Panasonic WH-MDC05F3E5 Service Manual
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Panasonic WH-MDC05F3E5 Service Manual

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Order No. PAPAMY1311029CE
Mono bloc Unit
WH-MDC05F3E5
Destination
Europe
WARNING
This service information is designed for experienced repair technicians only and is not designed for use by the general public.
It does not contain warnings or cautions to advise non-technical individuals of potential dangers in attempting to service a product.
Products powered by electricity should be serviced or repaired only by experienced professional technicians. Any attempt to
service or repair the products dealt with in this service information by anyone else could result in serious injury or death.
PRECAUTION OF LOW TEMPERATURE
In order to avoid frostbite, be assured of no refrigerant leakage during the installation or repairing of refrigerant circuit.
© Panasonic Corporation 2013.

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Summary of Contents for Panasonic WH-MDC05F3E5

  • Page 1 PRECAUTION OF LOW TEMPERATURE In order to avoid frostbite, be assured of no refrigerant leakage during the installation or repairing of refrigerant circuit. © Panasonic Corporation 2013.

  • Page 2: Table Of Contents

    12.3 Pump Down Operation [Service Mode: 01] .62 19. Exploded View and Replacement Parts List136 12.4 Flow Switch..........62 12.5 Indoor Unit Safety ........63 19.1 WH-MDC05F3E5 (Refrigerant System)... 136 12.6 Auto Restart Control ........63 19.2 WH-MDC05F3E5 (Water System)... 140 12.7 Indication Panel ...........63 12.8 Indoor Back-Up Heater Control ....64...

  • Page 3: Safety Precautions

    1. Safety Precautions  Read the following “SAFETY PRECAUTIONS” carefully before perform any servicing.  Electrical work and water installation work must be installed or serviced by a licensed electrician and licensed water system installer respectively. Be sure to use the correct rating and main circuit for the model installed. ...
  • Page 4 19. This equipment is strongly recommended to be installed with Residual Current Device (RCD) on-site according to the respective national wiring rules or country-specific safety measures in terms of residual current. 20. The unit is only for use in a closed water system. Utilization in an open water system may lead to excessive corrosion of the water piping and risk of incubating bacteria colonies, particularly Legionella, in water.

  • Page 5: Specifications

    2. Specifications WH-MDC05F3E5 Item Unit Refrigerant System Performance Test Condition EN 14511 Condition (Ambient/Water) A35W7 4.50 Cooling Capacity BTU/h 15300 kcal/h 3870 3.33 kcal/hW 2.87 Condition (Ambient/Water) A7W35 A2W35 5.00 4.80 Heating Capacity BTU/h 17100 16400 kcal/h 4300 4130 5.08 3.75...
  • Page 6 Item Unit Mono Bloc Unit Power Supply 1: Phase (ø) / Max. Current (A) / Max. Input Power (W) Single / 19.5 / 4.26k Power Supply 2: Phase (ø) / Max. Current (A) / Max. Input Power (W) Single / 13.0 / 3.00k Power Supply 3: Phase (ø) / Max.

  • Page 7: Features

    3. Features  Inverter Technology - Energy saving  High Efficiency  Compact Design  Environment Protection - Non-ozone depletion substances refrigerant (R410A)  Easy to use control panel - Auto mode - Holiday mode - Dry concrete function - Weekly timer setting ...

  • Page 8: Location Of Controls And Components

    4. Location of Controls and Components Mono Bloc Unit Air inlet (rear) Top Plate Air inlet (side) Cabinet Front Plate Air outlet Handle (2 pieces front and 2 pieces behind)
  • Page 9 4.1.1 Main Components (VIEW WITHOUT COVER) (VIEW WITHOUT PCB) DETAIL B DETAIL A View without cabinet top plate Component name Connector name Water inlet Cabinet top plate Pressure relief valve Overload protector Water outlet Flow switch Heater assembly Pressure gauge Expansion vessel Water pump Cover...

  • Page 10: Remote Control

    4.1.2 Location of Control 4.1.2.1 Remote Control The user interface allows the installer and user to setup, use and maintain the unit. 　 OFF/ON Button This button starts or stops the mode operation function of the unit. 11 12 Operation LED This LED indicates the unit is in operation.
  • Page 11 4.1.3 To adjust initial settings Dealer Select menus and determine settings according to the system available in the household. It is recommended that all alterations of settings are done by an authorised dealer or specialist. Operation LED Display • After initial installation, you may manually adjust the settings. The initial setting remains active until the user changes it.

  • Page 12: Remote Control Preparation

    Operation/settings to be done only by the authorised dealer/specialist. Dealer Operation/settings to be done by the authorised dealer/specialist or user. User Booster Heater To activate or deactivate the water tank’s booster heater. Note: If NO is selected, menu 11 is skipped. Booster Heater Delay Timer 20 minutes ~ To delay time for the booster heater to activate while the system is heating up...
  • Page 13 4.1.4 How to use User The system is turned off by an external switch. Turn on or off the system Press When the system is ON, the operation LED is lit and the actual water outlet temperature and outdoor ambient temperature are shown on the display.
  • Page 14 Operation/settings to be done only by the authorised dealer/specialist. Dealer Operation/settings to be done by the authorised dealer/specialist or user. User Dealer Display Temperature setting System temperature setting The system controls the temperature for each menu based on the outdoor ambient temperature. •...

  • Page 15: Holiday Mode

    User Desired temperature setting Shifting the water temperature This easily shifts the water outlet temperature if the setting is undesirable. to enter the water temperature shifting mode. to change setting. to set the desired temperature. (temperature range: -5 °C ~ 5 °C) Temperature setting <Water outlet temperature>...

  • Page 16: Weekly Timer Setting

    Operation/settings to be done only by the authorised dealer/specialist. Dealer Operation/settings to be done by the authorised dealer/specialist or user. User User Weekly timer setting Promotes energy saving by allowing you to set up to 6 programmes in any given day. Lights up if Timer operation is selected Indicates the next timer operation programme...
  • Page 17 Dry Concrete Function • During construction to dry the concrete under a preset temperature. simultaneously and hold for 5 seconds until the display shows “ ”. (The display shows “ ”). to select day. Press to set the desired temperature. to confirm the selection.

  • Page 18: Dimensions

    5. Dimensions Mono bloc Unit <Top View> (579) (10) <Side view> <Front View> <Side View> 1283 (20) Unit: mm...

  • Page 19: Refrigeration And Water Cycle Diagram

    6. Refrigeration and Water Cycle Diagram Outdoor Side Mono bloc Unit Water Pressure Gauge Expansion Liquid Vessel Water Capillary Side Flow Expansion Tube (2-Way Switch Valve Strainer Strainer Valve) Water Inlet (Connect Receiver Water Pipe Pump Sanitary Temp. Tank) Sensor Pipe Pipe Temp.
  • Page 20 Indoor Side Room Thermo (Optional) Fan Coil Unit (Heating / Cooling) Connect to Mono bloc Unit Terminal Board (Water System) Panel Heater Unit (Heating) 3-Way Valve 2-Way Valve To Water Inlet Mono bloc Unit From Water Outlet Mono bloc Unit Floor Heating Panel (Heating) Heater 1 (3kW)

  • Page 21: Block Diagram

    7. Block Diagram...

  • Page 22: Wiring Connection Diagram

    8. Wiring Connection Diagram...

  • Page 24: Electronic Circuit Diagram

    9. Electronic Circuit Diagram...

  • Page 26: Printed Circuit Board

    10. Printed Circuit Board 10.1 Water System 10.1.1 Main Printed Circuit Board CN-SOLAR CN-TH1 CN-TH2 CN-TH3 CN-FLOW CN-T1 CN-OLP2 CN-REMOTE2 CN-THERMO CN-PUMP2 CN-OLP1 CN-RCV2 CN-V3 DATA CN-PWR AC1-L3 CN-V2 AC1-N CN-HT...
  • Page 27 10.1.2 Solar Printed Circuit Board (Optional)

  • Page 28: Refrigerant System

    10.2 Refrigerant System 10.2.1 Main Printed Circuit Board CN-EV CN-TH1 CN-DIS CN-HPS CN-TANK CN-PSW1 CN-HOT CN-HT2 CN-HT1 AC-BLK02 AC-WHT02 COM3 AC-L CN-FM1...
  • Page 29 10.2.2 Capacitor Printed Circuit Board DCN-OUT DCP-OUT DCP-IN DCN-IN 10.2.3 Noise Filter Printed Circuit Board CN-ACL CN-ACN...

  • Page 30: Installation Instruction Mono Bloc Unit

    11. Installation Instruction Mono bloc Unit Dimension Diagram Front view Rear view Bottom view Water Outlet Pipe Water Inlet Pipe Optional cord / cable :- • 2-way valve cable (3 × min 0.5mm *Cooling model only Type • 3-way Valve cable (3 × min 0.5mm designation •...
  • Page 31 Main Components (VIEW WITHOUT COVER) (VIEW WITHOUT PCB) DETAIL B DETAIL A View without cabinet top plate Component name Connector name Cabinet top plate Water inlet Pressure relief valve Overload protector Water outlet Flow switch Heater assembly Pressure gauge Expansion vessel Water pump Cover RCCB...

  • Page 32: Select The Best Location

    11.1 Select the Best Location 11.2 Mono Bloc Unit Installation  Mono bloc unit will become heavy when filled with Install Mono bloc unit at outdoor only.  water. Please install the unit on a strong concrete floor Avoid location where ambient temperature is and consider the weight of the unit and water.

  • Page 33: Piping Installation

    11.3 Piping Installation WARNING This section is for authorized and licensed electrician / water system installer only. Work behind the front plate secured by screws must only be carried out under supervision of qualified contractor, installation engineer or service person. Please engage a licensed water circuit installer to install this water circuit.

  • Page 34: Connect The Cord And Cable To Mono Bloc Unit

    Drainage piping installation  Use a drain hose with inner diameter of 15 mm.  The hose must be installed in a continuously downward direction and left open to the frost-free atmosphere.  If drain hose is long, use a metal support fixture along the way to eliminate the wavy pattern of drain tube. ...
  • Page 35 Bind all power supply cords to the U- Shaped tube (Cover with foam) with band strap (field supply) Bind all power Bind all power supply Mounting Screws supply cords cords to the cabinet to the tube plate with band strap with band (field supply) strap (field...
  • Page 36 * Cooling * Cooling model only model only Terminals on the Mono bloc unit 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Lead wire cord Tank OLP Tank External Booster Heater Two-way Valve Three-way Valve Room Thermostat Solar Three- way...

  • Page 37: Selecting The Installation Location

    (Select the intended feeding-out position) Medium-sized square outlet box (obtain locally) Route the remote control cable (2) inside the Part No. DS3744 (Panasonic Co., Ltd.) or lower case in accordance with the intended equivalent. feeding-out direction. (Refer to the illustration...

  • Page 38: Checking And Test Cord Run Procedures

    Insert firmly the connector of remote control (Refer illustration “How to connect Remote cable (2) to connector (CON1) in the upper Control to Provided Connector” for detail.) case circuit board. Reinstall the cabinet front plate after (Refer to the illustration at below) connection complete.

  • Page 39: Operation And Control

    12. Operation and Control 12.1 Basic Function Inverter control, which equipped with a microcomputer in determining the most suitable operating mode as time passes, automatically adjusts output power for maximum comfort always. In order to achieve the suitable operating mode, the microcomputer maintains the set temperature by measuring the temperature of the environment and performing temperature shifting.
  • Page 40 Heat Mode Operation Time Chart 3 ways valve 2 ways valve Open Close Heat Pump Backup Heater ID W ater Pump Solar Request Solar 3 way valve W ater Outlet Temp Tank Temp. Timer for backup Backup Heater Backup Heater heater to on back Startup Timer Startup Timer...

  • Page 41: Cooling Operation

    12.1.3 Cooling Operation 12.1.3.1 Thermostat control  Compressor is OFF when Water Outlet Temperature – Internal Water Setting Temperature > -1.5°C for continuously 3 minutes.  Compressor is ON after waiting for 3 minutes, if the Water Outlet Temperature – Water Inlet Temperature (temperature at thermostat OFF is triggered) >3°C.

  • Page 42: Auto Mode Operation

    12.1.4 Auto Mode Operation COOL MODE Heat To Cool Setting Temp. Cool To Heat Setting Temp. HEAT MODE Outdoor Ambient  Control details: To enable the unit to operate either heat or cool mode automatically, heat to cool set temperature and cool to heat set temperature can be set by control panel.
  • Page 43 12.1.5 Tank Mode Operation Control contents:  3 ways valve direction 3 ways valve switch to tank side during Tank Thermo ON condition. Switch 3 ways valve to room side when tank achieve Tank Thermo OFF temperature and SOLAR turn ON condition. ...
  • Page 44 57°C 57°C 57°C 57°C...
  • Page 46 12.1.6 Heat + Tank Mode Operation Setting 1: When Heating priority is set by control panel: 1. 3 ways valve control: o 3 ways valve switch to room side during External Room Thermo ON OR Solar 3 ways valve ON OR Tank Thermo OFF time, and switch to tank side at External Room Thermo OFF AND Solar 3 ways valve OFF.
  • Page 47 Characteristic of heat pump thermo ON/OFF under tank side condition Water Outlet Thermo condition Heat pump THERMO OFF TEMP: 1. Heat pump THERMO OFF TEMP = 53°C + [+4°C]. 2. Water outlet temperature > Heat pump THERMO OFF TEMP for continuous 90 seconds, heat pump OFF and water pump continue ON.
  • Page 48 Heat + Tank Mode (Heating priority set) Under Solar Priority Set Condition: Under Solar Priority Not Set Condition:...
  • Page 49 Setting 2: When heating priority is not set by control panel:  When Solar Priority is set/not set by control panel: 1. 3 ways valve control: 3 ways valve switch to room side during heating heat-up interval, and switch to tank side during tank heat-up interval.
  • Page 50 Characteristic of heat pump thermo ON/OFF under tank side condition Water Outlet Thermo condition Heat pump THERMO OFF TEMP: 1. Heat pump THERMO OFF TEMP = 53°C + [+4°C] 2. Water outlet temperature > Heat pump THERMO OFF TEMP for continuous 90 seconds, heat pump OFF but water pump continue ON.
  • Page 53 50°C 57°C 57°C 50°C...
  • Page 54 12.1.7 Cool + Tank Mode Operation 12.1.7.1 Cooling Priority SET 1. 3 ways valve control:  3 ways valve switch to room side during External Room Thermo ON OR Tank Thermo OFF time, and switch to tank side at External Room Thermo OFF AND Solar 3 ways valve OFF. 2.
  • Page 55 Characteristic of heat pump thermo ON/OFF under tank side condition a) Water Outlet Thermo Condition Heat pump THERMO OFF TEMP: 1. Heat pump THERMO OFF TEMP = [53°C] + [+4°C]. 2. Water outlet temperature > Heat pump THERMO OFF TEMP for continuous 3 minutes, heat pump OFF. Next THERMO ON TEMP: 1.
  • Page 56 12.1.7.2 Cooling Priority NOT SET 1. 3 ways valve control:  3 ways valve switch to room side during room cooling interval and switch to tank side during tank heat-up interval. Both modes will switch alternately. Tank mode is the initial running mode of this cool + tank mode. 2.
  • Page 57 Water Inlet Thermo Condition Heat pump THERMO OFF TEMP: Water inlet temperature > [55°C] for continuous 60 seconds, heat pump OFF. THERMO ON TEMP: THERMO ON TEMP = Water inlet temperature > [55°C]. c) Solar Operation Condition (Only under Solar Priority Set Condition) ...
  • Page 58 12.1.8 Setting Water Outlet Temperature for Heat Mode  The set temperature defines the parameters for the outdoor ambient temperature dependent operation of the unit. Where by the internal water setting temperature is determined automatically depending on the outdoor temperature. The colder outdoor temperatures will result in warmer water and vice versa. The user has the possibility to shift up or down the target water temperature by control panel setting.

  • Page 59: Outdoor Fan Motor Operation

    12.1.9 Water Temperature Thermo Shift Setting  Switchs are ignored during “PUMPDW” = ON.  Switchs are ignored during “STATUS” = ON. ▲ ▼  “ ”, “ ”, ”SELECT” switch are ignored if “SETTING” = OFF.  “CANCEL” switch is ignored if “SETTING” = OFF & “STATUS” = OFF. ...

  • Page 60: Water Pump

    12.2 Water Pump 12.2.1 Water Pump Control  Once the indoor unit is ON, the water pump will be ON immediately and no error judgement for 9 minutes. However, during this 9 minutes operation, if there is any abnormality cause at outdoor or malfunction, the compressor should be OFF immediately and restart delay after 3 minutes.
  • Page 61 12.2.2 A-class Pump Specification Power for drive DC280-373V Pump Power for control DC15±10% Control Signal DC0V-DC6V Feedback Speed (puls signal) 4puls/rotation Control signal is analog voltage (DC0V-6V) generated by microcomputer PWM port. Microcomputer can change analog voltage by changing PWM duty. 12.2.3 Water Flow Rate Setting ...

  • Page 62: Pump Down Operation [Service Mode: 01]

    12.2.4 Water Pump Speed Feedback Error  Basically pump speed feedback is control by micon.  When pump speed is below low limit or over high limit for a few seconds, micon detect pump error and system is stopped.  Error detection conditions: ...

  • Page 63: Indoor Unit Safety

    12.5 Indoor Unit Safety 12.5.1 Indoor Unit Safety Control When water pump is ON, the system will start checking flow switch status (ON/OFF). If the flow switch ON for 10 seconds, the system will check on the water inlet temperature for 10 seconds. If the water inlet temperature not exceeds 80°C, the water pump shall be continuously running with normal mode.

  • Page 64: Indoor Back-Up Heater Control

    12.8 Indoor Back-Up Heater Control 12.8.1 Indoor Electric Heater Control Normal Heating Mode Heater On condition: a. Heater switch is ON b. After Heatpump thermo ON for [30] mins c. After water pump operate [9] mins d. Outdoor air temperature < Outdoor set temperature for heater e.

  • Page 65: Tank Booster Heater Control

    12.9 Tank Booster Heater Control 12.9.1 Tank Booster Heater Control Heating operation condition: Heater OFF Tank set temperature + Tank set temperature + [-5°C] [+2°C] Heater ON Booster heater Turn On condition: After BOOSTER HEATER DELAY TIMER fulfill during heatpump startup time in tank mode, or during switching from heating heat-up interval to tank heat-up interval in heat + tank mode (heating priority not set).

  • Page 66: Sterilization Mode

    12.11 Sterilization Mode  Purpose: To sterilize water tank by setting the required boiling temperature.  Control start condition: Tank connection menu is set to YES by control panel. Sterilization menu is set to YES by control panel. Sterilization signal received from control panel by timer. ...

  • Page 67: Anti Freeze Control

    12.13 Anti Freeze Control  Anti freeze protection control menu can be set YES or NO by control panel.  In heatpump system, there are 3 types of anti freeze control: 1. Expansion tank anti-freeze control  Expansion tank anti freeze heater ON condition: Outdoor ambient temp.

  • Page 68: Solar Operation (Optional)

    12.14 Solar Operation (Optional) 12.14.1 Solar Operation: External solar heat source signal can be connect to unit for proper control of heat source switching during tank boiling time. Control according to preset whether solar priority is set or not. When tank connection is NOT set at SETTING mode, solar operation is disabled. When Pump A (from solar pump station) is detected On through connection Y3 and Y4, then the Solar pump 3 Way Valve is requested ON (Refer to figure below).
  • Page 69 Solar Operation Chart in different mode and condition Tank Mode (Solar Priority SET condition) Tank Mode (Solar Priority NOT SET condition)
  • Page 70 Heat + Tank Mode (Heating Priority NOT SET) (Solar Priority SET condition) When solar 3 way valve turn on during Tank interval, cancel Tank interval immediately and switch 3-way valve to the After heating/cooling interval, stand by to go in tank side after solar 3 way room side and start a heating/cooling interval.
  • Page 71 Heat + Tank Mode (Heating Priority SET) & Cool + Tank Mode 3 way valve Room Side Heatpump Booster heater Off due to solar 3 way valve on Booster heater Thermo Off Solar priority set Booster heater Solar priority not Solar request Solar off due to upper limit...

  • Page 72: External Room Thermostat Control (Optional)

    12.15 External Room Thermostat Control (Optional) Purpose: Better room temperature control to fulfill different temperature request by external room thermostat. Recommended external room thermostat: Maker Characteristic Siemen (REV200) Touch panel Siemen (RAA20) Analog Connection of external room thermostat: Wire Connection and thermo characteristic of Siemen REV200: Setting L/L1 (H) Heat Thermo...

  • Page 73: Three Ways Valve Control

    12.16 Three Ways Valve Control Purpose: - 3 ways valve is used to change flow direction of hot water from heat pump between heating side and tank side. Control contents: 3 ways valve switch Off: During 3 ways valve switch Off time, the hot water will provide heat capacity to heating side. 3 ways valve switch On: During 3 ways valve switch On time, the hot water will provide heat capacity to tank side.

  • Page 74: External Off/On Control

    12.18 External OFF/ON Control  Communication circuit between indoor unit and external controller is as per below. External Controller mico Panasonic CN-THERMO  Maximum length of communication cable is 20 meter.  Control content: External Control Switch Control Panel OFF/ON...

  • Page 75: Holiday Mode

    12.19 Holiday Mode  Purpose: Promotes energy saving by allowing the user to stop the system during holiday and enables the system to resume at the preset temperature after holiday.  Control details: Range of days can be set in holiday mode is from 1 to 999 days. After days of holiday have been set, heat pump will stop and only resume operation at 12.00am at the end of holiday countdown.

  • Page 76: Protection Control

    13. Protection Control 13.1 Protection Control For All Operations 13.1.1 Time Delay Safety Control The compressor will not start for three minutes after stop of operation. 13.1.2 30 Seconds Forced Operation Once the compressor starts operation, it will not stop its operation for 30 seconds. However, it can be stopped using remote control.

  • Page 77: Low Pressure Protection Control

    13.1.6 Low Pressure Protection Control  Purpose: To protect the system operation.  Detection period: After compressor on for 5 minutes.  Detection conditions: When detection of Tem above 30°C. Calculation of average evaporation temperature (Tem). Use outdoor low pressure sensor. Tem use the value calculated for discharge temperature setting value.

  • Page 78: Protection Control For Heating Operation

    13.1.10 Crank Case Heater Control  Purpose: - For compressor protection during low outdoor ambient operation (during heating low temperature operation).  Control content: a. Trigger heater START condition When the outdoor air temperature is 4°C or below, and discharge temperature is 12°C or below. b.

  • Page 79: Protection Control For Cooling Operation

    13.3 Protection Control For Cooling Operation 13.3.1 Outdoor Air Temperature Control  The Compressor operating frequency is regulated in accordance to the outdoor air temperature as shown in the diagram below.  This control will begin 1 minute after the compressor starts. ...

  • Page 80: Servicing Mode

    14. Servicing Mode 14.1 Test Run Fill up the Tank Unit with water. For details refer to Tank Unit installation instruction and operation instruction. Antifreeze agent must be added into water circuit to prevent freezing of water when outdoor ambient temperatures is low.

  • Page 81: Maintenance Guide

    15. Maintenance Guide In order to ensure optimal performance of the unit, checks and inspections on the unit and the field wiring must be carried out regularly. Please request a licensed technician for carry out maintenance job. Before carried out any maintenance or repair work, and removing the front plate of heat exchanger unit, always switch off all power supply (i.e.
  • Page 82 External water filter (field supply) Clean the external water filter in regularly basic. External water filter is located inside the tube connector which is before water inlet connector of mono bloc unit (indicated with “WATER IN”). (Refer to figure below) Use spanner to detach the tube connector nut.
  • Page 83 10 Maintenance In order to ensure optimal performance of the unit, seasonal inspections on the unit, external filter and field wiring have to be carried out at regular intervals. This maintenance should be carried out by authorized dealer. WARNING Do not add or replace other than R410A type. It may cause product damage, burst, injury and etc. Use compatible R410A tools for refrigerant piping work and refrigerant charging during installation or servicing.

  • Page 84: Troubleshooting Guide

    16. Troubleshooting Guide 16.1 Refrigeration Cycle System In order to diagnose malfunctions, make sure that there are no electrical problems before inspecting the refrigeration cycle. Such problems include insufficient insulation, problem with the power source, malfunction of a compressor and a fan.

  • Page 85: Relationship Between The Condition Of The Air-To-Water Heatpump Indoor And Outdoor Units And Pressure And Electric Current

    16.2 Relationship between the Condition of the Air-to-Water Heatpump Indoor and Outdoor Units and Pressure and Electric Current Heating Mode Cooling Mode Condition of the Air-to-Water Heatpump Electric current Electric current indoor and Low Pressure High Pressure Low Pressure High Pressure during operation during operation outdoor units...

  • Page 86: Breakdown Self Diagnosis Function

    16.3 Breakdown Self Diagnosis Function 16.3.1 Self Diagnosis Function (Three Digits Alphanumeric Code)  When abnormality occur during operation, the system will stop operation, and OFF/ON control panel LED will blink and error code will display on the control panel Timer display LCD. ...

  • Page 87: Error Codes Table

    16.4 Error Codes Table Diagnosis display Abnormality/Protection control Abnormality judgement Primary location to verify No abnormality detected — —  Indoor/outdoor connection wire  Indoor/outdoor PCB Indoor/Outdoor capacity unmatched 90s after power supply  Specification and combination table in catalogue ...
  • Page 88 Diagnosis display Abnormality/Protection control Abnormality judgement Primary location to verify  Outdoor air temperature sensor Outdoor air temperature sensor Continue for 5 sec. abnormality (defective or disconnected)  Water inlet temperature sensor Indoor water inlet temperature sensor Continue for 5 sec. abnormality (defective or disconnected) Outdoor discharge pipe temperature...

  • Page 89: Self-Diagnosis Method

    16.5 Self-diagnosis Method 16.5.1 Connection Capability Rank Abnormality (H12) Malfunction Decision Conditions: During startup operation of cooling and heating, the capability rank of indoor checked by the outdoor is used to determine connection capability rank abnormality. Malfunction Caused: Wrong model interconnected. Wrong indoor unit or outdoor unit PCB (main) used.
  • Page 90 16.5.2 Compressor Tank Temperature Sensor Abnormality (H15) Malfunction Decision Conditions: During startup and operation of cooling and heating, the temperatures detected by the compressor tank temperature sensor are used to determine sensor error. Malfunction Caused: Faulty connector connection. Faulty sensor. Faulty outdoor unit PCB (main).
  • Page 91 16.5.3 Water Pump Abnormality (H20) Malfunction Decision Conditions: During startup and operation of cooling and heating, the rotation speed detected by the IPM of water pump motor during water pump operation is used to determine abnormal water pump (feedback of rotation > 6,000rpm or < 1,000rpm).
  • Page 92 16.5.4 Indoor Refrigerant Liquid Temperature Sensor Abnormality (H23) Malfunction Decision Conditions: During startup and operation of cooling and heating, the temperatures detected by the indoor refrigerant liquid temperature sensor are used to determine sensor error. Malfunction Caused: Faulty connector connection. Faulty sensor.
  • Page 93 16.5.5 Service Valve Error (H27) Malfunction Decision Conditions: During cooling operation, when:- [a] Indoor refrigerant pipe temperature at compressor startup - present indoor refrigerant pipe temperature < 2°C [b] Present high pressure - high pressure at compressor startup < 5kg/cm **Judgment only for first time cooling operation and not during pump down operation.
  • Page 94 16.5.6 Compressor Low Pressure Protection (H42) Malfunction Decision Conditions: During operation of heating and after 5 minutes compressor ON, when outdoor pipe temperature below -29°C or above 26°C is detected by the outdoor pipe temperature sensor. Malfunction Caused: Dust accumulation on the outdoor unit heat exchanger. Air short circuit at outdoor unit.
  • Page 95 16.5.7 Water Flow Switch Abnormality (H62) Malfunction Decision Conditions: During operation of cooling and heating, the water flow detected by the indoor water flow switch is used to determine water flow error. Malfunction Caused: Faulty water pump. Water leak in system. Faulty connector connection.
  • Page 96 16.5.8 Outdoor High Pressure Abnormality (H64) Malfunction Decision Conditions: During operation of cooling and heating, when the outdoor high pressure sensor output signal is 0 Vdc or 5 Vdc. Malfunction Caused: Faulty connector connection. Faulty sensor. Faulty outdoor unit PCB (main). Abnormality Judgment: Continue 4 times in 20 minutes.
  • Page 97 16.5.9 Indoor Backup Heater OLP Abnormality (H70) Malfunction Decision Conditions: During operation of indoor backup heater, when no power supplies to indoor backup heater or OLP open circuit. Malfunction Caused: Faulty power supply connector connection. Faulty connector connection. Faulty indoor backup heater overload protector (OLP). Faulty indoor unit PCB (main).
  • Page 98 16.5.10 Tank Temperature Sensor Abnormality (H72) Malfunction Decision Conditions: When tank connection is set to ON, the temperatures detected by the tank temperature sensor are used to determine sensor error. Malfunction Caused: Faulty connector connection. Faulty sensor. Faulty indoor unit PCB (main). Abnormality Judgment: Continue for 5 seconds.
  • Page 99 16.5.11 Indoor-Control Panel Communication Abnormality (H76) Malfunction Decision Conditions: During standby and operation of cooling and heating, indoor-control panel error occur. Malfunction Caused: Faulty connector connection. Faulty control panel. Faulty indoor unit PCB (main).
  • Page 100 16.5.12 Indoor/Outdoor Abnormal Communication (H90) Malfunction Decision Conditions: During operation of cooling and heating, the data received from outdoor unit in indoor unit signal transmission is checked whether it is normal. Malfunction Caused: Faulty outdoor unit PCB (main). Faulty indoor unit PCB (main). Indoor-outdoor signal transmission error due to wrong wiring.
  • Page 101 16.5.13 Tank Booster Heater OLP Abnormality (H91) Malfunction Decision Conditions: During operation of tank booster heater, and tank booster heater OLP open circuit. Malfunction Caused: Faulty connector connection. Faulty tank booster heater overload protector (OLP). Faulty indoor unit PCB (main). Abnormality Judgment: Continue for 60 seconds.
  • Page 102 16.5.14 Unspecified Voltage between Indoor and Outdoor (H95) Malfunction Decision Conditions: The supply power is detected for its requirement by the indoor/outdoor transmission. Malfunction Caused: Insufficient power supply. Faulty outdoor unit PCB (noise filter/main).
  • Page 103 16.5.15 Outdoor High Pressure Protection (H98) Malfunction Decision Conditions: During operation of heating, when pressure 4.0 MPa and above is detected by outdoor high pressure sensor. Malfunction Caused: Faulty water pump. Insufficient water flow rate in system. Water leak in system. 2/3 way closed.
  • Page 104 16.5.16 Indoor Freeze-up Protection (H99) Malfunction Decision Conditions: During anti-freezing control in cooling operation, when the indoor refrigerant liquid temperature < 0°C. Malfunction Caused: Faulty water pump. Insufficient water flow rate in system. Water leak in system. 2 way valve partially closed. Clogged expansion valve or strainer.
  • Page 105 16.5.17 Outdoor High Pressure Switch Activate (F12) Malfunction Decision Conditions: During operation of cooling and heating, when pressure 4.5 MPa and above is detected by outdoor high pressure switch. Malfunction Caused: Dust accumulation on the outdoor unit heat exchanger. Air short circuit at outdoor unit. Faulty water pump.
  • Page 106 16.5.18 Compressor Rotation Failure (F14) Malfunction Decision Conditions: A compressor rotation failure is detected by checking the compressor running condition through the position detection circuit. Malfunction Caused: Compressor terminal disconnect. Faulty outdoor unit PCB (main). Faulty compressor. Abnormality Judgment: Continue 4 times in 20 minutes.
  • Page 107 16.5.19 Outdoor Fan Motor (DC Motor) Mechanism Locked (F15) Malfunction Decision Conditions: The rotation speed detected by the Hall IC of the fan motor during fan motor operation is used to determine abnormal fan motor (feedback of rotation > 2550 rpm or < 50 rpm). Malfunction Caused: Operation stop due to short circuit inside the fan motor winding.
  • Page 108 16.5.20 Input Over Current Detection (F16) Malfunction Decision Conditions: During operation of cooling and heating, when outdoor current above 15.5 A (Heating) and 7.7 A (Cooling) is detected by the current transformer (CT) in the outdoor unit PCB. Malfunction Caused: Excessive refrigerant.
  • Page 109 16.5.21 Compressor Overheating (F20) Malfunction Decision Conditions: During operation of cooling and heating, when temperature above 112°C is detected by the compressor tank temperature sensor. Malfunction Caused: Faulty compressor tank temperature sensor. 2/3 way valve closed. Refrigerant shortage (refrigerant leakage). Clogged expansion valve or strainer.
  • Page 110 16.5.22 IPM Overheating (F22) Malfunction Decision Conditions: During operation of cooling and heating, when temperature 95°C is detected by the outdoor IPM temperature sensor. Malfunction Caused: Faulty outdoor unit fan motor. Faulty outdoor unit PCB (main). Abnormality Judgment: Continue 3 times in 30 minutes.
  • Page 111 16.5.23 Output Over Current Detection (F23) Malfunction Decision Conditions: During operation of cooling and heating, when outdoor DC current is above 39.0 ± 5.0 A is detected by the IPM DC Peak sensing circuitry in the outdoor unit PCB (main). Malfunction Caused: Faulty outdoor unit PCB (main).
  • Page 112 16.5.24 Refrigeration Cycle Abnormality (F24) Malfunction Decision Conditions: During operation of cooling and heating, compressor frequency > Frated. During operation of cooling and heating, running current: 0.65 A < I < 1.65 A. During operation of cooling, water inlet temperature - indoor refrigerant liquid temperature < 5°C. During operation of heating, indoor refrigerant liquid temperature - water inlet temperature <...
  • Page 113 16.5.25 Four Way Valve Abnormality (F25) Malfunction Decision Conditions: During heating operation, when the indoor pipe temperature of thermostat ON indoor unit < 0°C. During cooling operation, when the indoor pipe temperature of thermostat ON indoor unit > 45°C. Malfunction Caused: Faulty sensor.
  • Page 114 16.5.26 Outdoor High Pressure Switch Abnormal (F27) Malfunction Decision Conditions: During compressor stop, and outdoor high pressure switch is remain opened. Malfunction Caused: Faulty connector connection. Faulty switch. Faulty outdoor unit PCB (main). Abnormality Judgment: Continue for 1 minute.
  • Page 115 16.5.27 Outdoor Air Temperature Sensor Abnormality (F36) Malfunction Decision Conditions: During startup and operation of cooling and heating, the temperatures detected by the outdoor air temperature sensor are used to determine sensor error. Malfunction Caused: Faulty connector connection. Faulty sensor. Faulty outdoor unit PCB (main).
  • Page 116 16.5.28 Indoor Water Inlet Temperature Sensor Abnormality (F37) Malfunction Decision Conditions: During startup and operation of cooling and heating, the temperatures detected by the indoor water inlet temperature sensor are used to determine sensor error. Malfunction Caused: Faulty connector connection. Faulty sensor.
  • Page 117 16.5.29 Outdoor Discharge Pipe Temperature Sensor Abnormality (F40) Malfunction Decision Conditions: During startup and operation of cooling and heating, the temperatures detected by the outdoor discharge pipe temperature sensor are used to determine sensor error. Malfunction Caused: Faulty connector connection. Faulty sensor.
  • Page 118 16.5.30 Power Factor Correction (PFC) Abnormality (F41) Malfunction Decision Conditions: During operation of cooling and heating, when the PFC protection circuitry in the outdoor unit PCB (main) senses abnormal high DC voltage level. Malfunction Caused: Power supply surge. Compressor windings not uniform. Faulty outdoor unit PCB (main).
  • Page 119 16.5.31 Outdoor Pipe Temperature Sensor Abnormality (F42) Malfunction Decision Conditions: During startup and operation of cooling and heating, the temperatures detected by the outdoor pipe temperature sensor are used to determine sensor error. Malfunction Caused: Faulty connector connection. Faulty sensor. Faulty outdoor unit PCB (main).
  • Page 120 16.5.32 Outdoor Defrost Temperature Sensor Abnormality (F43) Malfunction Decision Conditions: During startup and operation of cooling and heating, the temperatures detected by the outdoor defrost temperature sensor are used to determine sensor error. Malfunction Caused: Faulty connector connection. Faulty sensor. Faulty outdoor unit PCB (main).
  • Page 121 16.5.33 Indoor Water Outlet Temperature Sensor Abnormality (F45) Malfunction Decision Conditions: During startup and operation of cooling and heating, the temperatures detected by the indoor water outlet temperature sensor are used to determine sensor errors. Malfunction Caused: Faulty connector connection. Faulty sensor.
  • Page 122 16.5.34 Outdoor Current Transformer Open Circuit (F46) Malfunction Decision Conditions: A current transformer (CT) open circuit is detected by checking the compressor running frequency (≥ rated frequency) and CT detected input current (< 0.65 A) for continuously 20 seconds. Malfunction Caused: CT defective.
  • Page 123 16.5.35 Cooling High Pressure Overload Protection (F95) Malfunction Decision Conditions: During operation of cooling, when pressure 4.0 MPa and above is detected by outdoor high pressure sensor. Malfunction Caused: Dust accumulation in the outdoor unit heat exchanger. Air short circuit at outdoor unit. 2 way valve closed.

  • Page 124: Disassembly And Assembly Instructions

    17. Disassembly and Assembly Instructions WARNING High Voltage are generated in the electrical parts area by the capacitor. Ensure that the capacitor has discharged sufficiently before proceeding with repair work. Failure to heed this caution may result in electric shocks. WARNING Be sure to switch off all the power supply before performing each of the below action.

  • Page 125: To Remove The Cabinet Rear Plate

    17.3 To Remove The Cabinet Rear Plate 4. Slide the cabinet rear plate downward to release the pawls. Then pull it out to remove it. 2. Remove 5 mounting screws. 3. Remove 6 mounting screws. 1. Remove 2 mounting screws. 17.4 To Remove Pressure Gauge 1.

  • Page 126: To Remove Rccb

    17.5 To Remove RCCB 2. Disconnect 2 lead wires (Black and White) 1. Disconnect 2 lead wires (Black and White) 3. Remove screws to remove RCCB. RCCB 17.6 To Remove Transformer 3. Remove 4 screws to remove Transformer. 2. Disconnect connector CN-T1 (White) from the Electronic Controller Board.

  • Page 127: To Remove Water System Electronic Controller Board

    17.7 To Remove Water System Electronic Controller Board CN-SOLAR CN-TH1 CN-TH2 CN-TH3 CN-FLOW CN-T1 CN-OLP2 CN-REMOTE2 CN-THERMO CN-PUMP2 CN-OLP1 CN-RCV2 CN-V3 DATA 4. Remove screw to remove CN-PWR Electronic Controller Board. AC1-L3 CN-V2 AC1-N CN-HT 3. Remove all the connectors from the Electronic Controller. Electronic Controller Board 2.

  • Page 128: To Remove Refrigerant Side Control Board Complete

    17.8 To Remove Refrigerant Side Control Board Complete 4. Remove 4 screws to remove the Control Board Complete 2. Remove earth wire FG1 and FG2 (Green). 1. Remove lead wire AC-BLK02 (Black), AC-WHT02 (White) and COM3 (Red) from the terminal board. 3.

  • Page 129: To Remove Pressure Relief Valve And Air Purge Valve

    17.9 To Remove Pressure Relief Valve and Air Purge Valve Air Purge Valve During reinstall Air Purge Valve. Make sure plug is fully close in clockwise direction. Packing Apply some water based 1. Turn the Air Purge Valve grease on packing surface anti-clockwise then remove.

  • Page 130: To Remove Water Pump

    17.11 To Remove Water Pump 3. Remove 2 retaining ring, then pull out the water pump. 2. Loosen the nut. 1. Disconnect CN-PUMP2 connector from Electronic Controller Board. When reinstall the water pipe, use grease or water at the joining.

  • Page 131: Technical Data

    18. Technical Data 18.1 Operation Characteristics 18.1.1 WH-MDC05F3E5 Heating Characteristics at Different Outdoor Air Temperature Condition Outdoor air temperature : 7°C (DBT), 6°C (WBT) Indoor water inlet temperature : 30°C Indoor water outlet temperature : 35°C 8.000 7.000 6.000 5.000 4.000...
  • Page 132 Cooling Characteristics at Different Outdoor Air Temperature Condition Outdoor air temperature : 35°C (DBT), -°C (WBT) Indoor water inlet temperature : 12°C Indoor water outlet temperature : 7°C 6.000 5.000 4.000 3.000 2.000 1.000 0.000 Outdoor Temperature (°C) 5.000 4.000 3.000 2.000 1.000...
  • Page 133 Cooling Characteristics at Different Outdoor Air Temperature Condition Outdoor air temperature : 35°C (DBT), -°C (WBT) Indoor water inlet temperature : 19°C Indoor water outlet temperature : 14°C 7.000 6.000 5.000 4.000 3.000 2.000 1.000 Outdoor Temperature (°C) 5.000 4.000 3.000 2.000 1.000...
  • Page 134 Cooling Characteristics at Different Outdoor Air Temperature Condition Outdoor air temperature : 35°C (DBT), -°C (WBT) Indoor water inlet temperature : 23°C Indoor water outlet temperature : 18°C 7.000 6.000 5.000 4.000 3.000 2.000 1.000 Outdoor Temperature (°C) 5.000 4.000 3.000 2.000 1.000...

  • Page 135: Heating Capacity Table

    18.2 Heating Capacity Table Water Out (°C) Input Input Input Input Input Input Capacity Capacity Capacity Capacity Capacity Capacity Outdoor Air (°C) Power Power Power Power Power Power 5000 1820 5000 1950 5000 2200 5000 2450 5000 1675 5000 2900 4500 1440 4500...

  • Page 136: Exploded View And Replacement Parts List

    19. Exploded View and Replacement Parts List 19.1 WH-MDC05F3E5 (Refrigerant System)
  • Page 138 Note:  The above exploded view is for the purpose of parts disassembly and replacement.  The non-numbered parts are not kept as standard service parts.
  • Page 139 < Model: Refrigerant System > SAFETY REF. NO. DESCRIPTION & NAME QTY. WH-MDC05F3E5 REMARK BASE PAN ASS’Y CWD52K1282 COMPRESSOR 5KD240XAA21 BUSHING - COMPRESSOR MOUNT CWH50055 NUT - COMPRESSOR MOUNT CWH561049 GASKET FOR TERMINAL COVER CWB811017 CRANKCASE HEATER CWA341043 CONDENSER COMPLETE...

  • Page 140: Wh-Mdc05F3E5 (Water System)

    19.2 WH-MDC05F3E5 (Water System)
  • Page 141 Note:  The above exploded view is for the purpose of parts disassembly and replacement.  The non-numbered parts are not kept as standard service parts.
  • Page 142 <Model: Water System > SAFETY REF. NO. DESCRIPTION & NAME QTY. WH-MDC05F3E5 REMARK BASE PAN ASS’Y CWD52K1360 HOT WATER COIL - COMPLETE CWB90C1067 RECEIVER CWB141066 FLOW SWITCH CWB621034 AIR PURGE VALVE CWB621094 PUMP CWB532116 BOTTLE COMP. CWH90C0035 HEATER ASS'Y CWA34K1026...

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