6 Thermistor <2-phase pipe> -40 C or below 90 C or above TH7 Thermistor <Ambient> -40 C or below 90 C or above TH8 Internal thermistor -35 C or below 70 C or above U5 Temperature of heatsink Abnormal if heatsink thermistor (TH8) detects 95: The outdoor fan motor is locked. 2 Failure of outdoor fan motor 3 Air flow path is clogged. 4 Rise of ambient temperature 5 Defective thermistor 6 Defective input circuit of outdoor power circuit board 7 Failure of outdoor fan drive circuit 2 Check outdoor fan. 3 Check air flow path for cooling. 4 Check if there is something which causes temperature rise around outdoor unit. (Upper limit of ambient temperature is 46:.) Turn off power, and on again to check if U5 is displayed within 30 minutes. If U4 is displayed instead of U5, follow the action to be taken for U4. 5 Check the thermistor (TH8) temperature by microprocessor. (SW2 on A-Control Service Tool: Refer to 8-7.) 6 Replace outdoor power circuit board. 7 Replace outdoor controller circuit board. U6 U7 Power module Check abnormality by driving power module in case overcurrent is detected. (UF or UP error condition) Too low superheat due to low discharge temperature Abnormal if discharge superheat is continuously detected less than or equal to -5: for 3 minutes even though linear expansion valve has minimum open pulse after compressor starts operating for 0 minutes. Outdoor stop valve is closed. 2 Decrease of power supply voltage 3 Looseness, disconnection or converse of compressor wiring connection 4 Defective compressor 5 Defective outdoor power circuit board Disconnection or loose connection of discharge temperature thermistor (TH4) 2 Defective holder of discharge temperature thermistor 3 Disconnection or loose connection of linear expansion valve s coil 4 Disconnection or loose connection of linear expansion valve s connector 5 Defective linear expansion valve Open stop valve. 2 Check facility of power supply. 3 Correct the wiring (U V W phase) to compressor. Refer to 8-7 (Outdoor power circuit board). 4 Check compressor referring to Replace outdoor power circuit board. 2 Check the installation conditions of discharge temperature thermistor (TH4). 3 Check the coil of linear expansion valve. Refer to Check the connection or contact of LEV-A and LEV-B on outdoor controller circuit board. 5 Check linear expansion valve. Refer to 8-6. U8 Outdoor fan motor Failure in the operation of the Abnormal if rotational frequency of the fan DC fan motor motor is not detected during DC fan motor 2 Failure in the outdoor circuit operation. controller board Fan motor rotational frequency is abnormal if; 00 rpm or below detected continuously for 5 seconds at 20: or more outside air temperature. 50 rpm or below or 500 rpm or more detected continuously for minute. Check or replace the DC fan motor. 2 Check the voltage of the outdoor circuit controller board during operation. 3 Replace the outdoor circuit controller board. (When the failure is still indicated even after performing the action above.) 9

20 Error Code Abnormal point and detection method Case Judgment and action Detailed codes To find out the details about U9 error, turn SW2-, 2-2, 2-3, 2-4, 2-5 and 2-6 when U9 error occurs. To find out the detail history (latest) about U9 error, turn SW2-, 2-2, 2-6. Refer to Overvoltage error Increase in DC bus voltage to 760V Abnormal increase in power source voltage 2 Defective outdoor power circuit board 3 Compressor has a ground fault. Check the field facility for the power supply. 2 Replace outdoor power circuit board. 3 Check compressor for electrical insulation. Replace compressor. 02 Undervoltage error Instantaneous decrease in DC bus voltage to 400V Decrease in power source voltage, instantaneous stop. 2 Defective 52C drive circuit in outdoor power circuit board 3 Disconnection or loose connection of rush current protect resistor RS 4 Defective rush current protect resistor RS 5 Disconnection or loose connection of main smoothing capacitor CB/CB2 Check the field facility for the power supply. 2 Replace outdoor power circuit board. 3 Check RS wiring. 4 Replace RS. 5 Check CB/CB2 wiring. U Input current sensor error/ L-phase open error Decrease in input current through outdoor unit to 0.A only if operation frequency is more than or equal to 40Hz or compressor current is more than or equal to 6A. Abnormal power synchronous signal No input of power synchronous signal to power circuit board Power synchronous signal of 44 Hz or less, or 65 Hz or more is detected on power circuit board. PFC error (Overvoltage/ Undervoltage/Overcurrent) PFC detected any of the followings a) Increase of DC bus voltage to 420V. b) Decrease in PFC control voltage to 2V DC or lower c) Increase in input current to 50A peak (For models equipped with single-phase PFC only) L-phase open 2 Disconnection or loose connection between TB and outdoor noise filter circuit board 3 Disconnection or loose connection of CN5 on the outdoor power circuit board/ CNCT on the outdoor noise filter board 4 Defective ACCT (AC current trans) on the outdoor power circuit board 5 Defective input current detection circuit in outdoor power circuit board 6 Defective outdoor controller circuit board Distortion of power source voltage, Noise superimposition. 2 Disconnection or loose connection of earth wiring 3 Disconnection or loose connection of CN2 on the outdoor power circuit board /controller circuit board 4 Defective power synchronous signal circuit in outdoor controller circuit board 5 Defective power synchronous signal circuit in outdoor power circuit board Not applicable for SHW230YKA model. Check the field facility for the power supply. 2 Check the wiring between TB and outdoor noise filter circuit board. 3 Check CN5/CNCT wiring. 4 Replace outdoor noise filter circuit board. 5 Replace outdoor power circuit board. 6 Replace outdoor controller circuit board. Check the field facility for the power supply. 2 Check earth wiring. 3 Check CN2 wiring. 4 Replace outdoor controller circuit board. 5 Replace outdoor power circuit board. Check for the switch settings for Model Select on the outdoor controller circuit board. 20 PFC/IGBT error (Undervoltage) When Compressor is running, DC bus voltage stays at 30V or lower for consecutive 0 seconds (Single phase model only) Not applicable for SHW230YKA model. Check for the switch settings for Model Select on the outdoor controller circuit board. 20

21 Error Code Abnormal point and detection method Case Judgment and action Ud Overheat protection Abnormal if outdoor pipe thermistor (TH3), condensing temperature T63HS detects 70: or more during compressor operation. Defective outdoor fan (fan motor) or short cycle of outdoor unit during cooling operation 2 Defective outdoor pipe thermistor (TH3), condensing temperature T63HS 3 Defective outdoor controller board Check outdoor unit air passage. 23 Turn the power off and on again to check the error code. If U4 is displayed, follow the U4 processing direction. UE Abnormal pressure of pressure sensor (63HS) Abnormal if pressure sensor (63HS) detects 0. MPa or less. Detection is inoperative for 3 minutes after compressor starting and 3 minutes after and during defrosting. Disconnection or contact failure of connector (63HS) on the outdoor controller circuit board 2 Defective pressure sensor 3 Defective outdoor controller circuit board Check connection of connector (63HS) on the outdoor controller circuit board. Check breaking of the lead wire for thermistor (63HS). 2 Check pressure by microprocessor. (Prssure sensor/ 63HS) (SW2: Refer to 8-8.) 3 Replace outdoor controller board. UF Compressor overcurrent interruption (When compressor locked) Abnormal if overcurrent of DC bus or compressor is detected within 30 seconds after compressor starts operating. Stop valve is closed. 2 Decrease of power supply voltage 3 Looseness, disconnection or converse of compressor wiring connection 4 Defective compressor 5 Defective outdoor power board Open stop valve. 2 Check facility of power supply. 3 Correct the wiring (U V W phase) to compressor. Refer to 8-7 (Outdoor power circuit board). 4 Check compressor. Refer to Replace outdoor power circuit board. UH Current sensor error or input current error Disconnection of compressor Abnormal if current sensor detects.0a wiring to.0a during compressor operation. (This error is ignored in case of test run mode.) 2 Defective circuit of current sensor on outdoor power circuit board 3 Decrease of power supply voltage Correct the wiring (U V W phase) to compressor. Refer to 8-7 (Outdoor power circuit board). 2 Replace outdoor power circuit board. 3 Check the facility of power supply. UL Low pressure (63L operated) Abnormal if 63L is operated (under -0.03MPa) during compressor operation. 63L: Low-pressure switch Stop valve of outdoor unit is closed during operation. 2 Disconnection or loose connection of connector (63L) on outdoor controller board 3 Disconnection or loose connection of 63L 4 Defective outdoor controller board 5 Leakage or shortage of refrigerant 6 Malfunction of linear expansion valve Check stop valve. 2~4 Turn the power off and on again to check if F3 is displayed on restarting. If F3 is displayed, follow the F3 processing direction. 5 Correct to proper amount of refrigerant. 6 Check linear expansion valve. Refer to

22 Error Code Abnormal point and detection method Cause Judgment and action UP Compressor overcurrent interruption Abnormal if overcurrent DC bus or compressor is detected after compressor starts operating for 30 seconds. Stop valve of outdoor unit is closed. 2 Decrease of power supply voltage 3 Looseness, disconnection or converse of compressor wiring connection 4 Defective fan of indoor/outdoor units 5 Short cycle of indoor/outdoor units 6 Defective input circuit of outdoor controller board 7 Defective compressor 8 Defective outdoor power circuit board 9 Dip switch setting difference of outdoor controller circuit board Open stop valve. 2 Check facility of power supply. 3 Correct the wiring (U V W phase) to compressor. Refer to 8-7 (Outdoor power circuit board). 4 Check indoor/outdoor fan. 5 Solve short cycle. 6 Replace outdoor controller circuit board. W Before the replacement of the outdoor controller circuit board, disconnect the wiring to compressor from the outdoor power circuit board and check the output voltage among phases, U, V, W, during test run. No defect on board if voltage among phases (U-V, V-W and W-U) is same. Make sure to perform the voltage check with same performing frequency. 7 Check compressor. Refer to Replace outdoor power circuit board. 9 Check the dip switch setting of outdoor controller circuit board. E0 or E4 Remote controller transmission error (E0)/signal receiving error (E4) Abnormal if main or sub remote controller cannot receive any transmission normally from Interface unit/flow temp. controller of refrigerant address 0 for 3 minutes. (Error code: E0) 2 Abnormal if sub-remote controller could not receive any signal for 2 minutes. (Error code: E0) Abnormal if Interface unit/flow temp. controller can not receive any data normally from remote controller board or from other Interface/Flow temp. controller board for 3 minutes. (Error code: E4) 2 Interface unit/flow temp. controller cannot receive any signal from remote controller for 2 minutes. (Error code: E4) Contact failure at transmission wire of remote controller 2 All remote controllers are set as sub remote controller. In this case, E0 is displayed on remote controller, and E4 is displayed at LED (LED, LED2) on the outdoor controller circuit board. 3 Miswiring of remote controller 4 Defective transmitting receiving circuit of remote controller 5 Noise has entered into the transmission wire of remote controller. Check disconnection or looseness of Interface unit/flow temp. controller or transmission wire of remote controller. 2 Set one of the remote controllers main, If there is no problem with the action above. 3 Check wiring of remote controller. Total wiring length: max. 500 m (Do not use cable x 3 or more.) The number of connecting remote controller: max. 2 units When it is not the above-mentioned problem of ~3 4 Diagnose remote controllers. a) When RC OK is displayed, remote controllers have no problem. Turn the power off, and on again to check. If abnormality generates again, replace PCB of Interface unit/flow temp. controller. b) When RC NG is displayed, replace remote controller. c) When RC E3 or ERC is displayed, noise may be causing abnormality. E or E2 Remote controller control board Abnormal if data cannot be read normally from the nonvolatile memory of the remote controller control board. (Error code: E) 2 Abnormal if the clock function of remote controller cannot be operated normally. (Error code: E2) Defective remote controller Replace remote controller. E3 or E5 Remote controller transmission error (E3)/signal receiving error (E5) Abnormal if remote controller could not fi nd blank of transmission path for 6 seconds and could not transmit. (Error code: E3) 2 When remote controller receives the transmitted data same time and compares these data. Abnormal if the data is judged to be different for 30 continuous times. (Error code: E3) Abnormal if Interface unit/flow temp. controller could not fi nd blank of transmission path. (Error code: E5) 2 When Interface unit/flow temp. controller receives the transmitted data same time and compares these data. Abnormal if the data is judged to be different for 30 continuous times. (Error code: E5) 2 remote controllers are set as main. (In case of 2 remote controllers) 2 Defective transmitting receiving circuit of remote controller 3 Defective transmitting receiving circuit of Interface unit/flow temp. controller 4 Noise has entered into transmission wire of remote controller. 22 Set a remote controller to main, and the other to sub. 2~4 Diagnose remote controller. a) When RC OK is displayed, remote controllers have no problem. Turn the power off, and on again to check. When becoming abnormal again, replace indoor controller board. b) When RC NG is displayed, replace remote controller. c) When RC E3 or ERC is displayed, noise may be causing abnormality.

23 Error Code Abnormal point and detection method Case Judgment and action E6 Interface unit/flow temp. controller or outdoor unit communication error (Signal receiving error) Abnormal if Interface unit/flow temp. controller cannot receive any signal normally for 6 minutes after turning the power on. 2 Abnormal if Interface unit/flow temp. controller cannot receive any signal normally for 3 minutes. Contact failure, short circuit or, miswiring (converse wiring) of Interface unit/flow temp. controller or outdoor unit connecting wire 2 Defective transmitting receiving circuit of outdoor controller circuit board 3 Defective transmitting receiving circuit of Interface unit/flow temp. controller 4 Noise has entered into Interface unit/flow temp. controller or outdoor unit connecting wire. * Check LED display on the outdoor controller circuit board. (Connect A-control service tool, PAC-SK52ST.) Check disconnection or looseness of Interface unit/flow temp. controller or outdoor unit connecting wire of Interface unit/flow temp. controller or outdoor unit. 2~4 Turn the power off, and on again to check. If abnormality generates again, replace Interface unit/flow temp. controller or outdoor controller circuit board. E8 Interface unit/flow temp. controller or outdoor unit communication error (Signal receiving error) (Outdoor unit) () Abnormal if outdoor controller circuit board could not receive anything normally for 3 minutes. Contact failure of Interface unit/ Flow temp. controller or outdoor unit connecting wire 2 Defective communication circuit of outdoor controller circuit board 3 Defective communication circuit of Interface unit/flow temp. controller 4 Noise has entered into Interface unit/flow temp. controller or outdoor unit connecting wire. Check disconnection or looseness of Interface unit/flow temp. controller or outdoor unit connecting wire of Interface unit/flow temp. controller or outdoor unit. 2~4 Turn the power off, and on again to check. Replace PCB of Interface unit/flow temp. controller or outdoor controller circuit board if abnormality is displayed again. E9 Interface unit/flow temp. controller or outdoor unit communication error (Transmitting error) (Outdoor unit) () Abnormal if 0 receiving is detected 30 times continuously though outdoor controller circuit board has transmitted. (2) Abnormal if outdoor controller circuit board could not fi nd blank of transmission path for 3 minutes. Interface unit/flow temp. controller or outdoor unit connecting wire has contact failure. 2 Defective communication circuit of outdoor controller circuit board 3 Noise has entered power supply. 4 Noise has entered Interface unit/flow temp. controller or outdoor unit connecting wire. Check disconnection or looseness of Interface unit/flow temp. controller or outdoor unit connecting wire. 2~4 Turn the power off, and on again to check. Replace outdoor controller circuit board if abnormality is displayed again. EF Non defined error code This code is displayed when non defi ned error code is received. Noise has entered transmission wire of remote controller. 2 Noise has entered Interface unit/flow temp. controlleroutdoor unit connecting wire. 2 Turn the power off, and on again to check. Replace Interface/FTC or outdoor controller circuit board if abnormality is displayed again. Ed Serial communication error Abnormal if serial communication between outdoor controller circuit board and outdoor power circuit board is defective. Wire disconnection or contact failure of connector CN2 between the outdoor controller circuit board and the outdoor power circuit board 2 Wire disconnection or contact failure of connector CN4 between the outdoor controller circuit board and the outdoor power circuit board 3 Defective communication circuit of outdoor power circuit board 4 Defective communication circuit of outdoor controller circuit board for outdoor power circuit board 2 Check connection of each connector CN2 and CN4 between the outdoor controller circuit board and the outdoor power circuit board. 3 Replace outdoor power circuit board. 4 Replace outdoor controller circuit board. 23

24 Error Code Abnormal point and detection method Cause Judgment and action P P2 Actual flow water temperature thermistor (TH) The unit is in 3-minute resume prevention mode if short/open of thermistor is detected. Abnormal if the unit does not reset normally after 3 minutes. (The unit returns to normal operation, if it has been reset normally.) 2 Constantly detected during cooling, heating ECO, anti freeze, hot water and heating operation. Short: -90: or more Open: -40: or less Pipe temperature thermistor/liquid (TH2) The unit is in 3-minute resume prevention mode if short/open of thermistor is detected. Abnormal if the unit does not reset normally after 3 minutes. (The unit returns to normal operation, if it has been reset normally.) 2 Constantly detected during cooling, heating ECO, anti freeze, hot water and heating (except defrosting) operation Short: 90: or more Open: -40: or less Defective thermistor characteristics 2 Contact failure of TB6 No.-2 on PCB of Interface unit/flow temp. controller 3 Breaking of wire or contact failure of thermistor wiring 4 Defective PCB of Interface unit/ Flow temp. controller Defective thermistor characteristics 2 Contact failure of TB6 No.3-4 on PCB of Interface unit/flow temp. controller 3 Breaking of wire or contact failure of thermistor wiring 4 Defective refrigerant circuit is causing thermistor temperature of 90: or more or -40: or less. 5 Defective PCB of Interface unit/ Flow temp. controller 3 Check resistance value of thermistor. 0: 5.0k" 0: 9.6k" 20: 6.3k" 30: 4.3k" 40: 3.0k" If you put force on (draw or bend) the lead wire with measuring resistance value of thermistor, breaking of wire or contact failure can be detected. 2 Check contact failure of TB6 No.-2 on PCB of Interface unit/flow temp. controller. Refer to 8. Turn the power on again and check restart after inserting connector again. 4 Check actual fl ow water temperature display on remote controller. Replace PCB of Interface unit/flow temp. controller if there is abnormal difference with actual fl ow water temperature. Turn the power off, and on again to operate after check. 3 Check resistance value of thermistor. For characteristics, refer to (P) above. 2 Check contact failure of TB6 No.3-4 on PCB of Interface unit/flow temp. controller. Refer to 8. Turn the power on and check restart after inserting connector again. 4 Check pipe <liquid> temperature with remote controller in test run mode. If pipe <liquid> temperature is extremely low (in cooling mode) or high (in heating mode), refrigerant circuit may have defective. 5 Check pipe <liquid> temperature with remote controller in test run mode. If there is extremely difference with actual pipe <liquid> temperature, replace PCB of Interface unit/ Flow temp. controller. Turn the power off, and on again to operate after check. P6 P9 Freezing/overheating protection is working Freezing protection (Cooling mode) The unit is in 6-minute resume prevention mode if pipe temperature stays under -5: for 3 minutes, 3 minutes after the compressor started. Abnormal if it stays under -5: for 3 minutes again within 6 minutes after 6-minute resume prevention mode. 2 Overheating protection (Heating, heating ECO, Anti freeze, Hot water mode) The units is in 6 minute resume prevention mode if pipe temperature is detected as over 70: after the compressor started. Abnormal if the temperature of over 70: is detected again within 30 minutes after 6 minute resume prevention mode. Actual tank temperature thermistor (TH5) The unit is 3-minute resume prevention mode if short/open of thermistor is detected. Abnormal if the unit does not reset normally after 3 minutes. (The unit returns to normal operation, if it has been reset normally) 2 Constantly detected during cooling, heating, heating ECO, anti freeze and hot water operation. (Cooling mode) Short cycle of air path 2 Low-load (low temperature) operation out of the tolerance range 3 Defective outdoor fan control 4 Overcharge of refrigerant 5 Defective refrigerant circuit (clogs) (Heating mode) Short cycle of air path 2 Over-load (high temperature) operation out of the tolerance range 3 Defective outdoor fan control 4 Overcharge of refrigerant 5 Defective refrigerant circuit (clogs) 6 Bypass circuit of outdoor unit is defective. Defective thermistor characteristics 2 Contact failure of TB6 No. 5-6 on PCB of interface unit/flow temp. controller 3 Breaking of wire or contact failure of thermistor wiring 4 Defective PCB of interface unit/flow temp. controller 24 (Cooling mode) Remove blockage. 3 Check outdoor fan motor. 45 Check operating condition of refrigerant circuit. (Heating mode) Remove blockage. 3 Check outdoor fan motor. 4~6 Check operating condition of refrigerant circuit. 3 Check resistance value of thermistor. 0: 5.0k" 0: 9.6k" 20: 6.3k" 30: 4.3k" 40: 3.0k" If you put force on (draw or bend) the lead wire with measuring resistance value of thermistor, breaking of wire or contact failure can be detected. 2 Check contact failure of TB6 No.5-6 on PCB of Interface unit/flow temp. controller. Refer to 8. Turn the power on again and check restart after inserting connector again. 4 Check actual tank temperature display on remote controller. Replace PCB of Interface unit/flow temp. controller if there is abnormal difference with actual tank temperature. Turn the power off, and on again to operate after check.

25 8-4. TROUBLESHOOTING A fl owing water sound or occasional hissing sound is heard. Water does not heat or cool well. Water or vapour is emitted from the outdoor unit. These sounds can be heard when refrigerant and/or water is (are) fl owing in the indoor unit or refrigerant pipe, or when the refrigerant and/or water is (are) chugging. Clean the filter of water piping. (Flow is reduced when the filter is dirty or clogged.) Check the temperature adjustment and adjust the set temperature. Make sure that there is plenty of space around the outdoor unit. During cooling mode, water may form and drip from the cool pipes and joints. During heating mode, water may form and drip from the heat exchanger of outdoor unit. During defrosting mode, water on the heat exchanger of outdoor unit evaporates and water vapour may be emitted. The operation indicator does not appear in the remote controller display. Turn on the power switch. will appear in the remote controller display. appears in the remote controller display. During external signal control, appears in the remote controller display and FTC operation cannot be started or stopped using the remote controller. When restarting the outdoor unit soon after stopping it, it does not operate even though the /OFF button is pressed. FTC operates without the /OFF button being pressed. FTC stops without the /OFF button being pressed. Remote controller timer operation cannot be set. PLEASE WAIT appears in the remote controller display. An error code appears in the remote controller display. Wait approximately 3 minutes. (Operation has stopped to protect the outdoor unit.) Is the on timer set? Press the /OFF button to stop operation. Is the FTC connected to a external signal? Consult the concerned people who control the FTC. Does appear in the remote controller display? Consult the concerned people who control the FTC. Has the auto recovery feature from power failures been set? Press the /OFF button to stop operation. Is the off timer set? Press the /OFF button to restart operation. Is the air conditioner connected to a central remote controller? Consult the concerned people who control the FTC. Does appear in the remote controller display? Consult the concerned people who control the FTC. Are timer settings invalid? If the timer can be set, WEEKLY, SIMPLE, or AUTO OFF appears in the remote controller display. The initial settings are being performed. Wait approximately 3 minutes. If the remote controller is not only for FTC, change it. The protection devices have operated to protect the FTC and outdoor unit. Do not attempt to repair this equipment by yourself. Turn off the power switch immediately and consult your dealer. Be sure to provide the dealer with the model name and information that appeared in the remote controller display. If the unit cannot be operated properly after test run, refer to the following table to find the cause. Symptom Wired remote controller LED, 2 (PCB in outdoor unit) PLEASE WAIT PLEASE WAIT Error code Display messages do not appear even when operation switch is turned (operation lamp does not light up). For about 2 minutes after power-on Subsequent to about 2 minutes after power-on After LED, 2 are lighted, LED 2 is turned off, then only LED is lighted. (Correct operation) Only LED is lighted. LED, 2 blink. Only LED is lighted. LED blinks twice, LED 2 blinks once. Cause For about 2 minutes following power-on,operation of the remote controller is not possible due to system start-up. (Correct operation) Connector for the outdoor unit s protection device is not connected. Reverse or open phase wiring for the outdoor unit s power terminal block (L, L2, L3) Incorrect wiring between FTC and outdoor (incorrect polarity of S, S2, S3) Remote controller wire short Note: Operation is not possible for about 30 seconds after cancellation of function selection. (Correct operation) For description of each LED (LED, 2, 3) provided on the FTC, refer to the following table. LED (power for microprocessor) Indicates whether control power is supplied. Make sure that this LED is always lit. LED2 (power for remote controller) Indicates whether power is supplied to the remote controller. This LED lights only in the case of the FTC which is connected to the outdoor unit refrigerant addresses 0. LED3 (communication between FTC and outdoor units) Indicates state of communication between the FTC and outdoor units. Make sure that this LED is always blinking. 25

26 8-5. HOW TO CHECK THE PARTS PUHZ-SHW230YKA Parts name TH3: Liquid pipe temperature TH4: Discharge temperature TH6: 2-phase pipe temperature TH7: Ambient temperature TH32: Suction pipe temperature TH34: Comp. surface temperature Check points Disconnect the connector then measure the resistance with a tester. (At the ambient temperature 0 ~30 ) TH4 TH34 TH3 TH6 TH7 TH32 Normal 60k ~ 40k 4.3k ~ 9.6k Abnormal Open or short Fan motor(mf,mf2) Solenoid valve coil <4-way valve> (2S4) Refer to next page. Measure the resistance between the terminals with a tester. (At the ambient temperature 20 ) Normal Abnormal 435±50 Open or short Motor for compressor (MC) U Measure the resistance between the terminals with a tester. (Winding temperature 20 ) Normal (U-V, U-W, W-V) Abnormal V W 0.37 Open or short Linear expansion valve (LEV-A/LEV-B/LEV-C) Disconnect the connector then measure the resistance with a tester. (Winding temperature 20 ) M Gray Orange Red Yellow Black Normal Gray - Black Gray - Red Gray - Yellow Gray - Orange 46±3 Abnormal Open or short 26

27 Check method of DC fan motor (fan motor / outdoor controller circuit board) Notes High voltage is applied to the connecter (CNF, 2) for the fan motor. Pay attention to the service. Do not pull out the connector (CNF, 2) for the motor with the power supply on. (It causes trouble of the outdoor controller circuit board and fan motor.) Self check Symptom : The outdoor fan cannot turn around. Fuse check Check the fuse (F5) on outdoor controller board. Did the fuse blow? No Wiring contact check Contact of fan motor connector (CNF, 2) Yes Replace outdoor controller board (C.B) and fan motor (MF, 2). Is there contact failure? Yes Recover wiring. No Power supply check (Remove the connector (CNF, 2)) Measure the voltage in the outdoor controller circuit board. TEST POINT :VDC (between (+) and 4 (-) of the fan connector): VDC DC250~330V TEST POINT :VCC (between 5 (+) and 4 (-) of the fan connector): VCC DC5V Is the voltage normal? No Replace outdoor controller board. OK Yes Replace the fan motor. Yes Check the operation of fan. NG Replace outdoor controller board. OK END Check the operation. END NG Replace the fan motor. 27

28 8-6. HOW TO CHECK THE COMPENTS <Thermistor feature chart> Low temperature thermistors Thermistor <Liquid pipe> (TH3) Thermistor <2-phase pipe> (TH6) Thermistor <Ambient> (TH7) Thermistor <Suction pipe> (TH32) Thermistor R0 = 5k' ± 3% B constant = 3480 ± 2% Rt =5exp{3480( 273+t 273 )} 0: 5k' 0: 9.6k' 20: 6.3k' 25: 5.2k' 30: 4.3k' 40: 3.0k' Resistance (k ) Temperature ( ) High temperature thermistor Thermistor <Discharge pipe> (TH4) Thermistor <Comp. surface> (TH34) Thermistor R20 = 7.465k' ± 2% B constant = 4057 ± 2% Rt =7.465exp{4057( 273+t 393 )} 20: 250k' 30: 60k' 40: 04k' 50: 70k' 60: 48k' 70: 34k' 80: 24k' 90: 7.5k' 00: 3.0k' 0: 9.8k' Resistance (k ) Temperature ( ) <HIGH PRESSURE SENSOR> Vout (V) SENSOR Vout WHT BLU BLK CTROLLER BOARD 5V DC 3 2 MICRO PROCESSOR HS GND PRESSURE (MPa) - : 5V (DC) - : Output Vout (DC) 28

29 Linear expansion valve () Operation summary of the linear expansion valve Linear expansion valve opens/closes through stepping motor after receiving the pulse signal from the outdoor controller board. Valve position can be changed in proportion to the number of pulse signal. <Connection between the outdoor controller board and the linear expansion valve> Outdoor controller board DC2V LEV 3 Gray Drive circuit 6 M Orange 2 Red 3 Yellow Black 5 Connector LEV-A LEV-B LEV-C <Output pulse signal and the valve operation> Output (Phase) Output OFF OFF OFF OFF OFF Opening a valve : Closing a valve : The output pulse shifts in above order. 2 3 OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF When linear expansion valve operation stops, all output phase become OFF. 4 OFF OFF OFF OFF OFF (2) Linear expansion valve operation Valve position (capacity) Close Open 500 pulse Opening a valve all the way When the switch is turned on, 700 pulse closing valve signal will be sent till it goes to A point in order to define the valve position. (The pulse signal is being sent for about 20 seconds.) When the valve moves smoothly, there is no sound or vibration occurring from the linear expansion valve : however, when the pulse number moves from B to A or when the valve is locked, more sound can be heard. No sound is heard when the pulse number moves from B to A in case coil is burnt out or motor is locked by open-phase. Sound can be detected by placing the ear against the screw driver handle while putting the screw driver to the linear expansion valve. Pulse number Extra tightening (about 32 pulse) 29

30 (3) How to attach and detach the coil of linear expansion valve <Composition> Linear expansion valve is separable into the main body and the coil as shown in the diagram below. Coil Stopper Main body Lead wire <How to detach the coil> Hold the lower part of the main body (shown as A) firmly so that the main body does not move and detach the coil by pulling it upward. Be sure to detach the coil holding main body firmly. Otherwise pipes can bend due to pressure. A <How to attach the coil> Hold the lower part of the main body (shown as A) firmly so that the main body does not move and attach the coil by inserting it downward into the main body. Then securely attach the coil stopper to main body. (At this time, be careful that stress is not added to lead wire and main body is not wound by lead wire.) If the stopper is not firmly attached to main body, coil may be detached from the main body and that can cause defective operation of linear expansion valve. To prevent piping stress, be sure to attach the coil holding the main body of linear expansion valve firmly. Otherwise pipe may break. Be sure to attach the stopper. A 30

31 8-7. TEST POINT DIAGRAM Outdoor controller circuit board PUHZ-SHW230YKA SW7 Demand control setting SW9 Function switch SW Forced defrost, detect history record reset, refrigerant address SW6 CN5 External signal output Compressor operating signal Abnormal signal CNDM Model select to 2: Input of low-level sound priority mode to 3: Input of external contact point SW4 Test operation SWP Pump down CN4 SW5 Transmission to outdoor power circuit board (CN4) Function switch Model select SW8 Pipe replace Wiring replace SV Option (Drain hose heater output) CNM Connect to A control service tool 2S4 4-way valve LEV-A,B,C Linear expansion valve 63HS Pressure sensor CN2 63L Thermistor <Liquid pipe> Connect to the outdoor power circuit board (CN2) -5: Reception from power circuit board 2-5: Zero cross signal (0-5V DC) 3-4: Not used 6-5: 6V DC 7-5: 6V DC TH7/6 CNAC Low pressure switch TH4 Thermistor <Discharge> TH3 2 to 4: Power supply for outdoor controller circuit board (230V AC) to 3: Power supply for indoor and outdoor unit connection wire (230V AC) Thermistor <Ambient, 2-phase pipe> TH32 Thermistor <Suction pipe> VFG (Voltage between right pins of PC5C and PC5D, pin 3 and pin 4) (Same as (CNF7(+)-4(-)) 63H High pressure switch VSP (Voltage between pins of C5A, C5B): DC 0V(when stopped), DC 6.5V (when operated) CNF, CNF2 Connect to the fan motor -4: V DC 5-4: 5V DC 6-4: 0-6.5V DC 7-4: 5V DC(When stopped) 7.5V DC(When operated) (0V-5V pulse) CNDC 280V DC (+, 3-) (Noise filter circuit board) 3 CNS S-S2: 230V AC

32 Outdoor noise filter circuit board PUHZ-SHW230YKA LI, LI2, LI3, NI POWER SUPPLY LI-LI2/LI-LI3/LI3-LI : AC400V input LI-NI/LI2-NI/LI3-NI : AC230V input (Connect to the terminal block (TB)) GD Connect to the earth CNAC, CNAC2 AC230V (Connect to the outdoor controller circuit board (CNAC)) GD3 Connect to the earth CNDC (Connect to the outdoor controller circuit board (CNDC)) CNCT Primary current (Connect to the outdoor power circuit board (CN5)) CNL Connect to the ACL4 LO, LO2, LO3 POWER SUPPLY LO-LO2/LO2-LO3/LO3-LO: AC400V OUTPUT (Connect to the outdoor power circuit board (TB-L, L2, L3)) 32

33 Outdoor power circuit board PUHZ-SHW230YKA CN5 CN4 Detection of primary current (Connect to the outdoor noise filter circuit board (CNCT)) Connect to the outdoor controller circuit board (CN4) Brief Check of POWER MODULE W Usually, they are in a state of being short-circuited if they are broken. Measure the resistance in the following points (connectors, etc.). If they are short-circuited, it means that they are broken.. Check of POWER MODULE Check of DIODE circuit L - P, L2 - P, L3 - P, L - N, L2 - N, L3 - N 2 Check of IGBT circuit P2 - U, P2 - V, P2 - W, N2 - U, N2 - V, N2 - W Note: The marks, L, L2, L3, N, N2, P, P2, U, V and W shown in the diagram are not actually printed on the board. CN2 Connect to the outdoor controller circuit board (CN2) -5: Power circuit board Transmitting signal to the controller board (0-5V DC) 2-5: Zero cross signal (0-5V DC) 3-4: Not used, 2, 6, 7 : + ] 6-5: 6V DC [ 5 : 7-5: 6V DC CN7 Connect to the outdoor converter circuit board (CN7) TB-U, TB-V, TB-W W W Connect to the compressor (MC) Voltage among phases: 0V-400V AC W L3 TB-L, TB-L2, TB-L3 L2 P L P2 TAB connecter on X52A Connect to the RS resistor Connect to the outdoor noise filter circuit board (LO, LO2, LO3) 400V AC N N2 TB-N Connect to the smoothing capacitor CB2 TB-P2 TB-C Connect to the smoothing capacitor CB + Connect to the smoothing capacitor CB, CB POWER MODULE

34 8-8. FUNCTI OF SWITCHES, CNECTORS AND JUMPERS Function of switches The black square ( ) indicates a switch position. Type of Switch switch Dip switch SW Action by the switch operation No. Function Effective timing OFF Forced defrost Start Normal When compressor is working in heating operation. Abnormal history clear Clear Normal off or operating Refrigerant address setting When power supply Push switch SW4 SW8 SWP *Up to 6 refrigerant address can be assigned. Test run Operating OFF Test run mode setting Heating Cooling No function No function Separate indoor/outdoor unit power supplies Used Not used Pump down Start Normal Under suspension When power supply Under suspension w Forced defrost should be done as follows. Change the DIP SW- on the outdoor controller board from OFF to. 2 Forced defrost will start by the above operation if all these conditions written below are satisfied. Heat mode setting 0 minutes have passed since compressor started operating or previous forced defrost finished. Pipe temperature is less than or equal to 8:. Forced defrost will finish if certain conditions are satisfied. Forced defrost can be done if above conditions are satisfied when DIP SW- is changed from OFF to. After DIP SW- is changed from OFF to, there is no problem if DIP SW- is left or changed to OFF again. This depends on the service conditions. 34

35 The black square ( ) indicates a switch position. Type of Switch Dip switch No. Function Action by the switch operation Switch OFF Effective timing No function Power failure 2 Auto recovery No auto recovery When power supply SW5 automatic recovery 2 3,4,5 No function 6 Model select Following SW5-6 reference SW Setting of demand control 3 Defrost Hz setting No function No function Defrost setting No function Function switch SW7- OFF OFF SW7-2 OFF OFF Defrost Hz 0.54 For high humidity Valid Power consumption (Demand switch ) 0% (Operation stop) 50% 75% Normal Normal Normal Always Always Always Always SW9 3,4 Starting Ambient temp. of flash injection SW9-3 OFF OFF SW9-4 OFF OFF Ambient temp. 3 C (Initial setting) 0 C 3 C 6 C Always 2 SW6 SW Model select OFF SW6 7 8 OFF SW5-6 w2 Power failure automatic recovery can be set by either remote controller or this DIP SW. If one of them is set to, Auto recovery activates. Please set Auto recovery basically by remote controller because all units do not have DIP SW. Please refer to the indoor unit installation manual. w3 SW7-,2 are used for demand control. SW7-,2 are effective only at the demand control. (Refer to next page : Special function (b)) w4 Please do not use SW7-3, 4,6 usually. Trouble might be caused by the usage condition. 35

36 Special function (a) Low-level sound priority mode (Local wiring) Unit enters into Low-level sound priority mode by external signal input setting. Inputting external signals to the outdoor unit decreases the outdoor unit operation sound 3 to 4 db lower than that of usual. Adding a commercial timer or on-off switch contactor setting to the CNDM connector which is optional contactor for demand input located on the outdoor controller board enables to control compressor operation frequency. W The performance depends on the load of conditioned outdoor temperature. Note: When the Dip SW9- on the control board of the outdoor unit is, set Dip SW9- to OFF. How to wire Purchased locally <Low-level sound priority mode circuit> Insulate this point securely as this is not used. Adapter for external signal input (PAC-SC36NA-E) Outdoor unit controller board Relay supply ~ SW X X Red 3 Brown 2 Orange CNDM SW : Switch X : Relay (Contact spec. : DCmA) Max. 0 m including local wiring ) Make the circuit as shown above with adapter for external signal input (PAC-SC36NA-E). 2) Turn SW to on for Low-level sound priority mode. Turn SW to off to release Low-level sound priority mode and normal operation. (b) On demand control (Local wiring) Demand control is available by external input. In this mode, power consumption is decreased within the range of usual 0~00%. How to wire Basically, the wiring is same with (a). Connect an SW which is procured locally between Orange and Red ( and 3) of the adapter for external signal input (PAC- SC36NA-E), and insulate the tip of the brown lead wire. It is possible to set it to the following power consumption (compared with ratings) by setting the SW7-, 2. SW7- SW7-2 Power consumption (SW on) OFF OFF 0% (Operation stop) OFF 50% OFF 75% 36

37 <Display function of inspection for outdoor unit> The blinking patterns of both LED (green) and LED2 (red) indicate the types of abnormality when it occurs. Types of abnormality can be indicated in details by connecting an optional part A-Control Service Tool (PAC-SK52ST) to connector CNM on outdoor controller board. [Display] ()Normal condition Unit condition When the power is turned on When unit stops When compressor is warming up When unit operates Outdoor controller board A-Control Service Tool LED (Green) LED2 (Red) Error code Indication of the display Lighted Lighted Lighted Lighted Lighted Not lighted Not lighted Lighted 00, etc. 08, etc. C5, H7 etc. Alternately blinking display Operation mode (2)Abnormal condition Indication Outdoor controller board Contents LED (Green) LED2 (Red) blinking 2 blinking Connector(63L) is open. Connector(63H) is open. 2 connectors are open. 2 blinking blinking Miswiring of I/F or FTC or outdoor unit connecting wire, excessive number of indoor units (4 units or more) Miswiring of I/F or FTC or outdoor unit connecting wire (converse wiring or disconnection) 2 blinking 3 blinking Startup time over Error code F3 F5 F9 I/F or FTC or outdoor unit communication error (signal receiving error) is detected by E6 FTC unit. I/F or FTC or outdoor unit communication error (signal receiving error) is detected by outdoor unit. (E8) I/F or FTC or outdoor unit communication error (transmitting error) is detected by (E9) outdoor unit. Remote controller signal receiving error is detected by remote controller. Remote controller transmitting error is detected by remote controller. Remote controller signal receiving error is detected by I/F or FTC unit. Remote controller transmitting error is detected by I/F or FTC unit. 4 blinking Error code is not defined. Error code displayed on remote controller 2 Refer to Technical manual of ATW, I/F, FTC. E0 E3 E4 E5 EF Error Inspection method Check if connector (63H or 63L) on the outdoor controller board is not disconnected. Check continuity of pressure switch (63H or 63L) by tester. Check if I/F or FTC or outdoor connecting wire is connected correctly. Check if 4 or more I/F or FTC units are connected to outdoor unit. Check if noise entered into I/F or FTC or outdoor connecting wire or power supply. Re-check error by turning off power, and on again. Check if I/F or FTC or outdoor connecting wire is connected correctly. Check if noise entered into I/F or FTC or outdoor connecting wire or power supply. Check if noise entered into I/F or FTC or outdoor controller board. Re-check error by turning off power, and on again. Check if connecting wire of I/F or FTC unit or remote controller is connected correctly. Check if noise entered into transmission wire of remote controller. Re-check error by turning off power, and on again. Check if noise entered into transmission wire of remote controller. Check if noise entered into I/F or FTC or outdoor connecting wire. Re-check error by turning off power, and on again. 37

38 Indication Outdoor controller board LED (Green) LED2 (Red) 3 blinking blinking Contents Abnormality of superheat due to low discharge temperature 2 blinking Abnormal high pressure (High pressure switch 63H operated.) Abnormal low pressure (Low pressure switch 63L operated.) 3 blinking Abnormality of outdoor fan motor rotational speed Protection from overheat operation (TH3), (T63HS) 4 blinking 5 blinking Abnormality of comp. surface temperature (TH34) and discharging temperature (TH4) Compressor overcurrent breaking(start-up locked) Compressor overcurrent breaking Abnormality of current sensor (P.B.) Abnormality of power module Open/short of outdoor thermistors (TH4, TH34) Open/short of outdoor thermistors (TH3, TH32, TH6, TH7 and TH8) Error code U2 U7 U UL U8 Ud UF UP UH U6 U3 U4 Error Inspection method Check if stop valves are open. Check if connectors (TH4, TH34, LEV-A, and LEV-B) on outdoor controller board are not disconnected. Check if unit is filled with specified amount of refrigerant. Measure resistance values among terminals on indoor valve and outdoor linear expansion valve using a tester. Check if outdoor unit have a short cycle on their air ducts. Check if connector(63h)(63l) on outdoor controller board is not disconnected. Check if heat exchanger and filter is not dirty. Measure resistance values among terminals on linear expansion valve using a tester. Check the outdoor fan motor. Check if connector (TH3) (63HS) on outdoor controller board is disconnected. Check if stop valves are open. Check looseness, disconnection, and converse connection of compressor wiring. Measure resistance values among terminals on compressor using a tester. Check if outdoor unit has a short cycle on its air duct. Check if connectors(th3,th32,th4, TH34 and TH7/6)on outdoor controller board and connector (CN3) on outdoor power board are not disconnected. Measure resistance value of outdoor thermistors. 6 blinking Abnormality of heatsink temperature 7 blinking Abnormality of voltage U5 U9 Check if outdoor unit have a short cycle on their air ducts. Measure resistance value of outdoor thermistor (TH8). Check looseness, disconnection, and converse connection of compressor wiring. Measure resistance value among terminals on compressor using a tester. Check if power supply voltage decreases. 4 blinking blinking Abnormality of water temperature thermistor (TH) Abnormality of pipe temperature thermistor / Liquid (TH2) Abnormality of actual tank temperature thermistor (TH5) 3 blinking Freezing (cooling)/overheating (heating, heating ECO, anti freeze, hot water) protection Error code displayed on remote controller 2 Refer to Technical manual of ATW, I/F and FTC. P P2 P9 P6 Check if terminal on I/F or FTC are not disconnected. Measure resistance value of I/F or FTC thermistors. Check if short cycle of air path. Check if heat exchanger and filter is not dirty. Measure resistance value on outdoor fan motor. Check if the inside of refrigerant piping is not clogged. 38

39 <Outdoor unit operation monitor function> [When optional part A-Control Service Tool (PAC-SK52ST) is connected to outdoor controller board (CNM)] Digital indicator LED displays 2 digit number or code to inform operation condition and the meaning of error code by controlling DIP SW2 on A-Control Service Tool. Operation indicator SW2 : Indicator change of self diagnosis SW2 setting Display detail Explanation for display Unit <Digital indicator LED working details> (Be sure that to 6 in the SW2 are set to OFF.) () Display when the power supply When the power supply, blinking displays by turns. Wait for 4 minutes at the longest. (2) When the display lights (Normal operation) Operation mode display. LED (Lighting) second interval SW2 (Initial setting) The tens digit : Operation mode The ones digit : Relay output Display Operation Model Warming-up Display Compressor Compressor 4-way valve O OFF / FAN 0 C COOLING / DRY H HEATING 2 d DEFROSTING 3 w C5 is displayed during replacement operation. 4 2 Display during error postponement 5 Postponement code is displayed when 6 compressor stops due to the work of 7 protection device. 8 Postponement code is displayed while error is being postponed. A (3) When the display blinks Inspection code is displayed when compressor stops due to the work of protection devices. Solenoid valve Display Inspection unit 0 Outdoor unit Interface or FTC Display Contents to be inspected (During operation) U Abnormal high pressure (63H operated) U2 Abnormal high discharging temperature, high comp. surface temperature, shortage of refrigerant U3 Open/short of outdoor unit thermistors (TH4, TH34) U4 Open/short of outdoor unit thermistors (TH3, TH32, TH6, TH7 and TH8) U5 Abnormal temperature of heatsink U6 Abnormality of power module U7 Abnormality of superheat due to low discharge temperature U8 Abnormality in outdoor fan motor Ud Overheat protection UF Compressor overcurrent interruption (When Comp. locked) UH Current sensor error UL Abnormal low pressure (63L operated) UP Compressor overcurrent interruption P~P9 Abnormality of Interface or FTC units Display Contents to be inspected (When power is turned on) F3 63L connector (red) is open. F5 63H connector(yellow) is open. F9 2 connectors(63h/63l) are open. E8 Interface or FTC/outdoor communication error (Signal receiving error) (Outdoor unit) E9 Interface or FTC/outdoor communication error (Transmitting error) (Outdoor unit) EA Miswiring of Interface or FTC/outdoor unit connecting wire Eb Miswiring of Interface or FTC/outdoor unit connecting wire (converse wiring or disconnection) EC Startup time over E0~E6 Communication error except for outdoor unit 39

40 SW2 setting Display detail Explanation for display Unit Pipe temperature / Liquid(TH3) The black square ( ) indicates a switch position (When the coil thermistor detects 0: or below, and temperature are displayed by turns.) (Example) When 0:; 0.5 secs. 0.5secs. 2 secs. 0 : Discharge temperature (TH4) (When the discharge thermistor detects 00: or more, hundreds digit, tens digit and ones digit are displayed by turns.) (Example) When 05:; 0.5 secs. 0.5secs. 2 secs. 05 : Output step of outdoor FAN Step The number of / OFF times of compressor (When the number of times is 00 or more, hundreds digit, tens digit and ones digit are displayed by turns.) (Example) When times ( times); 0.5 secs. 0.5secs. 2 secs times Compressor integrating operation times (When it is 00 hours or more, hundreds digit, tens digit and ones digit are displayed by turns.) (Example) When 2450 hours (245 0 hours); 0.5 secs. 0.5secs. 2 secs hours Compressor operating current w Omit the figures after the decimal fractions. A Compressor operating frequency (When it is 00Hz or more, hundreds digit, tens digit and ones digit are displayed by turns. (Example) When 25Hz; 0.5 secs. 0.5secs. 2 secs. 25 Hz LEV-A opening pulse (When it is 00 pulse or more, hundreds digit, tens digit and ones digit are displayed by turns. (Example) When 50 pulse; 0.5 secs. 0.5secs. 2 secs. 50 Pulse Error postponement code history () of outdoor unit Postponement code display Blinking: During postponement Lighting: Cancellation of postponement 00 is displayed in case of no postponement. Code display Operation mode on error occurring Operation mode of when operation stops due to error is displayed by setting SW2 like below. (SW2) Code display

41 SW2 setting Display detail Explanation for display Unit Pipe temperature / Liquid (TH3) on error occurring The black square ( ) indicates a switch position (When the coil thermistor detects 0: or below, and temperature are displayed by turns.) (Example) When 5:; 0.5 secs. 0.5secs. 2 secs. 5 : Discharge temperature (TH4) on error occurring (When the temperature is 00: or more, the hundreds digit, tens digit and ones digit are displayed by turns.) (Example) When 30:; 0.5 secs. 0.5secs. 2 secs. 30 : Compressor operating current on error occurring A Error code history () (latest) Alternate display of abnormal unit number and code When no error history, 0 and are displayed by turns. Code display Error code history (2) Alternate display of error unit number and code When no error history, 0 and are displayed by turns. Code display Thermo time (When it is 00 minutes or more, the hundreds digit, tens digit and ones digit are displayed by turns.) (Example) When 245 minutes; 0.5 secs. 0.5secs. 2 secs Minute Test run elapsed time (When it is 00 minutes or more, the hundreds digit, tens digit and ones digit are displayed by turns.) (Example) When 05 minutes; 0.5 secs. 0.5secs. 2 secs. 05 Minute 4

42 SW2 setting The black square ( ) indicates a switch position. Display detail Explanation for display Unit The number of connected indoor units 0 3 (The number of connected indoor units are displayed.) Unit Capacity setting display Displayed as an outdoor capacity code. Model Code SHW Code display Outdoor unit setting information The tens digit (Total display for applied setting) Setting details Display details H P / Cooling only 0 : H P : Cooling only Single phase / 3 phase 0 : Single phase 2 : 3 phase The ones digit Setting details Display details Code display Defrosting switch 0 : Normal : For high humidity (Example) When heat pump, 3 phase and defrosting (normal) are set up, 20 is displayed. Pipe temperature / Liquid (TH2) (When the temperature is 0: or less, and temperature are displayed by turns.) : Actual flow water temperature (TH) : Pressure saturation temperature (T63HS) (When the temperature is 0: or less, and temperature are displayed by turns.) :

43 The black square ( ) indicates a switch position. SW2 setting Display detail Explanation for display Unit Ambient temperature (TH7) (When the temperature is 0: or less, and temperature are displayed by turns.) : Outdoor heatsink temperature (TH8) (When the temperature is 0: or less, and temperature are displayed by turns.) (When the thermistor detects 00: or more, hundreds digit, tens digit and ones digit are displayed by turns.) : Discharge superheat SHd Cooling = TH4-T63HS Heating = TH4-T63HS (When the temperature is 00 C or more, hundreds digit, tens digit and ones digit are displayed by turns.) C Number of defrost cycles 0 FFFE 0 FFFE (in hexadecimal notation) (When more than FF in hex (255 in decimal), the number is displayed in order of 6 3 's and 6 2 's, and 6 's and 6 0 's places. (Example) When 5000 cycles; 0.5 secs. 0.5 secs. 2 secs. 9 C4 2 cycles Input current of outdoor unit (When it is 00 or more, hundreds digit, tens digit and ones digit are displayed by turns.) 0. A LEV-B opening pulse (When it is 00 pulse or more, hundreds digit, tens digit and ones digit are displayed by turns.) Pulse U9 error detail history (latest) Description Normal Overvoltage error Undervoltage error Input current sensor error L-phase open error Abnormal power synchronous signal Display Code display Display examples for multiple errors: Overvoltage (0) + Undervoltage (02) = 03 Undervoltage (02) + Power-sync signal error (08) = 0A DC bus voltage (When it is 00V or more, hundreds digit, tens digit and ones digit are displayed by turns.) V

44 SW2 setting Display detail Explanation for display Unit Capacity save When there is no setting of capacity save 00 is displayed. The black square ( ) indicates a switch position (When the capacity is 00% hundreds digit, tens digit and ones digit are displayed by turns.) (Example) When 00%; 0.5 secs. 0.5secs. 2 secs. 00 % Error postponement code history (2) of outdoor unit Postponement code display Blinking: During postponement Lighting: Cancellation of postponement 00 is displayed in case of no postponement. Code display Error postponement code history (3) of outdoor unit Postponement code display Blinking: During postponement Lighting: Cancellation of postponement 00 is displayed in case of no postponement. Code display Error code history (3) (Oldest) Alternate display of abnormal unit number and code When no error history, 0 and are displayed by turns. Code display Error thermistor display 3: Liquid pipe thermistor (TH3) 4: Discharge pipe thermistor (TH4) When there is no error thermistor, is displayed. 6: 2-phase pipe thermistor (TH6) 7: Ambient temp. thermistor (TH7) 8: Heatsink thermistor (TH8) 32: Suction pipe thermistor (TH32) 34: Comp. surface thermistor (TH34) Code display Operation frequency on error occurring (When it is 00Hz or more, hundreds digit, tens digit and ones digit are displayed by turns.) (Example) When 25Hz; 0.5 secs. 0.5secs. 2 secs. Hz 25 Fan step on error occurring Step LEV-A opening pulse on error occurring (When it is 00 pulse or more, hundreds digit, tens digit and ones digit are displayed by turns.) (Example) When 30 pulse; 0.5 secs. 0.5secs. 2 secs. 30 Pulse Actual water temperature (TH) on error occurring : 44

45 SW2 setting Display detail Explanation for display Unit Pipe temperature / Liquid (TH2) on error occurring The black square ( ) indicates a switch position. -39 ~88 (When the temperature is 0 C or less, and temperature are displayed by turns.) (Example) When 5 C; 0.5 secs. 0.5secs. 2 secs. 5 : Pressure saturation temperature (T63HS) on error occurring (When the temperature is 0 C or less, and temperature are displayed by turns.) (Example) When 5 C; 0.5 secs. 0.5secs. 2 secs. 5 : Outdoor pipe temperature / 2-phase. (TH6) on error occurring (When the temperature is 0 C or less, and temperature are displayed by turns.) (Example) When 5 C; 0.5 secs. 0.5secs. 2 secs. 5 : Outdoor outside temperature (TH7) on error occurring (When the temperature is 0 C or less, and temperature are displayed by turns.) (Example) When 5 C; 0.5 secs. 0.5secs. 2 secs. 5 : Outdoor heatsink temperature (TH8) on error occurring (When the temperature is 0 C or less, and temperature are displayed by turns.) (When the temperature is 00 C or more, hundreds digit, tens digit and ones digit are displayed by turns.) : Discharge superheat on error occurring SHd Cooling = TH4-T63HS Heating = TH4-T63HS (When the temperature is 00 C or more, hundreds digit, tens digit and ones digit are displayed by turns.) (Example) When 50 C; 0.5 secs. 0.5secs. 2 secs. 50 : Sub cool on error occurring SC 0 30 Cooling = T63HS-TH3 Heating = T63HS-TH (When the temperature is 00 C or more, hundreds digit, tens digit and ones digit are displayed by turns.) (Example) When 5 C; 0.5 secs. 0.5secs. 2 secs. 5 : Thermo-on time until error stops (When it is 00 minutes or more, hundreds digit, tens digit and ones digit are displayed by turns.) (Example) When 45 minutes; 0.5 secs. 0.5secs. 2 secs. 4 5 Minute 45

46 The black square ( ) indicates a switch position. SW2 setting Display detail Explanation for display Unit Pipe temperature / Liquid (TH2 (3)) (When the temperature is 0 C or less, and Indoor 3 temperature are displayed by turns.) : Controlling status of compressor operating frequency The following code will be a help to know the operating status of unit. The tens digit Display Compressor operating frequency control Primary current control 2 Secondary current control Outdoor suction pipe temperature (TH32) The ones digit (In this digit, the total number of activated control is displayed.) Display Compressor operating frequency control Preventive control for excessive temperature rise of discharge temperature Preventive control for excessive temperature rise of condensing temperature 2 4 Frosting preventing control 8 Preventive control for excessive temperature rise of radiator panel (Example) The following controls are activated. Primary current control LED Preventive control for excessive temperature rise of condensing temperature Preventive control for excessive temperature rise of heatsink (When the temperature is 0 C or less, and temperature are displayed by turns.) (Example) When 5 C; 0.5 secs. 0.5secs. 2 secs. 5 Code display : LEV-C opening pulse (When it is 00 pulse or more, hundreds digit, tens digit and ones digit are displayed by turns.) Pulse Comp. surface thermistor (TH34) (When the temperature is 0 C or less, and temperature are displayed by turns.) (When the discharge thermistor detects 00: or more, hundreds digit, tens digit and ones digit are displayed by turns.) (Example) When 05:; 0.5 secs. 0.5secs. 2 secs. 05 : U9 error details (To be shown while error call is deferred.) Description Normal Overvoltage error Undervoltage error Input current sensor error L-phase open error Abnormal power synchronous signal Display Code display Display examples for multiple errors: Overvoltage (0) + Undervoltage (02) = 03 Undervoltage (02) + Power-sync signal error (08) = 0A 46

47 9 DISASSEMBLY PROCEDURE PUHZ-SHW230YKA OPERATING PROCEDURE. Removing the service panel and top panel () Remove 3 service panel fixing screws (5 2) and slide the hook on the right downward to remove the service panel. (2) Remove screws (3 for front, 3 for rear/5 2) of the top panel and remove it. Photo Top panel fixing screws Top panel Grille fixing screws PHOTOS & ILLUSTRATI Slide Service panel Grille fixing screws Service panel fixing screws Cover panel fixing screws 2. Removing the fan motor (MF, MF2) () Remove the service panel. (See Photo ) (2) Remove the top panel. (See Photo ) (3) Remove 4 fan grille fixing screws (5 2) to detach the fan grille. (See Photo ) (4) Remove a nut (for right handed screw of M6) to detach the propeller. (See Photo 2) (5) Disconnect the connectors, CNF, CNF2 on controller circuit board in electrical parts box. (6) Remove 4 fan motor fixing screws (5 20) to detach the fan motor. (See Photo 3) Photo 2 Photo 3 Propeller Nut Front panel Fan motor fixing screws Fan motor Fan motor fixing screws 3. Removing the electrical parts box () Remove the service panel. (See Photo ) (2) Remove the top panel. (See Photo ) (3) Disconnect the indoor/outdoor connecting wires from terminal block. (4) Disconnect the connector CNF, CNF2, LEV-A, LEV-B and LEV-C on the controller circuit board. <Symbols on the board> CNF, CNF2 : Fan motor LEV-A, LEV-B, LEV-C : LEV (5) Disconnect the pipe-side connections of the following parts. Thermistor <Liquid>(TH3) Thermistor <Discharge>(TH4) Thermistor <2-phase pipe>(th6) Thermistor <Ambient>(TH7) Thermistor <Suction> (TH32) Thermistor <Comp. surface> (TH34) High pressure switch (63H) Low pressure switch (63L) High pressure sensor (63HS) 4-way valve coil (2S4) (6) Remove the terminal cover and disconnect the compressor lead wire. (7) Remove 2 electrical parts box fixing screws (4 0) and detach the electrical parts box by pulling it upward. The electrical parts box is fixed with 2 hooks on the left and hook on the right. Photo 4 Controller circuit board (C.B.) Terminal block (TB) Electrical parts box Electrical parts box fixing screws Terminal block (TB2) Noise filter circuit board (N.F.) 47

48 OPERATING PROCEDURE 4. Removing the thermistor <Outdoor 2-phase pipe> (TH6) () Remove the service panel. (See Photo ) (2) Remove the top panel. (See Photo ) (3) Disconnect the connectors, TH6 and TH7 (red), on the controller circuit board in the electrical parts box. (4) Loosen the 2 wire clamps on top of the electrical parts box. (5) Pull out the thermistor <Outdoor 2-phase pipe> (TH6) from the sensor holder. Photo 5 Electrical parts box PHOTOS Thermistor <Outdoor 2-phase pipe> (TH6) Note: In case of replacing thermistor <Outdoor 2-phase pipe> (TH6), replace it together with thermistor <Outdoor> (TH7) since they are combined together. Refer to No.6 below to remove thermistor <Outdoor>. Clamp 5. Removing the thermistor <Outdoor> (TH7) () Remove the service panel. (See Photo ) (2) Remove the top panel. (See Photo ) (3) Disconnect the connector TH7 (red) on the controller circuit board in the electrical parts box. (4) Loosen the 2 wire clamps on top of the electrical parts box. (See Photo 5) (5) Pull out the thermistor <Outdoor> (TH7) from the sensor holder. Note: In case of replacing thermistor <Outdoor> (TH7), replace it together with thermistor <Outdoor 2-phase pipe> (TH6), since they are combined together. Refer to No.5 above to remove thermistor <Outdoor 2-phase pipe>. Photo 6 Lead wire of thermistor <Outdoor> (TH7) Sensor holder 6. Removing the thermistor <Liquid pipe> (TH3), thermistor <Discharge> (TH4), thermistor <Suction pipe> (TH32) and thermistor <Comp. surface> (TH34) () Remove the service panel. (See Photo ) (2) Disconnect the connectors, TH3 (white), TH4 (white), TH32 (black) and TH34 (red) on the controller circuit board in the electrical parts box. (3) Loosen the clamp for the lead wire in the rear of the electrical parts box. [Removing the thermistor<liquid pipe>(th3)] (4) Pull out the thermistor <Liquid pipe> (TH3) from the sensor holder. [Removing the thermistor<discharge>(th4)] (4) Pull out the thermistor <Discharge> (TH4) from the sensor holder. [Removing the thermistor<suction pipe>(th32)] (4) Pull out the thermistor <Suction pipe> (TH32) from the thermo-holder. (TH32 : See Figure 2) [Removing the thermistor<comp. surface>(th34)] (4) Remove the sound proof cover (upper) for compressor. (5) Pull out the thermistor <Comp. surface> (TH34) from the holder of the compressor shell. Photo 7 Thermistor <Discharge> (TH4) Soundproof cover (upper) for compressor Compressor (MC) Thermistor <Outdoor pipe> (TH3) Thermistor <Comp. surface> (TH34) 48

49 OPERATING PROCEDURE 7. Removing the 4-way valve coil (2S4) and linear expansion valve coil (LEV-A, LEV-B, LEV-C) () Remove the service panel. (See Photo ) (2) Remove the top panel. (See Photo ) (3) Remove the electrical parts box. (See Photo 4) Figure Linear expansion valve coil (LEV-C) PHOTOS Linear expansion valve [Removing the 4-way valve coil] (4) Remove 4-way valve coil fixing screw (M4 6). (5) Remove the 4-way valve coil by sliding the coil toward you. [Removing the linear expansion valve coil] (4) Remove 3 right side panel fixing screws (5 2) in the rear of the unit then remove the right side panel. (5) Remove the linear expansion valve coil by sliding the coil upward. Linear expansion valve coil (LEV-A) Linear expansion valve coil (LEV-B) 8. Removing the 4-way valve () Remove the service panel. (See Photo ) (2) Remove the top panel. (See Photo ) (3) Remove the electrical parts box. (See Photo 4) (4) Remove 3 valve bed fixing screws (4 0), 4 ball valve and stop valve fixing screws (5 6) then remove the valve bed. (5) Remove 3 right side panel fixing screws (5 2) in the rear of the unit then remove the right side panel. (6) Remove the 4-way valve coil. (7) Recover refrigerant. (8) Remove the welded part of 4-way valve. 4-way valve coil (2S4) 4-way valve coil fixing screw 4-way valve Note : Recover refrigerant without spreading it in the air. Note 2: The welded part can be removed easily by removing the right side panel. Note 3: When installing the parts of refrigerant circuit, cover it with a wet cloth to prevent it from heating (20 C or more), then braze the pipes so that the inside of pipes are not oxidized. 9. Removing the linear expansion valve () Remove the service panel. (See Photo ) (2) Remove the top panel. (See Photo ) (3) Remove 3 valve bed fixing screws (4 0), 4 ball valve and stop valve fixing screws (5 6) then remove the valve bed. (4) Remove 3 right side panel fixing screws (5 2) in the rear of the unit then remove the right side panel. (5) Remove the linear expansion valve coil. (6) Recover refrigerant. (7) Remove the welded part of linear expansion valve. 49

50 OPERATING PROCEDURE 0. Removing the high pressure switch (63H) and low pressure switch (63L) () Remove the service panel. (See Photo ) (2) Remove the top panel. (See Photo ) (3) Remove 3 right side panel fixing screws (5 2) in the rear of the unit and remove the right side panel. (4) Pull out the lead wire of high pressure switch and low pressure switch. (5) Recover refrigerant. (6) Remove the welded part of high pressure switch and low pressure switch. Photo 8 PHOTOS Note : Recover refrigerant without spreading it in the air. Note 2: The welded part can be removed easily by removing the right side panel. Note 3: When installing the parts of refrigerant circuit, cover it with a wet cloth to prevent it from heating (00 C or more), then braze the pipes so that the inside of pipes are not oxidized. High pressure switch Figure 2 Suction pipe thermistor (TH32) Low pressur switch (63L). Removing the compressor (MC) () Remove the service panel. (See Photo ) (2) Remove the top panel. (See Photo ) (3) Remove 2 front cover panel fixing screws (5 2) and remove the front cover panel. (4) Remove 4 back cover panel fixing screws (5 2) and remove the back cover panel. (5) Remove the electrical parts box. (See Photo 4) (6) Remove 3 valve bed fixing screws (4 0), 4 ball valve and stop valve fixing screws (5 6), then remove the valve bed. (7) Remove 3 right side panel fixing screws (5 2) in the rear of the unit and remove the right side panel. (8) Remove 3 separator fixing screws (4 0) and remove the separator. (9) Remove the soundproof cover for compressor. (0) Remove the terminal cover and remove the compressor lead wire. () Recover refrigerant. (2) Remove the 3 points of the compressor fixing nut using a spanner or a adjustable wrench. (3) Remove the welded pipe of compressor inlet and outlet and remove the compressor. Photo 9 Compressor terminal Compressor (MC) Soundproof cover Compressor fixing nut Note: Recover refrigerant without spreading it in the air. 50

51 OPERATING PROCEDURE 2. Removing the power receiver () Remove the service panel. (See Photo ) (2) Remove the top panel. (See Photo ) (3) Remove 2 front cover panel fixing screws (5 2) and remove the front cover panel. (4) Remove 4 back cover panel fixing screws (5 2) and remove the back cover panel. (5) Remove the electrical parts box. (See Photo 4) (6) Remove 3 valve bed fixing screws (4 0) and 4 ball valve and stop valve fixing screws (5 6) and then remove the valve bed. (7) Remove 3 right side panel fixing screws (5 2) in the rear of the unit and then remove the right side panel. (8) Recover refrigerant. (9) Remove 4 welded pipes of power receiver inlet and outlet. (0) Remove 2 receiver leg fixing screws (4 0). Note: Recover refrigerant without spreading it in the air. Photo 0 Valve bed fixing screw Valve bed Separator PHOTOS Power receiver Valve bed fixing screws Compressor Separator fixing screw Compressor fixing nuts Power receiver leg fixing screws Photo Inlet pipe Outlet pipe Power receiver 3. Removing the pressure sensor (63HS) () Remove the service panel. (See Photo ) (2) Remove the top panel. (See Photo ) (3) Pull out the lead wire of pressure sensor. (4) Remove the band that is fixing the rubber mount and the sensor. (5) Recover refrigerant. (6) Remove the welded part of pressure sensor. Figure 3 High pressure switch (63H) 4-way valve Low pressure switch (63L) Note : Recover refrigerant without spreading it in the air. Note 2: The welded part can be removed easily by removing the right side panel. Note 3: When installing the pressure sensor, make sure to cover it with a wet cloth to prevent it from heating (00 C or more), then braze the pipes so that the inside of pipes are not oxidized. High pressure sensor (63HS) Rubber mount Muffler Fixing band Compressor (MC) 5