Airwell FLO 9 DCI Service Manual
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Airwell FLO 9 DCI Service Manual

Flo 9/12 dci series indoor/outdoor units
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REFRIGERANT
R410A
SM FLODCI 1-A.1 GB
FLO 9 / 12 DCI Series
Indoor Units
FLO 9 DCI
FLO 12 DCI
NOVEMBER – 2008
CONTENTS
Outdoor Units
GC 9 DCI
GC 12 DCI
HEAT PUMP

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Summary of Contents for Airwell FLO 9 DCI

  • Page 1 FLO 9 / 12 DCI Series Indoor Units Outdoor Units FLO 9 DCI GC 9 DCI FLO 12 DCI GC 12 DCI REFRIGERANT R410A HEAT PUMP NOVEMBER – 2008 SM FLODCI 1-A.1 GB CONTENTS...
  • Page 2 LIST OF EFFECTIVE PAGES LIST OF EFFECTIVE PAGES Note: Changes in the pages are indicated by a “Revision#” in the footer of each effected page (when none indicates no changes in the relevant page). All pages in the following list represent effected/ non effected pages divided by chapters.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Table of Contents INTRODUCTION ....................1-1 PRODUCT DATA SHEET ..................2-1 RATING CONDITIONS ..................3-1 OUTLINE DIMENSIONS ..................4-1 PERFORMANCE DATA ..................5-1 PRESSURE CURVES ...................6-1 ELECTRICAL DATA ....................7-1 WIRING DIAGRAMS .....................8-1 REFRIGERATION DIAGRAMS ................9-1 10. TUBING CONNECTIONS ..................10-1 11. CONTROL SYSTEM .....................11-1 12.

  • Page 4: Main Features

    INTRODUCTION General The new FLO DCI split wall mounted range has expanded, comprising two additional RC (heat pump) models: FLO 9 DCI ● FLO 12 DCI ● The indoor FLO units are available as LED or LCD display types featuring esthetic design, compact dimensions, and low noise operation.

  • Page 5: Indoor Unit

    INTRODUCTION Indoor Unit The indoor unit is wall mounted, and can be easily fitted to many types of residential and commercials applications. FLO 9, 12 ● New design is available in LCD and LED versions. Old design is available in LED version only. Indoor Unit features: Feature FLO 9, 12...

  • Page 6: Outdoor Unit

    INTRODUCTION Control The microprocessor indoor controller, and an infrared remote control, supplied as standard, provide complete operating function and programming. Remote controllers: RC-2/3/4/5/7, RC-4i-1, RCW, μBMS. Networking system Airconet version 4.2 and up, MIU SW version H8 and up. For further details please refer to the Operational Manual, Appendix A. Outdoor Unit The FLO DCI INV outdoor units can be installed as floor or wall mounted units by using a wall supporting bracket.

  • Page 7: Introduction

    INTRODUCTION 1.11 Matching Table 1.11.1 R410A INDOOR UNITS OUTDOOR UNITS MODEL REFR FLO 9 DCI FLO 12 DCI K 9 DCI K 12 DCI √ √ GC 9 DCI R410A √ √ GC 12 DCI R410A The above table lists outdoor units and FLO indoor units which can be matched together. In addition the listed outdoor units can be matched with other types of indoor units such as cassettes.

  • Page 8: Product Data Sheet

    PRODUCT DATA SHEET PRODUCT DATA SHEET FLO 9 / GC 9 DCI Model Indoor Unit FLO 9 DCI Model Outdoor Unit GC 9 R410A Installation Method of Pipe Flared Characteristics Units Cooling Heating Btu/hr 8530(4780-12280) 11600(5120-17060) Capacity (4) 2.5(1.4-3.6) 3.4(1.5-5.0) Power input (4) 0.595(0.42-1.0)
  • Page 9 PRODUCT DATA SHEET FLO 12 / GC 12 DCI Model Indoor Unit FLO 12 DCI Model Outdoor Unit GC 12 DCI R410A Installation Method of Pipe Flared Characteristics Units Cooling Heating Btu/hr 11940(4780-14670) 14670(5100-19790) Capacity (4) 3.5(1.4-4.3) 4.3(1.5-5.8) Power input (4) 0.99(0.42-1.25) 1.125(0.39-1.75) EER (Cooling) or COP(Heating) (4)

  • Page 10: Rating Conditions

    RATING CONDITIONS RATING CONDITIONS Rating conditions in accordance with ISO 5151 and ISO 13253 (for ducted units). Cooling: Indoor: C DB 19 C WB Outdoor: 35 C DB Heating: Indoor: C DB Outdoor: 7 C DB 6 C WB Operating Limits 3.1.1 R410A Indoor...
  • Page 11 OUTLINE DIMENSIONS OUTLINE DIMENSIONS Indoor Unit: FLO 9 / 12 DCI Outdoor Unit: GC 9 / 12 DCI SM FLODCI 1-A.1 GB CONTENTS...

  • Page 12: Performance Data

    PERFORMANCE DATA PERFORMANCE DATA FLO 9 DCI 5.1.1 Cooling Capacity (kW) - Run Mode ID COIL ENTERING AIR DB/WB TEMPERATURE [ºC] OD COIL ENTERING AIR DB DATA 22/15 24/17 27/19 29/21 32/23 TEMPERATURE 80 - 110 % of nominal -10 - 20...
  • Page 13 PERFORMANCE DATA 5.1.3 Heating Capacity (kW) - Run Mode) ID COIL ENTERING AIR DB TEMPERATURE [ºC] OD COIL ENTERING AIR DB/WB DATA TEMPERATURE [ºC] 2.16 2.01 1.86 -15/-16 0.49 0.54 0.58 2.41 2.26 2.11 -10/-12 0.59 0.64 0.68 2.59 2.44 2.29 -7/-8 0.66...
  • Page 14 PERFORMANCE DATA Capacity Correction Factor Due to Tubing Length 5.2.1 Cooling 1.01 1.00 0.99 0.98 0.97 0.96 0.95 0.94 0.93 0.92 0.91 9 10 11 12 13 14 15 16 17 18 19 20 Tubing Length [m] 5.2.2 Heating 1.02 1.00 0.98 0.96...
  • Page 15 PERFORMANCE DATA FLO 12 DCI 5.3.1 Cooling Capacity (kW) - Run Mode ID COIL ENTERING AIR DB/WB TEMPERATURE [ºC] OD COIL ENTERING AIR DB DATA 22/15 24/17 27/19 29/21 32/23 TEMPERATURE [ºC] 80 - 110 % of nominal -10 - 20 80 - 105 % of nominal (protection range) 25 - 50 % of nominal...
  • Page 16 PERFORMANCE DATA 5.3.3 Heating Capacity (kW) - Run Mode ID COIL ENTERING AIR DB TEMPERATURE [ºC] OD COIL ENTERING AIR DB/WB DATA TEMPERATURE [ºC] 2.74 2.55 2.35 -15/-16 0.68 0.74 0.81 3.05 2.86 2.66 -10/-12 0.81 0.88 0.95 3.28 3.09 2.90 -7/-8 0.92...
  • Page 17 PERFORMANCE DATA Capacity Correction Factor Due to TUbing Length 5.4.1 Cooling 1.01 1.00 0.99 0.98 0.97 0.96 0.95 0.94 0.93 0.92 0.91 9 10 11 12 13 14 15 16 17 18 19 20 Tubing Length [m] 5.4.2 Heating 1.02 1.00 0.98 0.96...
  • Page 18 PRESSURE CURVES PRESSURE CURVES Model: FLO 9 DCI 6.1.1 Cooling - Test Mode Suction Pressure VS. Outdoor Temp' Indoor DB/WB 1400 Temp. 1300 22/15 1200 24/17 1100 27/19 1000 29/21 32/23 Outdoor Temp.(°C DB) Discharge Pressure VS. Outdoor Temp' 4000...
  • Page 19 PRESSURE CURVES 6.1.2 Heating - Test Mode Suction Pressure VS. Outdoor Temp' 1300 Indoor DB 1200 Temp' 1100 1000 Outdoor Temp.(°C WB) Discharge Pressure VS. Outdoor Temp' 3500 3250 Indoor DB 3000 Temp' 2750 2500 2250 2000 1750 1500 1250 1000 Outdoor Temp.(°C WB) SM FLODCI 1-A.1 GB...

  • Page 20: Pressure Curves

    PRESSURE CURVES Model: FLO 12 DCI 6.2.1 Cooling - Test Mode Suction Pressure VS. Outdoor Temp' Indoor DB/WB 1400 Temp. 1300 22/15 1200 1100 24/17 1000 27/19 29/21 32/23 Outdoor Temp.(°C DB) Discharge Pressure VS. Outdoor Temp' 4000 Indoor DB/WB 3750 Temp.
  • Page 21 PRESSURE CURVES 6.2.2 Heating - Test Mode Suction Pressure VS. Outdoor Temp' 1300 Indoor DB 1200 Temp' 1100 1000 Outdoor Temp.(°C WB) Discharge Pressure VS. Outdoor Temp' Indoor DB 4000 3750 Temp' 3500 3250 3000 2750 2500 2250 2000 1750 1500 Outdoor Temp.(°C WB) SM FLODCI 1-A.1 GB...

  • Page 22: Electrical Data

    ELECTRICAL DATA ELECTRICAL DATA Single Phase Unit Model FLO 9 DCI FLO 12 DCI Power Supply 1 PH ,220-240VAC ,50HZ Connected to Indoor Maximum Current Inrush Current \ Starting Current\ Circuit Breaker Power Supply wiring no. x cross section 3 X 1.5 mm²...

  • Page 23: Wiring Diagrams

    WIRING DIAGRAMS WIRING DIAGRAMS FLO 9 / 12 DCI SM FLODCI 1-A.1 GB CONTENTS...

  • Page 24: Refrigeration Diagrams

    REFRIGERATION DIAGRAMS REFRIGERATION DIAGRAMS Heat Pump Models 9.1.1 FLO 9 / 12 DCI: Cooling Mode OUTDOOR UNIT INDOOR UNIT Sensor Sensor Flared Valves connection Reverse valve Indoor coil Strainer Strainer Outdoor coil 9.1.2 FLO 9 / 12 DCI: Heating Mode OUTDOOR UNIT INDOOR UNIT Sensor...

  • Page 25: Tubing Connections

    TUBING CONNECTIONS TUBING CONNECTIONS TUBE (Inch) ¼’’ ’’ TORQUE (Nm) Flare Nuts 11-13 40-45 13-20 13-20 Valve Cap Service Port Cap 11-13 11-13 10-1 SM FLODCI 1-A.1 GB CONTENTS...

  • Page 26: Control System

    CONTROL SYSTEM CONTROL SYSTEM 11.1 General Functions and Operating Rules The DCI software is fully parametric. All the model dependent parameters are shown in Blue color and with Italic style [parameter]. The parameters values are given in the last section of this control logic chapter of the service manual.
  • Page 27 CONTROL SYSTEM Target frequency limits as a function of outdoor air temperature )OAT(: OAT Range Cool mode limits Heat mode limits < 6 No limit MaxFreqAsOATC 6 ≤ OAT < 15 MaxFreqAsOAT1H 15 ≤ OAT < 24 MaxFreqAsOAT2H 24 ≤ OAT No limit 11.1.4 Frequency Changes Control...
  • Page 28 CONTROL SYSTEM 11.1.8 Heating Element Control Heating element can be started if LOAD > * Maxi mumNLOAD AND Indoor Coil temperature <45. The heating element will be stopped when LOAD < MaximumNLOAD OR if Indoor Coil Temperature > 11.1.9 Outdoor Fan Control 7 outdoor fan speeds are determined for each model.

  • Page 29: Fan Mode

    CONTROL SYSTEM 11.1.13 Electro Static Filter )ESF( Control ESF is on when ESF switch is on, Safety switch is pressed, unit is on, AND indoor fan is on. 11.1.14 Base Heater Control When OAT is connected, Base Heater will be on when unit is in heating and OAT<2 When OAT is disconnected, Base Heater will be on when unit is in heating.

  • Page 30: Dry Mode

    CONTROL SYSTEM 11.4.2 Indoor Fan Control in Heat Mode Indoor fan speed depends on the indoor coil temperature: ICTST ICTVL ICTL ICTH ICTT 11.5 Auto Cool/Heat Mode When in auto cool heat mode unit will automatically select between cool and heat mode according to the difference between actual room temperature and user set point temperature )ΔT(.
  • Page 31 CONTROL SYSTEM 11.7.2 Indoor Coil over Heating Protection ICT Trend Fast Decreasing No Change Increasing Fast Decreasing Increasing > 53 <ICT ≤ 55 49 < ICT ≤ 53 47 < ICT ≤ 49 45 < ICT ≤ 47 Norm Norm 43 <...
  • Page 32 CONTROL SYSTEM 11.7.5 Heat Sink Over Heating Protection (NA for DCI 25 and 35) HST Trend Decreasing No Change Increasing > 90 85 < HST ≤ 90 82 < HST ≤ 85 80 < HST ≤ 82 78 < HST ≤ 80 Norm Norm HST ≤...
  • Page 33 CONTROL SYSTEM 11.7.6.2 Deicing Protection Procedure Threshold COMP max. 12 minutes HEAT COOL OFAN EEVDeicerOpen 36 seconds, T3 = 6 seco 11.8 Condensate Water Over Flow Protection Each of the pins P1, P2, P3 can have two options: 1 – When it is shorted with P4 0 –...
  • Page 34 CONTROL SYSTEM Water Level LEVEL4 LEVEL 3 LEVEL1 Pump NLOAD BLINK OPER LED NORMAL 11.8.2 1 Level Logic (used in all models except for floor/ceiling models) Level Don`t Normal care Don`t Overflow care Overflow when Overflow when unit is ON unit is OFF Overflow Water Level...
  • Page 35 CONTROL SYSTEM 11.10 Operating the Unit from the Mode Button Forced operation allows to start, stop and operate in Cooling or Heating, in pre-set temperature according to the following table: Forced operation Mode Pre-set Temperature Cooling Heating 11.11 On Unit Controls and Indicators 11.11.1 Indoor Unit Controller Controls and Indicators For All Models Except for Floor/Ceiling model...
  • Page 36 CONTROL SYSTEM 11.11.2 Indoor Unit Controls and Indicators for LCD Display STBY Cool Heat Auto SPT(1*) SPT(1*) SPT(1*) SPT(1*) SPT(1*) SPT(1*) OFF(2*) ON(2*) ON(2*) ON(2*) ON(2*) ON(2*) OFF(2*) OFF(2*) OFF(2*) OFF(2*) OFF(2*) OFF(2*) (Low) User User User User User (Med) setting setting setting...
  • Page 37 CONTROL SYSTEM 11.11.3 Indoor Unit Controller Controls and Indicators for Floor/Ceiling Model STANDBY Lights up when the Air Conditioner is connected to power and is ready INDICATOR for operation OPERATE 1. Lights up during operation. INDICATOR 2. Blinks for 300 msec., to announce that a R/C infrared signal has been received and stored.
  • Page 38 CONTROL SYSTEM 11.12 Jumper Setting 11.1 . Indoor Unit Controller 0 = Open Jumper (disconnect jumper). 1 = Close Jumper (connect jumper). Self test Jumper – J1 OPERATION SELF-TEST NORMAL Compensation Jumper – J2 Model J2 (Default) Compensation Wall Mounted Activated Floor/Ceiling Deactivated...

  • Page 39: Test Mode

    CONTROL SYSTEM Model selection Jumper – J7, J8 Model J9- Presence Detector/Power Shedding OPERATION Presence Detector Power Shedding Jumper – J10 OPERATION WNG DCI LCD 11.12.2 Outdoor Unit Controller JP9 JUMPER LAYOUT Reserved (PIN ODU3 (PIN 7) ODU2 (PIN 5) ODU1 (PIN 3) ODU0 (PIN 1) GND (PIN 10)
  • Page 40 CONTROL SYSTEM 11.13.2 Unit Operation in Test Mode In test mode, the unit will operate in fixed settings according to the indoor fan speed setting: Indoor Fan Speed Setting Unit Setting Minimum Capacity Setting High Nominal Capacity Setting Auto Maximum Capacity Setting During test mode, protections are disabled, except for stop compressor status.
  • Page 41 CONTROL SYSTEM 11.14.2 Outdoor Units SW Parameters Parameter Name DCI 9 DCI 12 DCI 18 DCI 50 DUO Compressor Parameters MinFreqC MaxFreqC MinFreqH MaxFreqH Step1Freq Step2Freq Step3Freq Frequency limits as a function of outdoor air temperature MaxFreqAsOATC MaxFreqAsOAT1H MaxFreqAsOAT2H Compressor Over Heating Protection CTTOH1 CTTOH2 CTTOH3...

  • Page 42: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING FLO 9 / 12 DCI Warning When Power Up – the whole outdoor unit controller, including the wiring, is under HIGH VOLTAGE Never open the Outdoor unit before turning off the PowerHIG When turned off, the system is still charged (400V)yle It takes about 4 Min.
  • Page 43 TROUBLESHOOTING SYMPTOM PROBABLE CORRECTIVE ACTION CAUSE Compressor is on but Problem with Check outdoor fan motor according outdoor fan does not outdoor electronics to the procedure in section 12.5.3 work or outdoor fan below, if not OK replace controller Unit works in wrong Electronics or Check RV power connections, if OK, mode )cool instead of...
  • Page 44 TROUBLESHOOTING 12.3 Judgment by Indoor/Outdoor Unit Diagnostics Enter diagnostics mode - press for five seconds Mode button in any operation mode. Acknowledgment is by 3 short beeps and lights of COOL and HEAT LEDs. Then, every short pressing of Mode button will scroll between Indoor and Outdoor unit diagnostic modes by the acknowledgment of 3 short beeps and lighting of COOL and HEAT LED s.
  • Page 45 TROUBLESHOOTING 12.3.2 Indoor unit diagnosis and corrective actions Probable Cause Corrective Action Fault Check sensor connections or Sensor failures of replace sensor. all types Indoor and Outdoor Replace Indoor controller. Communication controllers are with different mismatch Versions. No Communication Communication or grounding Check Indoor to Outdoor wiring is not good.
  • Page 46 TROUBLESHOOTING Problem OCT is disconnected OCT is shorted CTT is disconnected CTT is shorted HST is disconnected (when enabled) HST is shorted (when enabled) OAT is disconnected (when enabled) OAT is shorted (when enabled) TSUC is disconnected (when enabled) TSUC is shorted (when enabled) IPM Fault Bad EEPROM DC under voltage...
  • Page 47 TROUBLESHOOTING 12.3.4 Outdoor unit diagnosis and corrective actions Probable Cause Corrective Action Fault Sensors failures of all Check sensors types connections or replace sensors. IPM Fault Electronics HW Check all wiring and problem umper settings, if OK, replace electronics. Bad EEPROM No action, unless special parameters are required for unit operation.
  • Page 48 TROUBLESHOOTING 12.4 Judgment by MegaTool MegaTool is a special tool to monitor the system states. Using MegaTool requires: • A computer with RS232C port. • A connection wire for MegaTool. • A special MegaTool software. Use MegaTool according to following procedure: •...
  • Page 49 TROUBLESHOOTING 12.6 Precaution, Advise and Notice Items 12.6.1 High voltage in Outdoor unit controller. Whole controller, including the wires that are connected to the Outdoor unit controller may have the potential hazard voltage when power is on. Touching the Outdoor unit controller may cause an electrical shock.

  • Page 50: Exploded Views And Spare Parts Lists

    EXPLODED VIEWS AND SPARE PARTS LISTS EXPLODED VIEWS AND SPARE PARTS LISTS 13.1 Indoor Unit: FLO 9 / 12 DC INV sans ionizer / without ionizer SM FLODCI 1-A.1 GB 13-1 CONTENTS...

  • Page 51: R410A

    EXPLODED VIEWS AND SPARE PARTS LISTS 13.2 Indoor Unit: FLO 9 DC INV R410A 13-2 SM FLODCI 1-A.1 GB CONTENTS...
  • Page 52 EXPLODED VIEWS AND SPARE PARTS LISTS 13.3 Indoor Unit: FLO 12 DC INV R410A SM FLODCI 1-A.1 GB 13-3 CONTENTS...
  • Page 53 EXPLODED VIEWS AND SPARE PARTS LISTS 13.4 Outdoor Unit: GC 9 / 12 DC INV 13-4 SM FLODCI 1-A.1 GB CONTENTS...
  • Page 54 EXPLODED VIEWS AND SPARE PARTS LISTS 13.5 Outdoor Unit: GC 9 DC INV Spare parts code Replaced by Description Observation 433218 Front panel 4526340 Baflfe 4526476 Propeller d=401mm 4527092 Fan motor 433215 Motor support 4523060 Bottom 4526403 4526403R Outdoor controler 4524177 Gas valve 3/8 "...
  • Page 55 EXPLODED VIEWS AND SPARE PARTS LISTS 13.6 Outdoor Unit: GC 12 DC INV Spare parts code Replaced by Description Observation 433218 Front panel 4526340 Baflfe 4526476 Propeller d=401mm 4527092 Fan motor 433215 Motor support 4523060 Bottom 4526403 4526403R Outdoor controler 4524177 Gas valve 3/8 "...

  • Page 56: Appendix A

    APPENDIX A APPENDIX A INSTALLATION AND OPERATION MANUAL ► INSTALLATION MANUAL FLO 9 / 35 DCI ► OPERATING MANUAL FLO 9 / 35 DCI SM FLODCI 1-A.1 GB 14-1 CONTENTS...

This manual is also suitable for:

Flo 12 dciGc 12 dciGc 9 dci

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