SERVICE MANUAL MODELS SPLIT TYPE ROOM AIR CONDITIONERS INDOOR UNIT AY-XP09DR-N AY-XP09DR-NC

Transcription

1 CHAPTER. SPECIFICATIONS [] AE-X09DR-N... - CHAPTER. EXTERNAL DIMENSIONS [] INDOOR UNIT... - [] OUTDOOR UNIT... - CHAPTER. WIRING DIAGRAMS [] INDOOR UNIT... - [] OUTDOOR UNIT... - CHAPTER. ELECTRICAL PARTS [] INDOOR UNIT... - [] OUTDOOR UNIT... - CHAPTER. BLOCK DIAGRAMS [] INDOOR UNIT... - [] OUTDOOR UNIT... - CHAPTER 6. MICROCOMPUTER CONTROL SYS- TEM [] INDOOR UNIT [] OUTDOOR UNIT CHAPTER 7. FUNCTIONS [] Functions [] Explanation of cluster circuit [] Outline of PAM circuit [] Explanation of IPM drive circuit [] Compressor digital position detection SERVICE MANUAL MODELS SPLIT TYPE ROOM AIR CONDITIONERS INDOOR UNIT C OUTDOOR UNIT AE-X09DR-N In the interests of user-safety (Required by safety regulations in some countries) the set should be restored to its original condition and only parts identical to those specified should be used. CONTENTS CHAPTER 8. FUNCTION AND OPERATION OF PRO- TECTIVE PROCEDURES [] Protection device functions and operations...8- [] Air conditioner operation in thermistor...8- [] Thermistor temperature characteristics [] How to operate the outdoor unit independently [] General troubleshooting chart [6] Malfunction (parts) check method [7] Outdoor unit check method [8] Troubleshooting guide...8- CHAPTER 9. REFRIGERATION CYCLE [] Flow for Refrigerant...9- [] Standard conditions...9- [] Temperature at each part and pressure in -way valve...9- CHAPTER 0. PERFORMANCE CURVES []...0- CHAPTER. DISASSEMBLING PROCEDURE [] Disassembly of indoor unit... - [] Disassembly of outdoor unit REPLACEMENT PARTS LIST Parts marked with " " are important for maintaining the safety of the set. Be sure to replace these parts with specified ones for maintaining the safety and performance of the set. This document has been published to be used for after sales service only. The contents are subject to change without notice.

2 Air Service Market ECHAPTER Conditioner Manual. SPECIFICATIONS [] AE-X09DR-N MODEL INDOOR UNIT OUTDOOR UNIT ITEMS C AE-X09DR-N Cooling capacity(min. ~ Max.) kw.6 ( ) Heating capacity(min. ~ Max.) kw.6 ( ) Moisture removal(at cooling) Liters/h Electrical data Phase Single Rated frequency Hz 0 Rated voltage V 0 Rated current Cool A. ( ) (Min - Max.) Heat A. (0.7-6.) Rated input Cool W 60 (0-900) (Min - Max.) Heat W 900 (0-00) Power factor Cool % 86 Heat % 9 Compressor Type Hermetically sealed rotary type Model RS09XDF Oil charge 0cc (RB68A or Freol Alphc 68M) Refrigerant system Evaporator Louver Fin and Grooved tube type Condenser Corrugate Fin and Grooved tube type Control Expansion valve Refrigerant (R0A) 000g De-lce system Micro computer controled reversed systems Noise level (at cooling) High db(a) 8 Low db(a) - Soft db(a) 8 - Fan system Drive Direct drive Air flow quantity High m /min. 9.9 (at cooling) Low m /min. 7.7 Soft m /min. 6.0 Fan Cross flow fan Propeller fan Connections Refrigerant coupling Flare type Refrigerant tube size Gas, Liquid /8", /" Drain piping mm O.D ø 8 Others Safety device Compressor: Thermal protector Fan motors: Thermal fuse Fuse, Micro computer control Air filters Polypropylene net (Washable) Net dimensions Width mm Height mm 8 0 Depth mm 0 0 Net weight kg 6 Note: The condition of star " " marked item are ISO : 99(E), condition T.

3 INVERTER AIR CONDITIONER CRMC-AJBE0 R0(AAA) PCS. SHARP CORPORATION Air Service Market ECHAPTER Conditioner Manual. EXTERNAL DIMENSIONS [] INDOOR UNIT [] OUTDOOR UNIT Ø

4 Air Service Market ECHAPTER Conditioner Manual. WIRING DIAGRAMS [] INDOOR UNIT LED INDICATION FOR SELF-DIAGNOSIS Temperature Indicator Blinking No Abnormal contents Short circuit of the Thermistor Overheat (compressor and cycle) Open circuit of the Thermistor Abnormal DC current Abnormal AC current Abnormal Thermistor or four way valv Abnormal outdoor fan motor Rotation of the compressor or compressor lock Abnormal PAM voltage and PAM clock signal Open circuit of serial signal line Short circuit of serial signal line 9 Abnormal fan motor of indoor unit <Indication of the abnormal condition> LED indicator will blink, if the set is in abnormal condition. WIRING DIAGRAM <CB878> INDOOR UNIT TERMINAL BOARD GREEN-YELLOW POWER SUPPLY SINGLE PHASE N BLUE BLACK LOUVER MOTOR (TOP) LOUVER MOTOR (BOTTOM) ROOM TEMP. THERMISTOR PIPE TEMP. THERMISTOR BCN0 RECEIVER BOARD UNIT IN OUT RY CONTROL BOARD UNIT NF DB CNA CNB NR CA TH YELLOW CN R76 SSR FU TH ORANGE CN C.A NF BCN C8 C99 C97 CN C98 C96 BCN FAN MOTOR CN0 BCN0 CN0 DISPLAY BOARD UNIT CLUSTER GENERATOR SERIAL SIGNAL CIRCUIT FU A POWER SUPPLY UNIT CN BLACK S N TERMINAL BOARD BLUE RED N EVAPORATOR OUTDOOR UNIT TERMINAL BOARD N [] OUTDOOR UNIT

5 Air Service Market ECHAPTER Conditioner Manual. ELECTRICAL PARTS [] INDOOR UNIT DESCRIPTION MODEL REMARKS Indoor fan motor MLB08 DC Motor Indoor fan motor capacitor Transformer FUSE QFS-GA0JBZZ (,.A) FUSE QFS-GA0JBZZ (, A) [] OUTDOOR UNIT DESCRIPTION MODEL REMARKS Compressor RS09XDF D.C. brush-less motor Outdoor fan motor ML-A90 DC Motor Outdoor fan motor capacitor WPE QFS-GA00JBZZ(, A) WPE0 QFS-GA0JBE0(, A) WPE QFS-GA0JBZZ(,.A) WPE QFS-GA06JBZZ(0, 0A) QFS-GA066JBZZ(0, A)

6 Air Service Market ECHAPTER Conditioner Manual. BLOCK DIAGRAMS [] INDOOR UNIT DC power supply circuit Fan motor PWM control circuit Rectification circuit A Fuse Indoor fan motor.a Fuse AC power Rotation pulse input circuit Fan motor pulse detect AC clock circuit CPU Remote controller signal reception circuit Buzzer drive circuit CPU reset circuit CPU oscillator circuit Room temp. detect circuit Heat exchanger pipe thermo circuit EEPROM Wireless remote control operation Audible operation confirmation Room temp. thermistor Heat exchanger pipe thermistor Louvre angle, fan speed Select circuit Serial I/O circuit Power supply relay drive circuit Wireless, preheat, Model select Indoor/outdoor control signal I/O Outdoor unit power supply on/off control Unit-unit wiring (AC power and serial signals) Auto restart circuit Test run circuit Auxiliary mode Power on circuit Cluster generator drive circuit Cluster generator sensor circuit Test run (forced operation) Auxiliary mode button ON/OFF Self diagnostics, fault diagnosis Cluster generator Serial signals Sub CPU Louvre motor drive circuit(upper) Louvre motor drive circuit(lower) LED drive circuit Flow direction control (louver motor upper) Flow direction control (louver motor lower) LED display

7 [] OUTDOOR UNIT Power supply circuit Smoothing circuit Power factor converter circuit Filter circuit 0A protection Unit-unit wiring (AC power and serial signals) CPU oscillator circuit DC overvoltage detection circuit Outdoor fan drive circuit Outdoor fan.a protection -way valve relay drive circuit Power transistor module drive circuit -way valve Power transistor module A protection CPU Serial I/O circuit CPU reset circuit Position detection circuit Compressor AC overcurrent detection circuit Compressor thermo circuit Heat exchanger pipe thermo circuit Outdoor temp. thermo. circuit Current transformer Compressor thermistor Heat exchanger pipe thermistor Outdoor temperature thermistor LED drive circuit Test mode circuit LED Expantion valve drive circuit Suction temp. thermo. circuit -way valve temp. thermo. circuit Expantion valve Suction pipe thermistor -way valve thermistor

8 6 Air Conditioner Service Manual Market ECHAPTER 6. MICROCOMPUTER CONTROL SYSTEM [] INDOOR UNIT. Electronic Control Circuit Diagram ½ R8A 0k 7 0.µ NF CA R kf kf CNE RB RA 680 W S SS 00k BCN ICD 000p C k R89 RM 0k Ð JPC JPA 07ER 09ER ER 0k JPK SBC ER g f e d c b a DC R R6 0kF JP 7.k SC XC.k.k ST0DÐ00 ZD. 9k 00k D W W R7 RD C8 00µ C9 0.07µ 680 W N RESET P Vss Xout Xin Vcc CNVss RESET Vref P7 P6 P P P P P P0 P P P 9 P0 0 P P P P P P6 6 P7 7 P00 P0 8 9 P0 0 P0 P0 P0 P06 P07 P0 8MHz R70 R.7k IC RESET R68.7K R9.7K MQ 9 8 VSS 6 7 RESET OE SDA SCL VCC VPP 7k R67 SW R0 0k BUSY OSC R69 00k R96 0kF JPH JPG JPE C C 0.µ 00µ BCN DSBA60 DB NR 680 0k R 0.0µ 6V C C C 00p C0 000p PC87XP PC87XP 680µ R C 00k 70µ C7 00k R6 0µ C R6 R AVss Vref Vss Xout Xin IC CN80 R7 6.8k EEPROM R6 k IC P7 P6 P P P P P P0 VCC P67 P66 P6 P6 P6 P00 P0 P0 P0 P0 P0 P06 P07 P0 P P P P P P6 P P0 P P P P P P6 P7 P0 P RST VSS P P P P P6 P7 P0 P P P P P P6 P7 P60 P6 P R9 CN90 HAJP R9 C90 R90 00k R9 R86 R87 JPC JPB JPA R8 k TR C8 C9 Q9 PC6 PC D D C7.7k R6 C kv FU C R W R 6.8k 6.8k R R 6k C 6V7µ DC DCV RPM V CN 0.0kF TH 0.0kF CN TH KRC08S Q KRC08S Q R7 R0 C6 0.0µ R8 C R 8.k R9.k D R R R6 /W /W DN60 IC6 SS D0 R6 6V C8 0.µ D7 DN V V K R9 0k R8 SS V R.8k CN ZD HZÐ D 0k R R 6k.7k R9 C0 0.0µ R8 00k OUT RY IN V 8 KRA06S KRA06S QA QB.7k R98 6.8k R7 k R97 k R7 AÐ 0k C9 7µ IC ICA k k 7p N L N PC PC87XP.AÐ FU KID600AF KID600AF KID600AF BZ 6 V V V k V JP JP JPF 0k 0k CNB CNA 6 PC87XP PC PC PC87XP R99 0k J RP RR 0k J 00µ Ð Ð Ð JPJ V R76 00 W 0.µ C 7 SSR.k 90/W R0 90/W R7 R DC Fan motor 7 CN GND Vcc Vs PG Vm NF 6.8k W RE W 6.8k RN PC C 00µ 00k R7.k R66 OSCA 680 W R0 R0E 680 W RC 680 W DN60 D8 PC PC8HXP V.7k M / W R9 M R /W M RF /W 0µ /W KID600AF V ICC KID678AF ICB PC876 Q7 KRA08S 0.µ C0 0.µ 0k 0k R6.7k DFL0U DFL0U ZD C 00p 0 0k RQ 0.0µ 6V C7 KRA08S QC 6V 0.0µ C7 0.µ CD 0.µ CC 0.µ CB C 7µ 6V C 0.µ C6 C7 0.µ 000p C JPB 000p C9 000p C6 C 6V 0µ C0 0µ 6V R60 R6 000p CA k R0 k R9.kF R8 SL0U DA DA DS6M R.kF ICE M7 C8 7 0.µ HZ6Ð kf R7 00µ C6 DC /W.k RW RX.k /W /W.k.k /W RY RZ C 0k C96 C97 C99 C98 C96 ~ C99 700P 0000P 0000P KRC0S 6V 0µ 6V 0µ 8.k MR7 D0 DFL0U IC 680 R7 0µH MMA R 0k R C 0.µ L IC PC87XP PC9 Q8 KRA06S R R6 DFL0U D 0½ R80 k KIA78MT IC7 KRA06S Q9 9kF

9 . Display Circuit Diagram LED0 LED0 LED0 LED0 D0 SS70A D0 SS70A D0 SS70A a b d R0 R0 R /W /W /W e R0 80 /W LED09 a b 6(A) c d e f g (B) (C) (D) (E) 8(F) 7(G) b a NC (H) (A) 0(B) c 8(C) d e f 6(D) (E) (F) g 7(G) NC 9(H) (COM) A F B G E C D H LED0 SL6 E F (COM) A G B C D H R0, R06, R09 80 W R07, R08, R0, R 80 /W R0 R06 R07 R08 R09 R0 R BCN0 CN0 g e d c b a CN BCN0 R0 7 /W C0 µ + C0 0.µ SHEMATIC DRAWING OF DISPLAY IC0 f 6

10 . Printed Wiring Board 6

11 [] OUTDOOR UNIT. Electronic Control Circuit Diagram TERMINAL BOARD N FC T 7 µf BLUE /W M R C FU T BROWN 0A FC GREEN / YELLOW T D R.K 7 µf L L C SA NR PC PC87-700pF CA CB CA CB 700pF 700pF C7A C7B C T 700P C 0.µ R77.0K W W W.0K.0K R78 R79 PC PC8 R76 6K R7.7K R7.7K C7 000P a b R8 00K PC PC87 C8 0.0µ RED R87 0K /W 7 µf C CT R89 T6 R88 0K /W.7kF FU PTC GR IN MRY OUT T C6A C6B 700pF IPM VUFB VUFS UP VPI VVFB VVFS VPI VP VWFB VWFS VPI WP VPC VNI UN VN WN VNC F0 R7 /W 68 C8 R8 C7 0.µ /W 0µ 68 D8 C9 0.µ C0 00µ D9 C8 0.µ C7 00µ R9.K C 0.µ C 00µ C9 R0.K D0 C 0.µ C 00µ C0 R.K C R.K C C6 C7 0.µ 0.µ 0.µ C R.K C R.K C V IC7 KID600AP CN V RY C9~C 000pF x 6 6 C8 000P 0.0µ C8 R06.K FC D k KRC0S Q6 EXPANSION VALV COIL R0 K R 00 R6 00 R 00 R 00 R7 00 R 00 N R0 0K k f Output c 8 MRY JP - WK R R 0K IC C µ C 0.µ OSC R.7K R6 K C 0.µ C6 000P RESET P 6 0 XIN P XOUT P VSS P0 R0 6.8K IC6 CNE Q Q KRA06S KRA06S ZD Q KRC0S R K Q8 KRA06S Q0 KRA06S R8 9.K R 0K Q9 KRC0S R86 6.8K C78 7µ R.K JP JP 0K P70 VDD 6 P7 P67 6 P7 P66 6 P7 P6 6 P7 P6 60 P7 P6 9 P76 P6 8 P77 P6 7 P00 P60 6 VAREF VASS P P P P 0 P0 9 P7 8 P6 7 P 6 P P P P P0 P7 0 P6 9 P 8 P IC 0 P0 P0 P0 P0 P0 P06 6 P07 7 P0 8 P 9 P 0 P P P P6 P7 P0 TEST P P a R7.K LED R 0K C70 6V 0µ R8 0K C7 6V 0µ C7 C7 C7 6V 0µ 6V 0µ R8 0K 6V 0µ R68 R69 R70 R7 R7 R9 0K CN (monitor) b R8 00 C76 C77 000P 0.0µ C6 C66 C67 C68 C69.A L (U) DB T RE C0 RE + D D GR GR T BL BL L6 (L) T 00µF T WH WH FU6 A R9 ~ R9 W K x D R90.0KF R9 6.8kF C79 0µ D Q CT60AM R0 0 RY DB R.K ZD C6 R8 7 /W 0.0µ 0 CN N M C0 C9 0.µ 00µ T0 R /W KF R7 0KF T C8 C8 0.µ 00µ R6.8K R6 K R6 K + R 70 W R.K R K R0 R0 R0 R0 R0~0 / W 7K x R0, 0 W 7K x NR R9 R9 R9 -WAY VALV COIL C6~69 0.0µ x R6 0K R6 0K R6 0K R66 0K R67 0K R00 0K R68 ~ 7 6.8KF x CN8 0 R9 R9 ~ R98 W 8K x R96 R97 R98 THERMISTOR C 0.0µ R.K R K R7 7 W 780 IC V D R7 7 W C8 00P D6.7K R6 0.µ TR R µ C60 R 0kF 0.µF R R R6 C86 6.kF 6.kF 6.KF FU 8 Vcc ~ Drain STR - L7 R 680 C7 70P C7 KV 0PF GND OCP / FB Source IC R.6 Q C 0µ R8.K SA86G R0.K D R6.6 R9.K C6 00PF D ZD D7 C0 680µ 0µ C9 R00 0K R9.7K P R /W 70KD R /W 00KF R6 0KF TH - WAY VALV TEMPERATURE C9 0 0.µ A DC FAN MOTOR CN MOTOR TO FAN A FU R6 /W 70KD M R8 R7.0kF.0kF C 6 0.µ CF0 CIN KIA9 IC8 IPM 0 C87 0.µ C6 0.µ FC FC T7 T8 T9 COMPRESSOR RE U <S> WH V OR <T> <R> W IC C JP 7 j PC PC9 700P CA 700P CB R07 0 Q C8 0.0µ KRC0S j FU A D R7 K R8 K R6 R60 R.8K.8K.8K C C C6 C88 C,, 6, pFx C9 000P c TH COMPRESSOR TEMPERATURE HEAT EXCHANGER TH TEMPERATURE TH OUT DOOR TEMPERATURE TH SUCTION TEMPERATURE R0 R9 R8 /W M x 6 R R R R0.8K ZD R M N R9 W 0.0 R99 R 00 KF R7 00 R8 00 C6 C6 C6 0P 0P 0P EARTH GREEN / YELLOW R R R /W /W /W 70KD 70KD 70KD Orange 6

12 . Printed Wiring Board 6

13 Air Service Market ECHAPTER Conditioner Manual7. FUNCTIONS [] Functions. Startup control The main relay remains off during the first seconds (first safety time) immediately after the power cord is plugged into an AC outlet in order to disable outdoor unit operation and protect outdoor unit electric components.. Restart control Once the compressor stops operating, it will not restart for 80 seconds to protect the compressor. Therefore, if the operating compressor is shut down from the remote control and then turned back on immediately after, the compressor will restart after a preset delay time. (The indoor unit will restart operation immediately after the ON switch is operated on the remote control.) Compressor operation Compressor ON OFF operation on remote control Compressor remains OFF for 80 seconds ON operation on remote control. Cold air prevention control When the air conditioner starts up in heating mode, the indoor unit fan will not operate until the temperature of the indoor unit heat exchanger reaches about ºC in order to prevent cold air from blowing into the room. Also, the indoor unit fan operates at low speed until the temperature of the indoor unit heat exchanger reaches about 8ºC so that people in the room will not feel chilly air flow. Indoor unit heat exchanger temperature 8. Odor prevention control Set fan speed Compressor can turn ON Compressor ON Indoor unit fan at low speed Indoor unit fan in non-operation When the air conditioner starts up in cooling mode, the discharged air temperature is lowered slightly, and for the reduction of unpleasant odors the operation of the indoor unit fan is delayed 60 seconds if the automatic fan speed mode in cooling mode is set.. Indoor unit heat exchanger freeze prevention control If the temperature of the indoor unit heat exchanger remains below 0ºC for consecutive minutes during cooling or dehumidifying operation, the compressor operation stops temporarily in order to prevent freezing. When the temperature of the indoor unit heat exchanger rises to ºC or higher after about 80 seconds, the compressor restarts and resumes normal operation. 6. Outdoor unit -way valve freeze prevention control If the temperature of the outdoor unit -way valve remains below 0ºC for 0 consecutive minutes during cooling or dehumidifying operation, the compressor operation stops temporarily in order to prevent freezing. When the temperature of the -way valve rises to 0ºC or higher after about 80 seconds, the compressor restarts and resumes normal operation. When the compressor operation stops temporarily, LED on the outdoor unit flashes twice. 7. Indoor unit overheat prevention control During heating operation, if the temperature of the indoor unit heat exchanger exceeds the indoor unit heat exchanger overheat prevention temperature (about to ºC) which is determined by the operating frequency and operating status, the operating frequency is decreased by about to Hz. Then, this operation is repeated every 60 seconds until the temperature of the indoor unit heat exchanger drops below the overheat protection temperature. Once the temperature of the indoor unit heat exchanger drops below the overheat protection temperature, the operating frequency is increased by about to 0 Hz every 60 seconds until the normal operation condition resumes. If the temperature of the indoor unit heat exchanger exceeds the overheat protection temperature for 60 seconds at minimum operating frequency, the compressor stops operating and then restarts after about 80 seconds, and the abovementioned control is repeated. When the compressor operation stops temporarily, LED on the outdoor unit flashes twice. 8. Outdoor unit overheat prevention control During cooling operation, if the temperature of the outdoor unit heat exchanger exceeds the outdoor unit heat exchanger overheat prevention temperature (about ºC), the operating frequency is decreased by about to Hz. Then, this operation is repeated every 60 seconds until the temperature of the outdoor unit heat exchanger drops to about ºC or lower. Once the temperature of the outdoor unit heat exchanger drops to about ºC or lower, the operating frequency is increased by about to 0 Hz every 60 seconds until the normal operation condition resumes. If the temperature of the outdoor unit heat exchanger exceeds the outdoor unit heat exchanger overheat protection temperature for 0 seconds at minimum operating frequency, the compressor stops operating and then restarts after about 80 seconds, and the abovementioned control is repeated. When the compressor operation stops temporarily, LED on the outdoor unit flashes twice. 9. Compressor overheat prevention control If the temperature of the compressor exceeds the compressor overheat prevention temperature (0ºC), the operation frequency is decreased by about to 0 Hz. Then, this operation is repeated every 60 seconds until the temperature of the compressor drops below the overheat protection temperature (00ºC). Once the temperature of the compressor drops below the overheat protection temperature, the operating frequency is increased by about to 0 Hz every 60 seconds until the normal operation condition resumes. 7

14 If the temperature of the compressor exceeds the overheat protection temperature (for 0 seconds in cooling operation or 60 seconds in heating operation) at minimum operating frequency, the compressor stops operating and then restarts after about 80 seconds, and the abovementioned control is repeated. When the compressor operation stops temporarily, LED on the outdoor unit flashes twice. 0. Startup control When the air conditioner starts in the cooling or heating mode, if the room temperature is ºC higher than the set temperature (in cooling operation) or.ºc lower (in heating operation), the air conditioner operates with the operating frequency at maximum. Then, when the set temperature is reached, the air conditioner operates at the operating frequency determined by fuzzy logic calculation, then enters the normal control mode after a while.. Peak control If the current flowing in the air conditioner exceeds the peak control current (see the table below), the operation frequency is decreased until the current value drops below the peak control current regardless of the frequency control demand issued from the indoor unit based on the room temperature. Peak control current Cooling operation Heating operation Approx. 0.0 A Approx..0 A. Outdoor unit fan delay control The compressor stops immediately after cooling, dehumidifying or heating operation is shut down, but the outdoor unit fan continues operation for 0 seconds before it stops.. Defrosting.. Reverse defrosting The defrost operation starts when the compressor operating time exceeds 0 minutes during heating operation, as shown below, and the outside air temperature and the outdoor unit heat exchanger temperature meet certain conditions. When the defrost operation starts, the indoor unit fan stops. The defrost operation stops when the outdoor unit heat exchanger temperature rises to about ºC or higher or the defrosting time exceeds 0 minutes. 0 min or more 0 min or more 0 min or more Start of heating operation. ON timer The ON timer can be activated by pressing the ON timer button. When the ON timer is activated, the operation start time is adjusted based on fuzzy logic calculations hour before the set time so that the room temperature reaches the set temperature at the set time.. OFF timer Defrosting Max. 0 min Defrosting Max. 0 min The OFF timer can be activated by pressing the OFF timer button. When the OFF timer is set, the operation stops after the set time. When this timer is set, the compressor operating frequency lowers for quieter operation, and the room temperature is gradually varied after one hour (reduced ºC three times (max. ºC) in heating, or increased 0.ºC three times (max. ºC) in cooling or dehumidifying operation) so that the room temperature remains suitable for comfortable sleeping. Heating operation Set temperature Activation of OFF timer Set temperature Activation of OFF timer 6. Power ON start hour later hour later - O C Cooling/dehumidifying operation - O C Max.. hours later 0. O C 0.O C 0.O C Max.. hours later - O C Max. hours later Max. hours later If a jumper cable is inserted in the location marked with HAJP on the indoor unit control printed circuit board (control PCB), connecting the power cord to an AC outlet starts the air conditioner in either cooling or heating mode, which is determined automatically by the room temperature sensor. When a circuit breaker is used to control the ON/OFF operation, please insert a jumper as described above. 7. Self-diagnostic malfunction code display Timer setting reached Timer setting reached 7.. Indoor unit ) When a malfunction is confirmed, all relays turn off and a flashing malfunction code number is displayed to indicate the type of malfunction. When the air conditioner is in non-operating condition, holding down the emergency operation switch for more than seconds activates the malfunction code display function. The operation continues only in the case of a serial open-circuit, and the main relay turns off after 0 seconds if the open-circuit condition remains. In the case of a serial short-circuit, the air conditioner continues operating without a malfunction code display, and the main relay turns off after 0 seconds if the short-circuit condition remains. The malfunction information is stored in memory, and can be recalled later and shown on display. ) The self-diagnostic memory can be recalled and shown on the display by stopping the operation and holding down the emergency operation button for more than seconds. ) The content of self-diagnosis (malfunction mode) is indicated by a flashing number. (For details, refer to the troubleshooting section.) 7.. Outdoor unit If a malfunction occurs, LED on the outdoor unit flashes in 0.-second intervals as shown below. (Example) Compressor high temperature abnormality ON OFF sec sec 0.6 sec 7

15 8. Information about auto mode In the AUTO mode, the temperature setting and mode are automatically selected according to the room temperature and outdoor temperature when the unit is turned on. Modes and Temperature Settings During operation, if the outdoor temperature changes, the temperature settings will automatically slide as shown in the chart. 9. Airflow control (Only for C) The airflow control holds the two upper and lower louvers at special positions during operation to prevent discharged air from directly blowing onto people in the room. 9.. Cooling/dehumidifying operation 9.. When the airflow button is pressed The upper louver is set at an upward angle to send the air along the ceiling. 9.. Heating the figures in ( ) are temperature settings 9.. When the airflow button is pressed The lower louver is positioned straight downward to send the air along the wall. The upper louver is set at a downward angle. 9.. Adjustment of Coanda-effect angle from remote control The louver direction can be finely adjusted to create a Coanda airflow when the upper and lower louvers are set to " " in cooling or dehumidifying operation, or to " " in heating operation. If it is difficult to produce a Coanda airflow along the ceiling in cooling operation because the air conditioner is not installed close to the ceiling or there is a beam or lighting fixture on the ceiling, or if it is difficult to produce a Coanda airflow along the wall in heating operation because furniture is located below the air conditioner, perform fine adjustment of the louver direction by following the procedure described below and obtain a desirable airflow. 9.. Adjustment of Coanda airflow direction in heating operation ) Set the operation mode to Heating and the Airflow Up/Down to " " using the remote control, and operate the air conditioner. ) With the remote control pointed away from the main unit to disallow signals from reaching the main unit, press the Stop button. ) When the Airflow Up/Down button is held down for more than seconds, the display shows " ". ) Now, the air conditioner is ready for adjustment of the Coanda airflow direction. Each pressing of the Airflow Up/Down button changes the display on the main unit in the order shown in the table below, and the louver direction changes accordingly. Adjust the direction while checking the actual louver angle and airflow direction. ) After the adjustment is completed, press the Stop button on the remote control. In heating operation Indication on main unit Louver correction angle 0 (Present position) Upward 0 Upward Downward 9.. Adjustment of Coanda airflow direction in cooling operation ) Set the operation mode to Cooling and the Airflow Up/Down to " " using the remote control, and operate the air conditioner. ) With the remote control pointed away from the main unit to disallow signals from reaching the main unit, press the Stop button. ) When the Airflow Up/Down button is held down for more than seconds, the display shows " ". ) Now, the air conditioner is ready for adjustment of the Coanda airflow direction. Each pressing of the Airflow Up/Down button changes the display on the main unit in the order shown in the table below, and the louver direction changes accordingly. Adjust the direction while checking the actual louver angle and airflow direction. ) After the adjustment is completed, press the Stop button on the remote control. In cooling operation Indication on main unit Louver correction angle 0 (Present position) Upward Upward Downward 0. Difference of operation in Auto and Manual modes In the Auto mode, the temperature setting is automatically determined based on the outside air temperature. In addition, the air conditioner operation differs from the operation in the Manual mode as explained below. 0.. Difference relating to set temperature Temperature setting method Temperature setting method Auto mode Cooling Heating Dehumidifying Automatic temperature setting based on outside air temperature. Can be changed within ±ºC using remote control. Manual mode Cooling Heating Dehumidifying Can be Can be Automatic setting. changed changed Can be between 8 between 8 changed within and ºC and ºC ±ºC. using remote using remote control. control. 7

16 . Limitation on operating frequency in heating operation If any of the following conditions is met minute after operation startup, the operating frequency is decreased to 90% in order to reduce the operating sound and save energy in exchange for room warming speed. ) First operation after power ON ) Outside air temperature is ºC or higher ) Room temperature is 0ºC or higher, or difference between set temperature and room temperature is ºC or less ) Current time is between 0:00 and 7:00 Note that the limitation is effective only for 60 minutes after operation startup.. Dehumidifying operation control If the room temperature is 6ºC or higher when dehumidifying operation starts, the dehumidifying operation provides a low cooling effect in accordance with the room temperature setting automatically determined based on the outside air operation. (The setting value is the same as the set temperature for cooling operation in the auto mode.) If the room temperature is lower than 6ºC when dehumidifying operation starts, the dehumidifying operation minimizes the lowering of the room temperature.. SELF CLEAN operation SELF CLEAN operation will provide efect to reduce the growth mold, and to dry inside of the air conditioner unit with Plasmacluster ions. Heating or Fan operation and Cluster operation are performed simultaneously. The judgment of whether Heating or Fan operation is used is based on the outside air temperature at minutes after the start of internal cleaning. The operation stops after 0 minutes. (The air conditioner shows the remaining minutes: ) Heating operation. Plasmacluster Ion function Fan operation O C Outside air temperature Operating the Plasmacluster Ion button while the air conditioner is in operation or in non-operation allows the switching of the operation mode in the following sequence: Cleaning operation Ion control operation Stop. Cleaning operation generates about equal amounts of (+)ions and (-)ions from the cluster unit to provide clean air. Ion balance operation generates more (-)ions than (+)ions from the cluster unit. If the Plasmacluster Ion generation function is operated together with the air conditioner operation, the indoor unit fan speed and louver direction are in accordance with the air conditioner settings. If the Plasmacluster Ion generation function is used without operating the air conditioning function, the indoor unit fan operates at a very low speed and the upper louver is angled upward and the lower louver remains horizontal. (The airflow volume and direction can be changed by using the remote control.). Hot keep When the room temperature rises above the set temperature by 0.6ºC or more, the ON/OFF operation of the compressor and indoor unit fan is controlled in order to lower the room temperature. (The values indicated below, such as "0.6ºC" and ".ºC," vary depending on the outside air temperature.). O C 0.6 O C Set temperature.. Hot keep zone With the compressor frequency at the lowest, if the room temperature is higher than the set temperature by 0.6ºC but no more than.ºc, the following processes will be activated. ) The compressor stops temporarily, and restarts after minutes. ) If the room temperature remains in the hot keep zone, the compressor is turned OFF and ON in -minute intervals. ) The indoor unit fan turns OFF and ON with a delay of 0 seconds from the compressor OFF/ON. ) After the above operation in -minute intervals is repeated four times, the interval extends to 6 minutes... Hot keep zone If the compressor ON/OFF in hot keep zone fails to bring the room temperature within.ºc above the set temperature, the following processes will be activated. ) The compressor repeats a cycle of 8-minute OFF and 6-minute ON. ) After the second time, the compressor remains completely OFF and only the indoor unit fan repeats OFF-ON in set intervals. ) While the compressor is completely OFF in ), the louvers are set horizontally to prevent cold air from blowing. The zone transition and the end of hot keep operation (room temperature lower than the set temperature) are judged when the compressor ON period ends. 6. Winter cool The air conditioner cannot be operated in the cooling mode during winter (low outside air temperature) in principle. However, by cutting the JP-WK (jumper wire) on the outdoor unit control printed circuit board (control PCB), cooling operation can be operated at a lower outside air temperature. When the outside air temperature is low, the outdoor unit fan operates at slower speed. 7. Auto restart When power failure occures, after power is recovered, the unit will automatically restart in the same setting which were active before the power failure. 7.. Operating mode (Cool, Heat, Dry) Temperature adjustment (within ºC range) automatic operation Temperature setting Fan setting Air flow direction Power ON/OFF Automatic operation mode setting Swing louvre Plasmacluster mode 7

17 7.. Setting not memorized Timer setting Full power setting Internal cleaning 7.. Disabling auto restart function By removing (cutting) jumper J (JPJ) on the printed circuit board (PCB), the auto restart function can be disabled. [] Explanation of cluster circuit The cluster unit generates cluster ions, which are circulated throughout the room by the air flow created by the blower fan (indoor unit fan motor) in the air conditioner unit. ) When microcomputer output turns "H," the IC6- output changes to "Lo," turning ON the SSR and applying 0 V to the cluster unit for the generation of cluster ions (positive and negative ions). ) When the SSR is ON, monitor voltage ( to. V) is applied to the microcomputer input. the monitor voltage is lower than 0. V or higher than. V for 0 consecutive minutes, an is detected and the cluster drive output (SSR) remains OFF until the operation is shut down. Note that the above condition will not cause the air conditioner to shut down in an mode, and the air conditioning operation continues. ) For a cluster mode change, microcomputer output changes to "H," and this sets the IC6- output to "Lo" and turns ON the Q8 (digital transistor). As a result, the relay inside the cluster unit is applied with V, and the internal relay turns ON. When the SSR is turned ON in this condition, more negative ions are generated to provide negative-ion-rich air. * Cluster mode switching is usually performed in the cluster OFF (SSR = OFF) status. AC Microcomputer output IC6- R7 R R0 V V SSR Q8 R76 C RE RN NF C8 8 Cluster unit 6 IC6- D 7 Microcomputer output Microcomputer input D D0 R C8 C9 R6 7

18 [] Outline of PAM circuit. PAM (Pulse Amplitude Modulation) The PAM circuit varies the compressor drive voltage and controls the rotation speed of the compressor. The IGBT shown in the block diagram charges the energy (electromotive force) generated by the reactor to the electrolytic capacitor for the inverter by turning ON and OFF. Reactor L DB 0 Noise filter Reactor L6 + IPM Compressor AC clock detection circuit DB IGBT IGBT drive circuit Overvoltage detection circuit Compressor position detector [PAM drive circuit] Microcomputer (IC) PAM drive circuit block diagram When the IGBT is ON, an electric current flows to the IGBT via the reactor (L) and diode bridge (DB). When the IGBT turns OFF, the energy stored while the IGBT was ON is charged to the voltage doubler capacitor via the diode bridge (DB). As such, by varying the ON/OFF duty of the IGBT, the output voltage is varied. DB Stored energy IGBT ON IGBT OFF L6 Reactor L DB IGBT 7 6

19 . High power factor control circuit This circuit brings the operating current waveform closer to the waveform of commercial power supply voltage to maintain a high power factor. Because of the capacitor input, when the PAM circuit is OFF, the phase of the current waveform deviates from the voltage waveform as shown below. To prevent this deviation, a current is supplied during the periods indicated by "O" in the diagram. To determine the length of period to supply a current, the zero-cross timing of the AC input voltage is input to the microcomputer via the clock circuit. The power source frequency is also determined at the same time. The IGBT turns ON after the time length determined by the zero-cross point to supply a current to the IGBT via the reactor. This brings the current waveform closer to the voltage waveform in phase. As described above, the ON/OFF operation of the IGBT controls the increase/decrease of the compressor power supply voltage (DC voltage) to improve the compressor efficiency and maintain a high power factor by keeping the current phase closer to that of the supply voltage. AC voltage waveform AC voltage waveform AC current waveform AC current waveform Zero-cross detection IGBT ON period AC voltage and current waveforms when PAM is OFF AC voltage and current waveform when PAM is ON.. Detailed explanation of PAM drive circuit sequence AC voltage waveform Clock A 0Hz 60Hz A.mS.0mS IGBT ON B C B C 00 S 00 S 0..mS 0..9mS.. AC clock (zero-cross) judgment The clock circuit determines the time from one rising point of the clock waveform to the next rising point. The detected clock waveform is used to judge the power source frequency (0/60 Hz). The zero-cross of the AC voltage is judged as the rising of the clock waveform, as shown in the diagram above... IGBT ON start time (delay time B) Based on the zero-cross of the AC voltage, the IGBT turns ON after a delay time set according to the power source frequency... IGBT ON time (C) After the above delay time, the IGBT turns ON to supply a current to the reactor. The ON time of the IGBT determines the amount of energy (level of DC voltage rise) supplied to the reactor. DC voltage level in each operation mode (varies depending on external load conditions) Cooling operation to 0 V Heating operation to 80 V 7 7

20 . PAM protection circuit To prevent excessive voltage of PAM output from damaging the IPM and electrolytic capacitor as well as the control printed circuit board (PCB), this circuit monitors the PAM output voltage and turns off the PAM control signal and PAM drive immediately when an abnormal voltage output is generated. At the same time, it shuts off the compressor operation. The PAM output voltage is distributed to pin () of the comparator (IC8). If this voltage exceeds the reference voltage at pin () of the IC8, the output of the comparator (IC8) reverses (from H to L) and it is input to pin (8) of the microcomputer (IC) to halt the PAM drive. The protection voltage level is as follows. 00uF C0 R K R 00K R7 0K R8 0K R K R 0KF R M IC8 (Overvoltage detection) R6 K IC During abnormal voltage output 8 Overvoltage V or higher.. Details of troubleshooting procedure for PAM.. PAM shutdown due to ) When the DC voltage detection circuit sends a signal exceeding the specified voltage to the microcomputer DC voltage of 0 V or higher (detection circuit input voltage of about 9. V or higher) [IC8 pin ()] When an is detected PAM IGBT turns OFF. Compressor turns OFF. All units shut down completely when the occurs four times. ) When the outdoor unit clock waveform differs from the specified value immediately before the PAM IGBT turns ON When there is no clock waveform input When a clock signal of other than specified power source frequency (0/60 Hz) is input When an is detected PAM IGBT does not turn ON. Compressor operates normally. Complete shutdown does not occur... PAM indication In case of ) An signal is sent to the indoor unit as soon as an is generated. Malfunction No. -0 is indicated when the code is called out by the indoor unit's self-diagnosis function. The LED on the outdoor unit flashes times when an is generated. The LED continues flashing in the -time cycle even after the compressor stops operating. The LED turns off (data is deleted from the memory) when the outdoor unit power is turned off. In case of ) An signal is sent to the indoor unit as soon as an is judged. Malfunction No. - is indicated when the code is called out by the indoor unit's self-diagnosis function. The LED on the outdoor unit flashes times when an is judged. The LED on the outdoor unit flashes in normal pattern when the compressor stops operating. (Compressor OFF or Thermostat OFF from remote control) * When a user complains that the air conditioner does not provide sufficient cool air or warm air In addition to conventional -generating reasons, there is a possibility that the PAM IGBT does not turn ON even if the compressor is operating. In that case, the DC voltage does not rise even though the compressor is operating, and lowers to the 80-VDC level. Check items Clock circuit check PAM IGBT check Fuse (Fu) open-circuit check 7 8

21 [] Explanation of IPM drive circuit The IPM for compressor drive is made by Mitsubishi Electric. The power supply for the IPM drive, the shunt resistance for overcurrent detection, etc., are provided outside the IPM (control PCB).. IPM drive power supply circuit The power supply for the upper-phase IGBT (HU, HV, HW) drive employs a bootstrap system, and provides power to the upper-phase IC. The -V power supply for the lower-phase IC is provided by the control printed circuit board (PCB)... Brief explanation of bootstrap system (single power drive system) To supply power to the upper-phase IC, the microcomputer (IC) turns ON the lower-phase IGBT (LU, LV, LW). This results in a charging current that flows to the electrolytic capacitor of each upper-phase IC input and charges the bootstrap capacitor with a -V current. The power supply for the subsequent stages is charged while the lower-phase IGBT is ON in ordinary compressor drive control. Initial charge period Charging current group P(Vcc) Bootstrap capacitor VDB (HU,HV,HW) HVIC High-voltage-withstanding, high-speed recovery diode U,V,W, VD (LU,LV,LW) LVIC N-side IGBT VCIN(n) N(GND Bootstrap circuit 7 9

22 .. DC overcurrent detection circuit When a current of about A or higher flows through the shunt resistance (R9) on the control printed circuit board (PCB), the voltage at this resistance is input to IPM CIN pin (6). Then, the gate voltage of the lower-phase IGBT (LU, LV, LW) inside the IPM turns OFF to cut off the overcurrent. At the same time, an L output of about.8 ms is generated from IPM Fo pin (8), and this results in an L input to overcurrent detection input pin () of the microcomputer (IC) and turns OFF the PWM signal output (IC pins (9) through ()) to the IGBT gate. Protection circuit status SET RESET (Lower phase) Internal IGBT gate (About A) SC a Output current Ic (A) SC reference voltage Sense voltage relative to shunt resistance Delay by CR time constant circuit Error output Fo About.8 ms P Shunt resistance Overcurrent R9 N IC IPM overcurrent detection circuit CiN 6 FO 8 7 0

23 [] Compressor digital position detection. 0º energizing control (digital position detection control) This control system detects the digital position detection signal and adjusts the rate of acceleration/deceleration accordingly. The motor's induced voltage waveform is input to the comparator in the form of PWM-switched pulse waveform, and a position detection signal is generated as a reference voltage equaling / of 80 VDC. However, since there is no induced voltage waveform when the PWM waveform is OFF, the microcomputer performs internal processing so that detection is enabled only when it is ON. Based on the detected position signal, actual PWM waveform output timing is determined. Since it does not use a filter circuit, the detection accuracy is high. The microcomputer performs internal processing to cancel spike voltage during the regenerative process. Furthermore, even if the induced voltage is low, position detection is still possible, thus allowing sensor-less operation at low rotation speed in the initial stage of operation. This reduces the starting current and improves the IPM reliability. Terminal voltage waveform Reference voltage (/ of DC voltage) Spike voltage (cancelled) Comparator output waveform (Position signal waveform) 7

24 Air Service Market ECHAPTER Conditioner Manual8. FUNCTION AND OPERATION OF PROTECTIVE PROCEDURES [] Protection device functions and operations Function Operation Self-diagnosis result display Description Detection period Reset condition Indoor unit display Indoor unit Outdoor unit Indoor unit fan lock Operation stops if there is no input of rotation pulse signal from indoor unit fan motor for minute. Indoor unit fan rotation speed Indoor unit freeze prevention -way valve freeze prevention Indoor unit heat exchanger overheat shutdown Outdoor unit heat exchanger overheat shutdown 6 Compressor discharge overheat shutdown 7 Dehumidifying operation temporary stop 8 DC overcurrent Operation stops if rotation pulse signal from indoor unit fan indicates abnormally low speed (about 00 rpm or slower). Compressor stops if temperature remains below 0ºC for minutes. Compressor stops if temperature of outdoor unit -way valve remains below 0ºC for 0 continuous minutes during cooling or dehumidifying operation. Operating frequency lowers if indoor unit heat exchanger temperature exceeds overheat temperature during heating operation. Compressor stops if indoor unit heat exchanger temperature exceeds overheat temperature for 60 seconds at minimum frequency. Overheat temperature setting value indoor unit heat exchanger thermistor temperature: about to ºC Operation frequency lowers if outdoor unit heat exchanger temperature exceeds about ºC during cooling operation. Compressor stops if outdoor unit heat exchanger temperature exceeds about ºC for 0 seconds at minimum frequency. Operating frequency lowers if temperature of compressor chamber thermistor (TH) falls below about 0ºC. Compressor stops if temperature of compressor chamber thermistor (TH) remains at about 0ºC (for 0 seconds in cooling operation, or 60 seconds in heating operation) at minimum frequency. Compressor stops if outside air temperature thermistor is lower than about 6ºC during dehumidifying operation. Compressor stops if electric current of about 0 A ( A for AY- RSC) or higher flows in IPM. When indoor unit fan is in operation When indoor unit fan is in operation When in cooling or dehumidifying operation When in cooling or dehumidifying operation When in heating operation When in cooling or dehumidifying operation When compressor is in operation When in dehumidifying operation When compressor is in operation Operation OFF or ON Yes None Operation OFF or ON Yes None Automatic reset when heat exchanger temperature rises above freeze prevention temperature (ºC or higher) Automatic reset when temperature of -way valve rises above 0ºC. Automatic reset after safety period (80 sec). Automatic reset after safety period (80 sec). Automatic reset after safety period (80 sec). None None None Yes Yes None Yes Yes None Yes Yes None Yes Yes Automatic reset when outside air temperature rises above 6ºC. None Yes Yes Operation OFF or ON Yes Yes Yes 8

25 9 AC overcurrent 0 AC overcurrent in compressor OFF status AC maximum current AC current deficiency Thermistor installation or -way valve Compressor high temperature Outdoor unit heat exchanger thermistor short-circuit 6 Outdoor unit outside air temperature thermistor short-circuit 7 Outdoor unit suction thermistor short-circuit 8 Outdoor unit -way valve thermistor short-circuit 9 Outdoor unit heat exchanger thermistor open-circuit 0 Outdoor unit outside air temperature thermistor open-circuit Outdoor unit suction thermistor open-circuit Outdoor unit -way valve thermistor open-circuit Outdoor unit discharge thermistor open-circuit Operating frequency lowers if compressor AC current exceeds peak control current value. Compressor stops if compressor AC current exceeds peak control current value at minimum frequency. Indoor and outdoor units stop if AC current exceeds about A while compressor is in non-operation status. Compressor stops if compressor AC current exceeds 7 A. Compressor stops if operating frequency is 0 Hz or higher and compressor AC current is about.0 A or lower. Compressor stops if high and low values of temperatures detected by outdoor unit heat exchanger thermistor (TH) and -way valve thermistor (TH) do not match operating cycle. Compressor stops if compressor chamber thermistor (TH) exceeds about ºC, or if there is short-circuit in TH. Compressor stops if there is short-circuit in outdoor unit heat exchanger thermistor (TH). Compressor stops if there is short-circuit in outdoor unit outside air temperature thermistor (TH). Compressor stops if there is short-circuit in outdoor unit suction thermistor (TH). Compressor stops if there is short-circuit in outdoor unit -way valve thermistor (TH). Compressor stops if there is open-circuit in outdoor unit heat exchanger thermistor (TH). Compressor stops if there is open-circuit in outdoor unit outside air temperature thermistor (TH). Compressor stops if there is open-circuit in outdoor unit suction thermistor (TH). Compressor stops if there is open-circuit in outdoor unit -way valve thermistor (TH). Compressor stops if there is open-circuit in outdoor unit discharge thermistor (TH). When compressor is in operation When compressor is in non-operation When compressor is in operation When compressor is in operation minutes after compressor startup 8 Function Operation Self-diagnosis result display Description Detection period Reset condition Indoor unit Indoor unit Outdoor unit Serial signal Power relay turns OFF if indoor unit cannot receive serial signal from outdoor unit for 8 minutes. Compressor stops if outdoor unit cannot receive serial signal from indoor unit for 0 seconds. display Operation OFF or ON Yes Yes Yes Replacement of defective parts such as IPM Yes Yes Yes Operation OFF or ON Yes Yes Yes Operation OFF or ON Yes Yes Yes Operation OFF or ON Yes Yes Yes When in operation Operation OFF or ON Yes Yes Yes At compressor startup At compressor startup At compressor startup At compressor startup At compressor startup At compressor startup At compressor startup At compressor startup At compressor startup When in operation When in operation Operation OFF or ON Yes Yes Yes Operation OFF or ON Yes Yes Yes Operation OFF or ON Yes Yes Yes Operation OFF or ON Yes Yes Yes Operation OFF or ON Yes Yes Yes Operation OFF or ON Yes Yes Yes Operation OFF or ON Yes Yes Yes Operation OFF or ON Yes Yes Yes Operation OFF or ON Yes Yes Yes Operation OFF or ON (Automatic reset when less than 8 minutes) Reset after reception of serial signal Yes None None None None

26 Function Operation Self-diagnosis result display Description Detection period Reset condition Indoor unit Indoor unit Outdoor unit Compressor startup Compressor stops if compressor fails to start up. 6 Compressor rotation Compressor stops if there is no (at 0 input of position detection signal energizing) from compressor or input is abnormal. 7 Outdoor unit DC fan Operation stops if there is no input of rotation pulse signal from outdoor unit fan motor for 0 seconds. 8 PAM overvoltage Compressor stops if DC voltage is 0 V or higher. 9 PAM clock When power source frequency cannot be determined (at startup), or when power source clock cannot be detected for continuous second (at startup). The outdoor unit restarts four times before the indoor unit is displayed (complete shutdown). A single judgment results in the display of the indoor unit (complete shutdown). The outdoor unit restarts eight times before the indoor unit is displayed (complete shutdown). [] Air conditioner operation in thermistor. Indoor unit display At compressor startup Operation OFF or ON Yes Yes Yes Compressor operating Operation OFF or ON Yes Yes Yes at 0º energizing When outdoor unit fan is in operation Operation OFF or ON Yes Yes Yes When in operation Operation OFF or ON Yes Yes Yes At compressor startup, when in operation Compressor continues operation without stopping. None Yes Yes Item Mode Control operation Room temperature thermistor (TH) Heat exchanger thermistor (TH) Auto Operation mode judgment When resistance is low (temperature judged higher than actual) Cooling mode is activated even if room temperature is low. Cooling Frequency control Room becomes too cold. Dehumidifying Room temperature memory Frequency control Normal operation. Heating Frequency control Room does not become warm. Cooling Dehumidifying Heating Freeze prevention Cold air prevention Indoor unit evaporator may freeze. Cold air prevention deactivates too soon and cold air discharges. Short-circuit Cooling mode is activated in most cases. Air conditioner operates in full power even when set temperature is reached. Room temperature is stored in memory as.0ºc, and compressor does not stop. Hot keep status results immediately after operation starts. Frequency does not increase above 0 Hz (0 Hz). Indoor unit evaporator may freeze. Compressor operates at low speed or stops, and frequency does not increase. When resistance is high (temperature judged lower than actual) Heating mode is activated even if room temperature is high. Room does not become cool. Normal operation. Room becomes too warm. Compressor stops occasionally. Cold air prevention deactivates too slow. Open-circuit Heating mode is always activated. Compressor does not operate. Room temperature is stored in memory as 8.ºC, and compressor does not operate. Air conditioner operates in full power even when set temperature is reached. Compressor does not operate. Cold air prevention does not deactivate, and indoor unit fan does not rotate. 8

27 . Outdoor unit Item Mode Control operation Compressor chamber thermistor (TH) Heat exchanger thermistor (TH) Outside air temperature thermistor (TH) Suction pipe thermistor (TH) -way valve thermistor (TH) Cooling Dehumidifying Heating Cooling Dehumidifying Heating Auto Cooling Dehumidifying Heating Cooling Dehumidifying Heating Cooling Dehumidifying Heating Expansion valve control and compressor protection Outdoor unit heat exchanger overheat prevention Expansion valve control Defrosting Operation mode judgment Operation not affected Rating control Defrosting Expansion valve control Expansion valve control Expansion valve control Operation not affected When resistance is low (temperature judged higher than actual) Compressor operates, but room does not become cool or warm (expansion valve is open). Compressor operates at low speed or stops. Defrosting operation is not activated as needed, and frost accumulates on outdoor unit (expansion valve is closed). Cooling mode is activated even if room temperature is low. Normal operation. Defrosting operation is activated unnecessarily. Compressor operates, but room does not become cool (expansion valve is open). Compressor operates, but room does not become warm (expansion valve is open). Frost accumulates on indoor unit evaporator and room does not become cool (expansion valve is closed). Normal operation. Short-circuit Compressor high temperature indication. Outdoor unit thermistor short-circuit indication. Outdoor unit thermistor short-circuit indication. Outdoor unit thermistor short-circuit indication. Outdoor unit thermistor short-circuit indication. Outdoor unit thermistor short-circuit indication. Outdoor unit thermistor short-circuit indication. Outdoor unit thermistor short-circuit indication. Outdoor unit thermistor short-circuit indication. Outdoor unit thermistor short-circuit indication. When resistance is high (temperature judged lower than actual) Layer short-circuit or open-circuit may result in compressor in normal operation. Normal operation. Defrosting operation is activated unnecessarily, and room does not become warm (expansion valve is open). Heating mode is activated even if room temperature is high. Normal operation. Defrosting operation is not activated, and frost accumulates on outdoor unit. Frost accumulates on evaporator inlet section, and room does not become cool (expansion valve is closed). Frost accumulates on expansion valve outlet section, and room does not become warm (expansion valve is closed). Compressor operates, but room does not become cool (expansion valve is open). Normal operation. Open-circuit Outdoor unit thermistor open-circuit indication. Outdoor unit thermistor open-circuit indication. Outdoor unit thermistor open-circuit indication. Outdoor unit thermistor open-circuit indication. Outdoor unit thermistor open-circuit indication. Outdoor unit thermistor open-circuit indication. Outdoor unit thermistor open-circuit indication. Outdoor unit thermistor open-circuit indication. Outdoor unit thermistor open-circuit indication. Outdoor unit thermistor open-circuit indication. 8

28 [] Thermistor temperature characteristics. Indoor unit thermistor temperature characteristics K 00 CN CN Resistance (K ) Tester - + Tester 0 0 Heat exchanger thermistor TH (orange) Resistance at : k Room temperature thermistor TH (yellow) Resistance at : 0 k Temperature( ) TH Room temperature thermistor TH Heat exchanger thermistor Thermistor Room temperature Symbol TH (CN) Color Yellow Before measuring resistance, disconnect connectors as shown above. Heat exchanger TH (CN) Orange. Outdoor unit thermistor temperature characteristics Connector CN8 0 Connector CN K Resistance 00K (K ) 00K 00K 00K 0 0K Tester Tester Resistance Resistance at 0 (K ) 0K.7 k (In case of TH heat exchanger thermistor) Resistance at Resistance at.76 k 0K. k TH TH.8K.06K 0K.7K.8K.7K Temperature( ) Temperature( ) TH Compressor thermistor TH Heat exchanger thermistor TH Outdoor air temperature thermistor TH Suction thermistor TH -way valve thermistor Thermistor Compressor thermistor Heat exchanger thermistor Outdoor air temperature thermistor Suction thermistor -way valve thermistor No. TH TH TH TH TH Connector No. () - No. () No. () - No. () No. () - No. (6) No. (7) - No. (8) No. (9) - No. (0) Color Red Orange Green Black Yellow Before measuring resistance, disconnect connectors from PWB. 8

29 [] How to operate the outdoor unit independently. Cooling in 0 Hz fixed mode To operate the outdoor unit independently, short-circuit the sections indicated by arrows in the diagram below with an adapter, and apply 0 VAC between () and (N) on the terminal board of the outdoor unit. This allows the outdoor unit to be operated in cooling mode independently. (Do not operate the outdoor unit in this condition for an extended period of time.) (L) Connect with IC clip Test mode cooling at 0 Hz Short-circuit negative terminal of capacitor (C) and jumper wire (JP)usingICclip,etc. [] General troubleshooting chart. Indoor unit does not turn on Main cause Inspection method Normal value/condition Remedy Cracked PWB. Check visually. There should be no cracking in Replace PWB. (Cracked pattern) PWB or pattern. Open-circuit in FU (0 V, A), FU (0 V, A) Check melting of FU, FU. There should be no open-circuit. Replace PWB.. Indoor unit fan does not operate Main cause Inspection method Normal value/condition Remedy Open-circuit in heat exchanger Measure thermistor resistance See [Thermistor temperature Replace thermistor. thermistor (TH) (in heating operation) (dismount for check). characteristics] on page 8-. There should be no open-circuit Replace thermistor. or faulty contact. Disconnected heat exchanger thermistor (TH) (in heating operation) Inspect connector on PWB. Check thermistor installation condition. Thermistor should not be disconnected. Install correctly.. Indoor unit fan speed does not change Main cause Inspection method Normal value/condition Remedy Remote control not designed to allow fan speed change. Check operation mode. Fan speed should change except during dehumidifying operation, ventilation, light dehumidifying operation, internally normal operation Explain to user.. Remote control signal is not received Main cause Inspection method Normal value/condition Remedy Batteries at end of service life. Measure battery voltage.. V or higher (two batteries in Install new batteries. series connection) Batteries installed incorrectly. Check battery direction. As indicated on battery compartment. Install batteries in indicated direction. Lighting fixture is too close, or fluorescent lamp is burning out. Turn off light and check. Signal should be received when light is turned off. Change light position or install new fluorescent lamp. Use Sevick light (Hitachi). Check if Sevick light (Hitachi) is Signal may not be received Replace light or change position. used. sometimes due to effect of Sevick light. Operating position/angle is inappropriate. Operate within range specified in manual. Signal should be received within range specified in manual. Explain appropriate handling to user. Open-circuit or short-circuit in wiring of light receiving section. Check if wires of light receiving section are caught. Wires of light receiving section should not have any damage caused by pinching. Replace wires of light receiving section. 8 6

30 Main cause Inspection method Normal value/condition Remedy Defective light receiving unit. Check signal receiving circuit (measure voltage between terminals and of connector BCNB). Tester indicator should move when signal is received. Replace PWB. Dew condensation on light receiving unit.. Louvers do not move 6. There is noise in TV/radio 7. Malfunction occurs 8. Compressor does not start Check for water and rust. Signal should be received within range specified in manual. 9. Operation stops after a few minutes and restarts, and this process repeats Take moisture-proof measure for lead wire outlet of light receiving section. Main cause Inspection method Normal value/condition Remedy Caught in sliding section. Operate to see if louvers are caught in place. Louvers should operate smoothly. Remove or correct catching section. Disconnected connector (DCNC, DCND on relay PWB, louver motor side) Inspect connectors. Connectors or pins should not be disconnected. Install correctly. Contact of solder on PWB (connector section on PWB) Check visually. There should not be solder contact. Correct contacting section. Main cause Inspection method Normal value/condition Remedy Grounding wires not connected properly. Check grounding wire connections. Grounding wires should be connected properly. Connect grounding wires properly. TV/radio is placed too close to outdoor unit. Check distance between TV/radio and outdoor unit. If TV/radio is placed too close, it may become affected by noise. Move TV/radio away from outdoor unit. Other than above. Check for radio wave interference. (See page ) Main cause Inspection method Normal value/condition Remedy Malfunction caused by noise. Check for radio wave interference. (See page ) Main cause Inspection method Normal value/condition Remedy Erroneous inter-unit connection. Check wiring between indoor and Terminal board -N: 0 VAC, 0 Correct wiring. outdoor units. Hz Terminal board : serial signal Damaged IPM. Check IPM continuity. See [IPM check method] on page Replace IPM Dried-up electrolytic capacitor. Check electrolytic capacitor. See [Inverter electrolytic capacitor (C0) check method] on page 8-9. Replace electrolytic capacitor. Blown outdoor unit fuse. Power supply voltage is too low. Compressor lock. Check 0-A fuse. Check -A fuse. Measure power supply voltage during startup. Supply current and touch compressor cover (sound absorbing material) to check if operation starts. Fuse should not be blown. Replace fuse/diode bridge. Replace fuse. Replace outdoor unit PWB assembly. 0±0 VAC, 0 Hz Make sure that power supply voltage is 80 V or higher. Compressor should start normally. Apply external impact to compressor. Replace compressor. Main cause Inspection method Normal value/condition Remedy Dried-up electrolytic capacitor. Measure 80-VDC line voltage. 0 V or higher. Replace electrolytic capacitor. Layer short-circuit in expansion valve coil. Measure resistance. 6±Ω in each phase (at 0 C) Replace coil. CAUTION: If fuse FU/FU/FU (outdoor unit control circuit board) is blown, be careful of charging voltage in inverter electrolytic capacitor C0. To discharge stored electricity, unplug the power cord and connect the plug of a soldering iron (0AC, 0W) between the positive and negative terminals of inverter electrolytic capacitor C0. 8 7

31 [6] Malfunction (parts) check method. Procedure for determining defective outdoor unit IPM/compressor The following flow chart shows a procedure for locating the cause of a malfunction when the compressor does not start up and a DC overcurrent indication occurs. Connect power cord to AC outlet. Using remote control, operate air conditioner so that compressor starts. After about 0 seconds Is there 0 VAC between () and (N) on outdoor unit PCB? YES Is LED on outdoor unit flashing? NO NO Check inter-unit wiring. Check indoor unit PWB. Does LED remain lit? No (unlit) Is there 80 VDC between pins IPM () and (6)? NO Check posistor (PTC) (about 0 at ). Check IPM. Check fan motor. Check outdoor unit PCB. Check wiring. Check PAM IGBT (Q). YES YES YES Compressor starts up. Immediately after startup Serial signal. Check inter-unit wiring. Check indoor and outdoor unit PWBs. + V, + V on PWB. YES NO Disconnect expansion valve connector. Does LED indicate DC overcurrent? NO YES Replace outdoor unit PWB. Check compressor. /-way valve closed. Refrigerant shortage. Replace outdoor unit PWB. Replace expansion valve. YES + V on PWB. NO Replace outdoor unit PWB. Does LED indicate rotation? YES Outdoor unit PWB. / V display section. Voltage OK. YES Replace outdoor unit OK End. NO NO NO Normal Replace outdoor unit PWB. Replace compressor. 8 8

32 . Procedure for determining defective expansion valve Measure resistance in expansion valve coil. Normal resistance between red terminal of expansion valve lead wire and each terminal: about 6 (at 0 ) NO Checker LED (red) YES Insert checker shown at left into connector (CN) on control PWB, and operate air conditioner..6k.6k.6k.6k 6 Replace control PWB. NO Do LEDs on checker light in orderly sequence (lighting of LED => lighting of LEDs) Connector J.S.T. XAP-06V- Terminal SXA-00T-P0.6 YES If frost accumulates on -way valve after 0 to 0 minutes of cooling operation, then thermistors with yellow and black lead wires may be defective. Check these thermistors.. Diode bridge check method Turn off the power and let the inverter electrolytic capacitor (C0) discharge completely. Then use a tester and check continuity. When using a digital tester, the (+) and (-) tester lead wires in the table must be reversed. Needle-type tester Normal resistance value B (several M ) Value in ( ) is for digital tester.. Inverter electrolytic capacitor (C0) check method Turn off the power, let the inverter electrolytic capacitor (C0) discharge completely, and remove the capacitor from the control printed circuit board (PWB). First, check the case for cracks, deformation and other damages. Then, using a needle-type tester, check continuity. Determination of normal condition The tester needle should move on the scale and slowly returns to the original position. The tester needle should move in the same way when polarities are reversed. (When measurement is taken with the polarities reversed, the tester needle exceeds the scale range. Therefore, let the capacitor discharge before measurement.) 8 9

33 . IPM check method Turn off the power, let the large capacity electrolytic capacitor (C0) discharge completely, and dismount the IPM. Then, using a tester, check leak current between C and E. When using a digital tester, the (+) and (-) tester lead wires in the table must be reversed. Needle-type tester Normal resistance value Needle-type tester Normal resistance value (-) (+) (-) (+) P N U V W (several MΩ).. IPM internal circuit diagram U N V (several MΩ) W Values in ( ) are for digital tester. VUFB VUFS VP UP VVFB VVFS VP VP VWFB VWFS VP WP VPC VN UN VN WN FO VNC HVIC VCC VB IN HO COM VS HVIC VCC VB IN HO COM VS HVIC VCC VB IN HO COM VS LVIC VCC UN VN WN Fo GND UOUT VOUT WOUT VNO CIN CFO IGBT D IGBT D IGBT D IGBT D IGBT D IGBT6 D6 7 6 CFO CIN DIP-IPM 6 P U V W N [7] Outdoor unit check method After repairing the outdoor unit, conduct the following inspection procedures to make sure that it has been repaired completely. Then, operate the compressor for a final operation check.. Checking procedures No Item Check method Normal value/condition Remedy. Preparation Disconnect compressor cords (white, orange, red: wires) from compressor terminals, and connect simulated load (lamp used as load). Operate air conditioner in cooling or heating test operation mode. Inverter DC power supply voltage check Measure DC voltage between IPM pins () and (6). 80 VDC Replace control PWB. Replace diode bridge. Correct soldered section of Fasten tabs (T, T, T - T) on control PWB and IMP (U, V, W). (Repair solder cracks.) IPM circuit check Check that lamps (load) light. Check position detection voltage (+ V, V) on control PWB. Each voltage should be normal. All lamps (load) should light with same intensity. Replace control PWB. 8 0

34 No. Compressor check Measure compressor coil resistance (for each phase of U, V and W). Use multi-meter or digital tester capable of displaying two digits right of the decimal point (0.0Ω). Expansion valve check Measure expansion valve coil resistance. 6 Final check Turn off power, and connect compressor cords to compressor. Operate air conditioner. Measure DC voltage between IPM pins () and (6). Item Check method Normal value/condition Remedy. Troubleshooting of outdoor unit electric components Resistance value at 0 C Ω Each phase 6±Ω (at 0 C) Compressor should operate normally. 00 VDC or higher. Correct connections at compressor terminals. Replace compressor. Replace expansion valve. Replace control PWB. Replace outdoor unit thermistor. Replace compressor (in case of compressor lock). Does LED light? YES NO Is 0 V applied between and N on outdoor unit terminal board? NO YES Is voltage between IPM pins () and (6) 0 V or higher? YES NO / Short-circuit in DC fan motor Short-circuit in IPM Short-circuit in diode bridge Blown fuse Defective electrolytic capacitor Wire disconnection, PWB pattern damage Short-circuit in PAM IGBT (Q) Check indoor unit. Is switching power supply output of VDC, VDC produced? NO Defective switching power supply circuit Malfunction of -terminal regulator IC, IC Short-circuit in expansion valve coil Malfunction of transistor array IC7 Solder contact or other problems YES Is VDC output produced? NO Malfunction of -terminal regulator IC, IC YES Microcomputer oscillator Malfunction of microcomputer reset IC Malfunction of microcomputer Does LED flash? NO Malfunction of serial signal circuit Check wiring between indoor and outdoor units. YES Normal 8

35 . Caution in checking printed circuit boards (PWB).. Non-insulated control circuit The GND terminals of the low-voltage circuits (control circuits for microcomputer and thermistors and drive circuits for expansion valve and relays) on the control printed circuit board (PWB) are connected to the compressor drive power supply (80-VDC negative terminal). Therefore, exercise utmost caution to prevent electric shock. If a measuring instrument used for the test is grounded, its chassis (ground) has the same electric potential as the 0-V probe. Since non-insulated circuits have the following voltage potential difference from the ground, connection of the grounding wire results in a short-circuit between the 0-V line and the ground, thus allowing an excessive current to flow to the tester to cause damage. If the sheaths of the thermistor lead wires or expansion valve lead wires inside the outdoor unit become damaged due to pinching by the front panel or other metal parts or contacting a pipe, a high voltage can flow and destroy the circuits. To prevent these problems, carefully conduct assembly work. Terminal board Outdoor unit circuits Reactor Point (E) AC + - IPM M Ground 0-V line Point (F) Compressor motor 80-VDC line Ground voltage Voltage at point (E) V line 0-V line voltage (point (F)) Do not touch the cabinet or bring metal parts into contact with the cabinet. Danger!! Do not connect the grounding wire. Reason The oscilloscope (chassis ground) has the same electric potential as the 0-V probe. The entire electronic control section of the outdoor unit has a voltage potential difference from the ground as shown in the above diagram. When the oscilloscope is set up, the 0-V line and the ground voltage (ground) will be short-circuited, resulting in an excessive current flow to cause damage to the oscilloscope or indoor electric circuits. 8

36 [8] Troubleshooting guide. Self-Diagnosis Function and Display Mode To call out the content of the self-diagnosis memory, hold down the emergency operation button for more than seconds when the indoor unit is not operating. The number of indications displayed by the LEDs on the outdoor unit differs from that for the 00 cooling unit models (for detailed display of malfunction information). The display of malfunction No. differs from that of the 00 cooling unit models. To show detailed malfunction information, two types of numbers flash alternately. (example: "" "-0") ) The content of the self-diagnosis memory can be called out and displayed on the seven-segment display section on the indoor unit. (The data cannot be called out for display by the LED on the outdoor unit.) ) If the power cord is unplugged from the AC outlet or the circuit breaker is turned off, the self-diagnosis memory loses the stored data. a) The self-diagnosis display function of the indoor unit indicates the content of diagnosis by showing the main category (number) and the sub-category (-number) alternately in -second intervals on the seven-segment display section of the indoor unit. Example of self-diagnosis display on indoor unit:compressor high-temperature b) The self-diagnosis display function of the outdoor unit indicates the information by flashing LED on the outdoor unit according to the content of self-diagnosis. The self-diagnosis display function of the outdoor unit is active only for about to 0 minutes after self-diagnosis is performed during operation, and the display returns to normal condition after this display period. The content of self-diagnosis cannot be called out by the self-diagnosis display function of the outdoor unit. Example of self-diagnosis display on outdoor unit:compressor high-temperature ON OFF sec sec 0.6 sec sec 0.6 sec sec sec sec 0.6 sec sec 0.6 sec sec sec c) The content of diagnosis is transferred to the indoor unit via serial communication, but it does not trigger a complete shutdown operation. : Flashes in -sec intervals (normal), : On, : Off, : Flashes times in 0.-sec intervals (When LED on the outdoor unit flashes in -sec intervals, the outdoor unit is in normal condition.) Status of indoor/ outdoor units Subcategory Indoor/outdoor units in operation Indoor/outdoor units in complete shutdown Indication by LED on outdoor unit * Normal flashing Malfunction No. displayed on main unit display section * Main category Main category Content of diagnosis Inspection location/method Remedy Sub-category 0 0 Normal time -0 Outdoor unit thermistor shortcircuit Heat exchanger thermistor short-circuit - Outside temperature thermistor short-circuit - Suction thermistor short-circuit - -way valve thermistor short-circuit () Measure resistance of the outdoor unit thermistors. (TH to TH: Approx.. kω at C) () Check the lead wire of the outdoor unit thermistor for torn sheath and short-circuit. () No abnormality found in above inspections () and (). () Replace the outdoor unit thermistor assembly. () Replace the outdoor unit thermistor assembly. () Replace the outdoor unit control PWB assembly. 8

37 Status of indoor/ outdoor units Indoor/outdoor units in complete shutdown Indoor unit in operation Outdoor unit in temporary stop Indoor unit in operation Outdoor unit in temporary stop (Temporary stop for cycle protection) Indoor/outdoor units in complete shutdown Indication by LED on outdoor unit * Malfunction No. displayed on main unit display section * Main category Subcategory Main category times -0 Cycle temperature Compressor hightemperature - Temporary stop due to compressor discharge overheat * - Temporary stop due to outdoor unit heat exchanger overheat * - Temporary stop due to outdoor unit heat exchanger overheat * - Temporary stop due to -way valve freeze * times -0 Dry operation Temporary stop due to dehumidifying operation * times -0 Outdoor unit thermistor opencircuit Content of diagnosis Inspection location/method Remedy Sub-category Heat exchanger thermistor open-circuit - Outside temperature thermistor open-circuit - Suction thermistor open-circuit - -way valve thermistor open-circuit - Discharge thermistor open-circuit () Check the outdoor unit air outlet for blockage. () Check if the power supply voltage is 90 V or higher at full power. () Check the pipe connections for refrigerant leaks. () Measure resistance of the outdoor unit compressor thermistor. (TH: Approx. kω at C) () Check the expansion valve for proper operation. (Temporary stop for cycle protection) (Temporary stop for cycle protection) (Temporary stop for cycle protection) (Temporary stop for cycle protection) () Check connector CN8 of the outdoor unit thermistor for secure installation. () Measure resistance of outdoor thermistors TH to TH. () Check the lead wires of thermistors TH through TH on the outdoor unit control PWB for open-circuit. () No abnormality found in above inspections () through (). () Ensure unobstructed air flow from the outdoor unit air outlet. () Connect power supply of proper voltage. () Charge the specified amount of refrigerant. () Replace the outdoor unit compressor thermistor assembly. () Replace the expansion valve coil, expansion valve or outdoor unit control PWB assembly. () Correct the installation. () Replace the outdoor unit thermistor assembly. () Replace the outdoor unit thermistor assembly. () Replace the outdoor unit control PWB assembly. 8

38 Status of indoor/ outdoor units Indoor/outdoor units in complete shutdown () Replace the compressor. Indoor/outdoor units in complete shutdown Indoor/outdoor units in complete shutdown Indication by LED on outdoor unit * Malfunction No. displayed on main unit display section * Main category Subcategory Main category 6 times 6-0 Outdoor unit DC DC overcurrent () IPM continuity check () Replace the outdoor unit control PWB assembly. () Check the IPM and heat sink for secure installation. () Check the outdoor unit fan motor for proper rotation. () No abnormality found in above inspections () through (). () No abnormality found in above inspections () through (). 7 times 7-0 Outdoor unit AC AC overcurrent () Check the outdoor unit air outlet for blockage. - AC overcurrent in OFF status - AC maximum current - AC current deficiency 9 times 9-0 Outdoor unit cooling/heating switchover Content of diagnosis Inspection location/method Remedy Sub-category Thermistor installation or -way valve () Check the outdoor unit fan for proper rotation. () Correct the installation (tighten the screws). () Replace the outdoor unit fan motor. () Replace the outdoor unit control PWB assembly. () Ensure unobstructed air flow from the outdoor unit air outlet. () Check the outdoor unit fan motor. () IPM continuity check () Replace the outdoor unit control PWB assembly. () Check the outdoor unit air outlet for blockage. () Check the outdoor unit fan for proper rotation. () Check if there is an opencircuit in the secondary winding of the current transformer of the outdoor unit control PWB. () Check if the refrigerant volume is abnormally low. () Check if the refrigerant flows properly. () Check to make sure outdoor unit thermistor TH (heat exchanger) and TH (-way valve) are installed in correct positions. () Measure resistance of thermistors TH and TH. () Check the -way valve for proper operation. () No abnormality found in above inspections () through (). () Ensure unobstructed air flow from the outdoor unit air outlet. () Check the outdoor unit fan motor. () Replace the outdoor unit control PWB assembly. () Charge the specified amount of refrigerant. () Correct refrigerant clogs. (-way valve, -way valve, pipe, expansion valve) () Correct the installation. () Replace the thermistor assembly. () Replace the -way valve. () Replace the outdoor unit control PWB assembly. 8

39 Status of indoor/ outdoor units Indoor/outdoor units in complete shutdown () Check connector CN of the outdoor unit DC fan motor for secure installation. Indoor/outdoor units in complete shutdown () Replace the compressor. Indoor/outdoor units in complete shutdown Indoor/outdoor units in operation Indoor unit in operation Outdoor unit in complete shutdown Indication by LED on outdoor unit * Malfunction No. displayed on main unit display section * Main category Subcategory Main category times -0 Outdoor unit DC fan Outdoor unit DC fan rotation times -0 DC compressor Compressor startup times -0 Outdoor unit PAM - Compressor rotation (0 energizing ) PAM overvoltage Compressor rotation 8 6 () Check the outdoor unit fan motor for proper rotation. () Correct the installation. () Replace the outdoor unit fan motor. () Check fuse FU. () Replace the outdoor unit control PWB assembly. () Outdoor unit control PWB () Replace the outdoor unit control PWB assembly. () Check the colors (red, white, orange) of the compressor cords for proper connection. (PWB side, compressor side) () Check if the IPM terminal resistance values are uniform. () No abnormality found in above inspections () and (). () No abnormality found in above inspections () through (). () Check the AC power supply voltage for fluctuation. () No abnormality found in above inspection (). - PAM clock () Check the PAM clock for proper input. 7-0 Wires between units Content of diagnosis Inspection location/method Remedy Sub-category Serial open-circuit () Check the wires between units. () Check voltage between Nos. and on the indoor/ outdoor unit terminal boards. Outdoor unit does not () Check the wires between turn on due to erroneous wiring () Check the outdoor unit units. fuse. () Check -V, -V and -V voltages on the PWB. Check resistance between IPM terminals. () Check pins No. and 7 of connector CN of the outdoor unit fan motor for short-circuit. () Correct the installation. (U: Red, V: White, W: Orange) () Replace the outdoor unit control PWB assembly. () Replace the outdoor unit control PWB assembly. () Connect stable power supply. () Replace the outdoor unit control PWB assembly. () Replace the outdoor unit control PWB assembly. () Connect stable power supply. () Replace the outdoor unit control PCB assembly. () Correct the wiring. () Replace the fuse/outdoor unit control PCB assembly. () Replace the outdoor unit control PCB assembly. () Replace the outdoor unit fan motor. () Outdoor unit control PCB () Replace the outdoor unit control PCB board. 8-0 Serial short-circuit () Check the wires between units. () Correct the wiring. - Serial erroneous wiring () Check the wires between units. () Correct the wiring.

40 Status of indoor/ outdoor units Indoor/outdoor units in complete shutdown 9-0 Indoor unit fan Indoor unit fan () Check the indoor fan motor for proper rotating operation.(check fan lock.) () Check the lead wire of the indoor fan motor for opencircuit. () Check CN of the indoor unit fan motor for secure installation. () No abnormality found in above inspections () through (). Indoor/outdoor units in operation Indoor/outdoor units in operation Indication by LED on outdoor unit * Malfunction No. displayed on main unit display section * Main category Subcategory Main category 0-0 Indoor unit control PCB 88 Control and display PCBs Malfunction indications due to erroneous wiring during air conditioner installation Content of diagnosis Inspection location/method Remedy Sub-category () Replace the indoor fan motor. () Replace the indoor fan motor. () Correct the installation of CN of the indoor fan motor. () Replace the indoor unit control PWB. EEPROM data (EEPROM read data ) Replace the indoor unit control PWB. Communication () Check for disconnected connector between control PCB and display PCB, and open-circuit in lead wires. () Check that control PCB outputs signals correctly. () Insert connectors correctly, or replace control PWB. () Replace control PWB. Inter-unit wiring mode Indoor unit relay Malfunction diagnosis display Indoor Outdoor unit unit Indoor unit relay Malfunction diagnosis display Indoor Outdoor unit unit Indoor unit relay Malfunction diagnosis display Indoor Outdoor unit unit Indoor unit relay Malfunction diagnosis display Indoor Outdoor unit unit Indoor unit relay Malfunction diagnosis display Indoor Outdoor unit unit Symptom Turns On momentarily, then turns Off. "8-" Relays turns Off after about 0 minutes. None (Displays "8-0" when malfunction code is called out.) Relays turns Off after about 0 minutes. None (Displays "8-0" when malfunction code is called out.) Turns On momentarily, then turns Off. "8-" Turns On momentarily, then turns Off. "8-" 8 7

41 Air Service Market ECHAPTER Conditioner Manual9. REFRIGERATION CYCLE [] Flow for Refrigerant Indoor unit Evaporator Flare coupling Flare coupling -way valve Silencer -way valve Heating s Cooling Strainer Outdoor unit Accumulator Compressor Capillary tube B Expansion valve Coil Condenser C Reverse valve [] Standard conditions Indoor side Outdoor side Dry-bulb Temp. (ºC) Relative Humidity (%) Dry-bulb Temp. (ºC) Relative Humidity (%) Cooling Heating * REFRIGERANT PIPE LENGTH 7.m [] Temperature at each part and pressure in -way valve Model NO. Condition Cooling Heating way valve pressure (MPaG)

42 Air Service Market ECHAPTER Conditioner Manual0. PERFORMANCE CURVES NOTE ) Indoor fan speed: Hi ) Vertical adjustment louver ", Horizontal adjustment louver "front" ) Indoor air temp. : Cooling 7 C, Heating 0 C ) Power source :, 0Hz [] C. At Cooling. At Heating Input(W) Input(W) Cooling capacity(kw) Heating capacity(kw) Outside air temp.( C) Outside air temp.( C) 0

43 Air Service Market ECHAPTER Conditioner Manual. DISASSEMBLING PROCEDURE [] Disassembly of indoor unit Be sure to disconnect the power cord from the AC power outlet before starting the disassembly procedure. When reassembling the unit after repairing, be sure to install screws to their original positions. The screws used are not the same in specifications such as corrosion-resistant treatment, tip shape and length. After the air conditioner is repaired or parts are replaced, measure insulation resistance of the equipment using an insulation resistance meter. If the measured resistance is lower than MΩ, inspect parts and repair or replace defective parts. ) Open the front panel. ) Disconnect the VA wires. ) Remove the cord clamp retaining screw (). ) Open the horizontal louver cover. ) Remove the cord clamp. 6) Remove the horizontal louvers.( pieces)

44 7) Remove the air filters. )Remove the control box cover retaining screw (), and remove the control box. 8) Remove the front panel retaining screws (). )Remove the light receiving unit retaining screw (). 9) Disengage the hook on the back side (indicated with "O" in the diagram below), and dismount the front panel. 0)Remove the ground wiring fixed screw (). )Open the 6 tabs on the lead wire guide.

45 )Disconnect the Display PWB connector. 8)Remove the thermistor. )Remove the Display PWB. 9)Remove the control box. 6)Remove the control box retaining screw. 0)Remove the dew cover. )Remove the side panel L and drain pan retaining screws (). 7)Disconnect the connectors ([fan motor / cluster / louver motor] x, rimit switch).

46 )Remove the screw cover of the drain pan. 7)Dismount the drain pan. )Remove the drain pan retaining screws (). 8)Then, disengage the left side. )Remove the cluster holder retaining screws (). )Remove the cluster holder. 9)Remove the heat exchanger retaining screws (). 6)Dismount the cluster ( tabs). 0)Disengage the heat exchanger.

47 )Remove the motor cover retaining screws (). )Disengage the horizontal louver cover (hinge). Move the cover to the position shown in the diagram, then pull it to detach.