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AISIN SEIKI E1 Series Service Manual

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09D-EDN-1
AISIN GHP
E1 MODEL
SERVICE MANUAL
UNITED STATES
OF AMERICA
AISIN
Spec.
8 TON
15 TON
Gas type
Natural Gas
AXGP096E1NHS
AWGP180E1NHS

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  • Page 1 09D-EDN-1 AISIN GHP E1 MODEL SERVICE MANUAL UNITED STATES OF AMERICA AISIN Spec. 8 TON 15 TON Gas type Natural Gas AXGP096E1NHS AWGP180E1NHS...
  • Page 3 Introduction Safety Precautions The following is an important safety notice you must follow in order to prevent injuries and/or damages that may be caused by incorrect operation in repair, inspection and maintenance of the Gas Heat Pump. Be sure to read these precations carefully and follow the instructions.
  • Page 4 Precautions of Usage Be sure to stop the operation and turn OFF the electric leakage breaker when you do maintenance. Otherwise, you could be shocked or injured. Even if the GHP is stopped, the fan may automatically start temporary run to protect units or maintain capacity. Be sure to turn OFF the electric leakage breaker when you touch the inside of the outdoor or indoor units.

  • Page 5: Table Of Contents

    CONTENTS Introduction 1. Product Appearance................7 2. Product Specifications ................8 1) Model Name Structure ....................8 2) Configuration......................... 9 3. Outdoor Unit Specifications ..............12 4. Outdoor Unit External Dimensions ............16 5. Outdoor Unit Internal Structure.............. 18 6. Operating Principle ................24 1) Refrigerant System Diagram..................
  • Page 6 CONTENTS 32) Indoor Air Filters Inspection ..................61 33) Remote Controller Operation Inspection ..............62 34) Indoor Unit Temperature Inspection................62 35) Check After Work ......................62 REPLACEMENT OF MAIN COMPONENTS 1. Before Starting Your Work..............63 2. Replacement of Engine Unit..............65 3.
  • Page 7 CONTENTS 8) High Pressure Abnormality in Heating Operation ............. 188 9) Refrigerant Low Pressure Abnormality ..............189 10) Overheated Refrigerant Discharge Temperature in Cooling Operation ....190 11) Overheated Refrigerant Discharge Temperature in Heating Operation ....191 12) Communication Failure / Indoor Unit System Failure..........192 13) Gas Heat Pump is Operating but Not Cooling............
  • Page 8 CONTENTS 46) Inspect Refrigerant Low Pressure Sensor..............224 47) Inspect Sub Heat Exchanger Liquid Flow Control Valve........... 225 48) Inspect Outdoor Heat Exchanger Liquid Flow Control Valve ........226 49) Inspect Reversing Valve ................... 227 50) Check for Readings of the Compressor Discharge Pipe Temperature Sensor..227 51) Check for Readings of the Outside Air Temperature Sensor ........

  • Page 9: Product Appearance

    Introduction Introduction 1. Product Appearance 8 TON 15 TON Multi zone type Combination Multi type Outdoor unit※ Outdoor unit※ AISIN ※ Refer to "Outdoor Unit Model Name Structure" for outdoor unit model name.

  • Page 10: Product Specifications

    Introduction 2. Product Specifications Model Name Structure [ Outdoor Unit Model Name Structure ] Code Model name (Example) Model code list Code Item Symbol and description Brand : AISIN brand : Multi zone type Type : Combination Multi type Outdoor unit : Outdoor unit Refrigerant type : R410A...

  • Page 11: Configuration

    Introduction Configuration 8 TON Power supply Power supply Single-phase 230 or 208V Single-phase 230 or 208V ｝ ｝ Over- Over- current current It’s indicates the breaker on the power distribution board of building or facility. Outdoor unit breaker breaker Electric Electric leakage leakage...
  • Page 12 Introduction 15 TON [ Stand-alone installation ] Power supply Power supply Single-phase 230 or 208V Single-phase 230 or 208V ｝ ｝ Over- Over- current current It’s indicates the breaker on the power distribution board of building or facility. Outdoor unit breaker breaker Electric...
  • Page 13 Introduction [ Combined installation ] Power supply Power supply Single-phase 230 or 208V Single-phase 230 or 208V Power supply Single-phase 230 or 208V Over- Over- current current breaker breaker Outdoor unit Outdoor unit Over- current Electric Electric It’s indicates the breaker on the power distribution board breaker leakage leakage...

  • Page 14: Outdoor Unit Specifications

    Introduction 3. Outdoor Unit Specifications [8 Ton Fuel gas type : Natural Gas] (60 Hz) Model AXGP096E1NHS Type 8 Ton Multi zone type Rated cooling 96,000 (8) Capacity BTU/h (Ton) Rated heating 103,000 (8.6) Height 81.8 (2077) External Width inch (mm) 55.1 (1400) dimensions Depth...
  • Page 15 Introduction Type x number of unit Scroll type x 2 units inch /rev Displacement 5.26 x 2 (86.2 x 2) /rev) Cooling 840 ~ 1785 Speed range Compressor Heating 840 ~ 3150 Specified refrigerant oil NL10 Amount of refrigerant oil gal (L) 1.06 (4) Power transmission system...
  • Page 16 Introduction [15 Ton Fuel gas type : Natural Gas] (60 Hz) Model AWGP180E1NHS Type 15 TON combination Multi type Rated cooling 180,000 (15) Capacity BTU/h (Ton) Rated heating 205,000 (17) Height 81.8 (2077) External Width inch (mm) 65.4 (1660) dimensions Depth 34.6 (880) Mass...
  • Page 17 Introduction Type x number of unit Scroll type x 2 units inch /rev Displacement 5.26 x 2 (86 x 2) /rev) Cooling 1170 ~ 3900 Speed range Compressor Heating 1170 ~ 3802 Specified refrigerant oil NL10 Amount of refrigerant oil gal (L) 1.06 (4) Power transmission system...

  • Page 18: Outdoor Unit External Dimensions

    Introduction 4. Outdoor Unit External Dimensions 8 TON...
  • Page 19 Introduction 15 TON...

  • Page 20: Outdoor Unit Internal Structure

    Introduction 5. Outdoor Unit Internal Structure 8 TON Thermostats FRONT Ignition coils (3 pieces) Engine coolant temperature sensor Engine oil pressure switch Engine Electromagnetic compressor capacity valve 2 Engine oil pan heater (unit with drain heater kit only) Compressor 2 Compressor 1 Engine coolant pump Electromagnetic compressor...
  • Page 21 Introduction PANEL SIDE Sub heat exchanger liquid flow control valve Subcooling valve Outdoor heat exchanger liquid flow control valve Strainer (for vapor) Outdoor liquid pipe temperature sensor Dryer filter Electromagnetic Stop valve (for vapor) compressor capacity valve 1 Stop valve (for liquid) Refrigerant line connection Accumulator port (for vapor)
  • Page 22 Introduction Communication I/F PCB Main PCB Electric leakage breaker EMC PCB Power supply PCB Cold district PCB (unit with drain Reactor heater kit only) Igniter DCBL PCB Capacitor ENLARGE Diode Transformer 1 Figure 3 In control box Exhaust port Radiator cap Outdoor heat exchanger (rear) Outdoor fans Engine compartment temperature...
  • Page 23 Introduction 15 TON FRONT Igniter Sspark plugs (4 pieces) Ignition coils (4 pieces) Thermostats Engine coolant temperature sensor Engine oil pressure sensor Engine Engine speed sensors Gas regulator Exhaust water drain Electromagnetic heater (unit with drain heater gas valves kit only) Compressor heater Engine coolant pump Exhaust water drain filter...
  • Page 24 Introduction Sub heat exchanger SIDE PANEL SIDE liquid flow control valve Subcooling valve Outdoor heat exchanger liquid flow control valve Strainer (for vapor) Outdoor liquid pipe temperature sensor Dryer filter Electromagnetic compressor capacity Stop valve (for vapor) valve 1 Refrigerant high pressure switch 1 Stop valve (for liquid) Refrigerant line connection...
  • Page 25 Introduction Communication I/F PCB Main PCB Electric leakage breaker EMC PCB Power supply PCB Cold district PCB Capacitor (unit with drain heater kit only) DCBL PCB ENLARGE Reactor Transformer 1 Diode Transformer 2 Figure 3 In control box Exhaust port Outdoor heat exchanger (rear) Outdoor fans Radiator cap...

  • Page 26: Operating Principle

    Introduction 6. Operating Principle Refrigerant System Diagram 1. Cooling Refrigerant (R410A) coming out of the compressors flows into the outdoor heat exchanger after passing through the oil separator and the reversing valve. Then heat is dissipated by the outside air, the refrigerant condenses into a liquid, eventually entering an overcooled status in the subcooling heat exchanger.
  • Page 27 Introduction 15 TON shows the refrigerant flow direction Outdoor heat exchanger Check valve for liquid pipe Outdoor heat exchanger liquid flow control valve Strainer (for liquid) Sub heat exchanger Sub heat exchanger Fusible plug liquid flow control valve Electronic expansion valve Reversing valve Indoor heat exchanger liquid pipe temperature sensor...
  • Page 28 Introduction 2. Heating The refrigerant (R410A) coming out of the compressors flows into the indoor heat exchanger after passing through the oil separator and the reversing valve. Dissipating heat to the room, the refrigerant condenses into a liquid in the indoor heat exchanger. After that, the refrigerant reduces its pressure at the indoor electronic expansion valve.
  • Page 29 Introduction 15 TON shows the refrigerant flow direction Outdoor heat exchanger Check valve for liquid pipe Outdoor heat exchanger liquid flow control valve Strainer (for liquid) Sub heat exchanger Sub heat exchanger Fusible plug liquid flow control valve Electronic expansion valve Reversing valve Indoor heat exchanger liquid pipe temperature sensor...

  • Page 30: Engine Coolant / Fuel Gas / Intake Air And Exhaust Air System Diagrams

    Introduction Engine Coolant / Fuel Gas / Intake Air and Exhaust Air System Diagrams 1. 8 TON Engine coolant · · · a) When the engine coolant temperature is 140 ℉ (60 ℃ ) or lower Engine coolant sent from the engine coolant pump ( ① ) is heated throuth the exhaust air heat exchanger ( ②...
  • Page 31 Introduction Engine coolant · · · b) When the engine coolant temperature is 140 ℉ (60 ℃ ) or higher and lower than 158 ℉ (70 ℃ ) Engine coolant flows into the sub heat exchanger ( ⑤ ) and heats refrigerant to increase heating efficiency in heating operation.
  • Page 32 Introduction Engine coolant · · · c) When the engine coolant temperature is 158 ℉ (70 ℃ ) or higher Engine coolant flows into the radiator ( ⑥ ) via the thermostat ( ④ ) to dissipate heat, and returns to the engine coolant pump ( ① ). shows the coolant flow direction ①...
  • Page 33 Introduction Fuel gas · · · Fuel gas flowing through the series of electromagnetic gas valves ( ⑪ ) is depressurized down to atmospheric pressure by the gas regulator ( ⑩ ) and supplied to the gas mixer ( ⑨ ). The high-pressure portion of the fuel system is separated from the engine compartment to assure safety.
  • Page 34 Introduction Intake Air and Intake air enters the gas mixer ( ⑨ ) through the air filter ( ⑫ ) to be mixed with the fuel. The air/fuel Exhaust Air · · · mixture then flows into the engine ( ⑧ ) cylinder. Exhaust air dissipates heat at the exhaust air heat exchanger ( ②...
  • Page 35 Introduction 2. 15 TON Engine coolant · · · a) When the engine coolant temperature is 140 ℉ (60 ℃ ) or lower Engine coolant sent from the engine coolant pump ( ① ) is heated throuth the exhaust air heat exchanger ( ②...
  • Page 36 Introduction Engine coolant · · · b) When the engine coolant temperature is 140℉ (60℃) or higher and lower than 158 ℉ (70℃) Engine coolant flows into the sub heat exchanger ( ⑤ ) and heats refrigerant to increase heating efficiency in heating operation. In low-temperature cooling, engine coolant enhanc- es evaporation efficiency.
  • Page 37 Introduction Engine coolant · · · c) When the engine coolant temperature is 158 ℉ (70 ℃ ) or higher Engine coolant flows into the radiator ( ⑥ ) via the thermostat ( ④ ) to dissipate heat, and returns to the engine coolant pump ( ① ). shows the coolant flow direction ①...
  • Page 38 Introduction Fuel gas · · · Fuel gas flowing through the series of electromagnetic gas valves ( ⑪ ) is depressurized down to atmospheric pressure by the gas regulator ( ⑩ ) and supplied to the gas mixer ( ⑨ ). The high-pressure portion of the fuel system is separated from the engine compartment to assure safety.
  • Page 39 Introduction Intake Air and Intake air enters the gas mixer ( ⑨ ) through the air filter ( ⑫ ) to be mixed with the fuel. The air/fuel Exhaust Air · · · mixture then flows into the engine ( ⑧ ) cylinder. Exhaust air dissipates heat at the exhaust air heat exchanger ( ②...

  • Page 40: Periodic Inspection

    PERIODIC INSPECTION PERIODIC INSPECTION 1. Inspection Items and Intervals Periodic maintenance and inspection as well as replacement of the parts are required for long-term use of the Gas Heat Pump (GHP) air conditioner.The table below lists the maintenance and inspection items and replace- ment parts when the yearly operation hours of a GHP are 3,333 or more hours.

  • Page 41: Parts Requiring Periodic Replacement

    PERIODIC INSPECTION Remote Controller Operation Inspection △ △ Indoor Unit Temperature Inspection △ ※ △ ※ 1. Perform periodic inspection in accordance with the table above, every 3 years or every 10,000 hours, whichever comes first. (Use the genuine parts specified by AISIN for replacement, refill, engine oil, engine coolant, engine cool- ant additive, and valve cleaner.) 2.

  • Page 42: Procedure And Method Of Periodic Inspection

    PERIODIC INSPECTION 3. Procedure and Method of Periodic Inspection Before starting your work Indicates a potentially hazardous situation that could result in death or serious injury. Indicates a potentially hazardous situation that may result in injury as well as damage to properties.
  • Page 43 PERIODIC INSPECTION Necessary tools Tools Purpose Torque wrench Tightening with required torque 12 mm socket head 6 mm hexagon wrench Phillips-head screwdriver Oil filter wrench Replacing the oil filter Plug wrench Removing the spark plug Engine coolant jug Hook Removing the fuel gas hose Ratchet socket wrench 14 mm socket head 14 mm wrench...

  • Page 44: Engine Oil Inspection / Refilling

    PERIODIC INSPECTION Engine Oil Inspection / Refilling 1. Check the oil level with an oil level gauge on the sub Oil level gauge oil reservoir. NOTE) When the outdoor unit is running or just has Sub oil reservoir stopped, wait for 5 minutes before you check the engine oil amount.

  • Page 45: Spark Plug Replacement

    PERIODIC INSPECTION 3. Tighten the oil filter by hand until the gasket comes Oil filter into contact with the bracket. 4. Further tighten the filter by 3/4 turns with the oil filter wrench. NOTE) Even if the oil filter says "Tighten hard with your hands", be sure not to tighten it by 3/4 or more turns with an oil filter wrench.
  • Page 46 PERIODIC INSPECTION 2. Unscrew 6 nuts to remove the cap. Nuts (6 pieces) 3. Remove the air filter element. 4. Clean the dust inside the cap and the case. 5. Set the new air filter element so the deeper side is Aair filter elements placed in the case.

  • Page 47: Compressor Belt Replacement

    PERIODIC INSPECTION Compressor Belt Replacement 1. [ 15 TON only ] Unscrew 5 bolts to remove the front side stay. Outdoor unit capacity Stay 8 TON Without 15 TON With Stay Bolts (5 pieces) 2. Loosen a locknut and an adjustment bolt adequately. 3.

  • Page 48: Exhaust Water Drain Filter Inspection / Refilling

    PERIODIC INSPECTION Exhaust Water Drain Filter Inspection / Refilling 1. [ Unit with drain heater kit only ] Move 2 clamps in the rear of the outdoor unit, and remove the 2 exhaust water drain hose. Exhaust water drain hoses Clamps 2.
  • Page 49 PERIODIC INSPECTION 5. [ 15 TON only ] Unscrew 2 bolts to remove the oil tray. Bolts 6. Unscrew a bolt (2 bolts for 8 TON) to remove the exhaust water drain filter box. NOTE) Do not tilt the box when removing it, because the box contains exhaust drain water.

  • Page 50: Drain Oil Filter Replacement

    PERIODIC INSPECTION Drain Oil Filter Replacement ?Do this work following " Exhaust Water Drain Filter Inspection / Refilling". 1. Remove the drain oil filter No.1 (for separation), No.2 (for absorption) and the gasket. 2. Clean the inside of the box. Clean the portion holding Filter No.1 Filter No.2 the drain oil filters in particular.
  • Page 51 PERIODIC INSPECTION 6. [ 15 TON only ] Mount the oil tray and tighten 2 bolts. Tightening torque 2.2 ± 0.7 lb·ft (3.0 ± 0.9 N·m) Bolts 7. [ 15 TON only ] Mount the stay and tighten 2 nuts. Tightening torque 8.9 ±...

  • Page 52: Engine Coolant Additive Refilling

    PERIODIC INSPECTION Engine Coolant Additive Refilling 1. Remove the radiator cap to put the specified amount of engine coolant additive. Radiator cap NOTE) If the engine coolant reaches full level before com- pleting refilling, drain the engine coolant from the drain plug on the engine block and refill the remain- ing engine coolant additive.

  • Page 53: Engine Coolant Leakage Inspection

    PERIODIC INSPECTION Engine Coolant Leakage Inspection 1. Check the engine coolant hoses for cracks or deteri- oration. 2. Check if the clamp is attached securely. 3. Check the engine coolant hoses and connections for leakage. NOTE) Be sure to check in the heat exchanger com- partment.

  • Page 54: Exhaust Water Drain Hose Inspection

    PERIODIC INSPECTION Exhaust Water Drain Hose Inspection 1. Check the exhaust water drain hoses for disconnec- Exhaust water drain hoses tion. 2. Check if the clamp is attached securely. 3. Check the exhaust water drain hoses and hose con- necting points for exhaust drain water leakage. NOTE) Be sure to check in the heat exchanger com- partment.

  • Page 55: Fuel Gas Leak Inspection

    PERIODIC INSPECTION 2. Remove the 2 fuel gas hoses. Hook 1) Insert the hook between the fuel gas pipe and fuel gas hose. Apply the gas leak detector liquid so that Fuel gas hose the liquid gets through the clearance between the fuel gas pipe and fuel gas hose.

  • Page 56: Compressor Inspection

    PERIODIC INSPECTION If there is any problem such as fuel gas leakage or fuel gas odor during inspection, be sure to fix the problem. If there is dirt or leaf soil around the fuel system parts, be sure to clean up around the fuel system parts.

  • Page 57: Refrigerant And Engine Coolant Line Contact Inspection

    PERIODIC INSPECTION Refrigerant and Engine Coolant Line Contact Inspection 1. Check the refrigerant line and engine coolant line for contact with other parts. [Refrigerant line] [Engine coolant line] Inspection interval Every 3 years (10,000 hours) Engine Valve Cleaning 1. Run the outdoor unit. Clamp 2.

  • Page 58: Engine Valve Clearance Inspection / Adjustment (8 Ton Only)

    PERIODIC INSPECTION Engine Valve Clearance Inspection / Adjustment (8 TON only) [ 8 TON only ] Caps 1. Close the fuel gas valve. 2. Hold and pull the caps to remove the cables (3 places). Spark plugs NOTE) Do not pull the cable. 3.

  • Page 59: Oil Level Switch Cleaning / Inspection

    PERIODIC INSPECTION 11. Install the cylinder head cover and spark plugs with the reverse procedure for the removal. NOTE) Do not use a feeler gauge with a blade thickness of 0.008 inch (0.2 mm) or more. When adjusting a clearance of 0.008 inch (0.2 mm) or more, use two blades of feeler gauge.

  • Page 60: Accumulator Condensed Water Drainage Inspection

    PERIODIC INSPECTION 2. Check the inside of the outdoor heat exchanger compartment for dirt such as fallen leaves. Outdoor heat exchanger compartment If there is dirt or leaf soil in the outdoor heat exchanger compartment, clean up the outdoor heat exchanger compartment. Inspection interval Every 3 years (10,000 hours) Accumulator Condensed Water Drainage Inspection...

  • Page 61: Engine Startability Inspection

    PERIODIC INSPECTION Engine Startability Inspection 1. Crank the engine to check if the engine starts within 3 sets. Inspection interval Every 3 years (10,000 hours) Engine Mount Replacement [ 8 TON only ] 1. Check engine mount replacement location. Engine mount Engine mount (rear side) (front side) 2.
  • Page 62 PERIODIC INSPECTION 6. Unscrew 2 bolts to remove the rear side engine Rear side mount. 7. Set the new engine mount with spacer to the base plate and tighten with 2 bolts. Tightening torque 31.0 lb·ft (42.0 N·m) Engine mount Bolts 8.

  • Page 63: Inspection For Operation Noise

    PERIODIC INSPECTION 12. Mount the front side engine bracket and tighten Bolts Front side 4 bolts. (4 pieces) Tightening torque 14.8 lb·ft (20.0 N·m) 13. Check the bolts are tightened with the specified tight- ening torque. 14. Lower the jack slowly. Remove the wooden block and jack.

  • Page 64: Remote Controller Operation Inspection

    PERIODIC INSPECTION Remote Controller Operation Inspection 1. Check if the system works properly by operating the system with the remote controller. Inspection interval Every 3 years (10,000 hours) Indoor Unit Temperature Inspection 1. Operate all the indoor units, and measure discharge and intake air temperature for each indoor unit. Inspection interval Every 3 years (10,000 hours) Check After Work...

  • Page 65: Replacement Of Main Components

    REPLACEMENT OF MAIN COMPONENTS REPLACEMENT OF MAIN COMPONENTS 1. Before Starting Your Work Indicates a potentially hazardous situation that could result in death or serious injury. Indicates a potentially hazardous situation that may result in injury as well as damage to properties.
  • Page 66 REPLACEMENT OF MAIN COMPONENTS Necessary tools Tools Purpose Torque wrench Tightening with required torque Hose clipper Clipping hoses Thickness: approximately 1-1/2 inch (40 mm), length: 24 inch (600 mm) or longer, 2 pieces Engine Replacement (8 TON) Thickness: approximately 3 inch (80 mm), length: 24 inch (600 mm) or longer, 1 piece Wooden block...

  • Page 67: Replacement Of Engine Unit

    REPLACEMENT OF MAIN COMPONENTS 2. Replacement of Engine Unit [Necessary items] Part name Part No. Quantity Set, Engine ASSY AISIN Coolant S Parts See parts catalog AISIN Gas Engine Oil L-10000G Bolt, Washer Base Head Hexagon (8 TON only) [ 8 TON ] [Removal] 1.
  • Page 68 REPLACEMENT OF MAIN COMPONENTS 3. Remove the engine coolant pump. 1) Unscrew 2 bolts to remove the cover. Bolts 2) Unscrew 2 bolts to remove the engine coolant pump. Bolts 4. Loosen the drain plug cap, and drain engine coolant from the engine.
  • Page 69 REPLACEMENT OF MAIN COMPONENTS 6. Remove the 2 engine coolant hoses from the engine. Engine coolant hoses Breather hose 7. Remove the breather hose from the exhaust air heat exchanger. 8. Unscrew a bolt connecting the thermostat to the outdoor unit, and separate the thermostat. Bolt Thermostat 9.
  • Page 70 REPLACEMENT OF MAIN COMPONENTS 10. Remove the exhaust air heat exchanger. Exhaust pipe Bolts 1) Unscrew 2 nuts ans 2 bolts to remove the exhaust pipe. NOTE) The outdoor unit has the deodorizing catalyst instead of the exhaust pipe if the deodorant kit Nuts is installed.
  • Page 71 REPLACEMENT OF MAIN COMPONENTS 11. Remove the compressor belt. compressor belt 1) Loosen a locknut and an adjustment bolt adequate- 2) Loosen 4 bolts in the front of the outdoor unit, and remove the compressor belt. Locknut Adjustment bolt Bolts 12.
  • Page 72 REPLACEMENT OF MAIN COMPONENTS 14. Dismount the engine. 1) Place a wooden block (thickness: approximately Bracket 3 inch (80 mm), length: 24 inch (600 mm) or longer) under the compressor bracket. Oil pan 2) Place 2 wooden blocks (thickness: approximately 1-1/2 inch (40 mm), length: 24 inch (600 mm) or longer) under the oil pan.
  • Page 73 REPLACEMENT OF MAIN COMPONENTS 6) Double-check if the hoses or wire harnesses are disconnected from the engine. If connected, disconnect the hoses or wire harnesses. 7) Unscrew 6 bolts (both sides) to remove the engine brackets (both sides). Dismount the engine. NOTE) When placing the engine on the floor, place wooden blocks, rag or other appropriate material on the floor and put the engine on...
  • Page 74 REPLACEMENT OF MAIN COMPONENTS 6) Unscrew a bolt to remove the blow-by hose. Bolt Blow-by hose 7) Unscrew 2 bolts to remove the gas mixer. Gas mixer Bolts 8) Unscrew 6 nuts to remove the exhaust manifold. Nuts (6 pieces)
  • Page 75 REPLACEMENT OF MAIN COMPONENTS [Reassembling] 1. Unscrew 6 bolts from the new engine to remove the flywheel. NOTE) Once removed, the bolts can not be reused. Bolts (6 pieces) Put on the shelf these bolts. 2. Mount the surrounding parts on the new engine. 1) Mount the exhaust manifold and tighten 6 nuts.
  • Page 76 REPLACEMENT OF MAIN COMPONENTS 4) Mount the bracket and tighten 7 bolts. Tightening torque 31.0 lb·ft (42.0 N·m) Bolts Bracket 5) Mount the starter and tighten 2 bolts. Starter Tightening torque 31.0 lb·ft (42.0 N·m) Pulley Bolts 6) Mount the flywheel and tighten new 6 bolts. Bolts NOTE) Use new bolts.
  • Page 77 REPLACEMENT OF MAIN COMPONENTS 4) Mount the brackets (both sides) and tighten 4 bolts. Tightening torque 14.8 lb·ft (20.0 N·m) Bracket Bolts (4 pieces) 5) Fix the engine by tightening 2 bolts of engine mount (both sides). Tightening torque 31.0 lb·ft (42.0 N·m) Bolts Engine mount 6) Mount 3 compressor brackets to the engine and...
  • Page 78 REPLACEMENT OF MAIN COMPONENTS 8) Mount the front side bracket and tighten 5 bolts Front side in the order shown right. ② ①② Tightening torque 14.8 lb·ft (20.0 N·m) ③ ① ③～⑤ Tightening torque 31.0 lb·ft (42.0 N·m) ④ 9) Remove the 3 wooden blocks under the compres- sor bracket and oil pan.
  • Page 79 REPLACEMENT OF MAIN COMPONENTS 6. Mount the compressor belt. Compressor belt 1) Attach the compressor belt. 2) Lightly tighten 4 mounting bolts of front side com- pressor. 3) Adjust the belt tension with the adjustment bolt. Bolts Adjustment bolt Belt tension※ Belt tension adjustment standard (Replacement) Belt tension adjustment standard (Inspection) Mechanical...
  • Page 80 REPLACEMENT OF MAIN COMPONENTS 2) Fix the exhaust air heat exchanger and stay by tightening 2 nuts. Tightening torque 14.8 lb·ft (20.0 N·m) Nuts 3) Fix the exhaust air heat exchanger and stay by tightening 2 bolts. Tightening torque 14.8 lb·ft (20.0 N·m) Bolts 4) Connect the exhaust hose to the exhaust air heat exchanger.
  • Page 81 REPLACEMENT OF MAIN COMPONENTS 3) Connect the 2 relay connectors of the gas mixer Gas mixer Ignition coils wire harnesses. 4) Connect the relay connector of engine oil pressure switch wire harness. 5) Connect the connectors (3 places) to the 4 ignition coils.
  • Page 82 REPLACEMENT OF MAIN COMPONENTS 3) Mount 2 oil trays and tighten 2 bolts. 2.2 ± 0.7 lb·ft Tightening torque (3.0 ± 0.9 N·m) Bolts 13. Mount the engine coolant pump. 1) Mount the engine coolant pump and tighten 2 bolts. 3.7 ±...
  • Page 83 REPLACEMENT OF MAIN COMPONENTS 17. Refill the engine coolant. 1) Open the radiator cap, and fill the radiator with the engine coolant to the full capacity. Radiator cap 50 ~ 60 vol% Engine coolant concentration (engine coolant: 0.55, (volumetric concentration) water: 0.45).
  • Page 84 REPLACEMENT OF MAIN COMPONENTS [ 15 TON ] [Removal] 1. Drain engine oil. Oil hoses 1) Clamp the oil hose with 2 hose clippers at both sides of joint. 2) Disconnect the joint and drain oil from the engine and the sub oil reservoir. Sub oil reservoir 3) Disconnect the 3 oil hoses from the engine.
  • Page 85 REPLACEMENT OF MAIN COMPONENTS 3. Remove the engine coolant pump. Pump inlet side 1) Disconnect the engine coolant hose at the engine coolant pump inlet side. 2) Unscrew 2 bolts to remove the cover. Bolts 3) Unscrew 2 bolts to remove the engine coolant pump.
  • Page 86 REPLACEMENT OF MAIN COMPONENTS 5. Loosen the drain plug cap, and drain engine coolant from the engine. NOTE) It makes draining easier to insert a hose with approximately 1/4 inch (7 mm) inner diameter into the drain plug. Drain plug 6.
  • Page 87 REPLACEMENT OF MAIN COMPONENTS 9. Remove the muffler. Muffler Nuts 1) Unscrew 2 nuts. 2) Disconnect the 2 pipes at the outlet and inlet ports of muffler and remove the muffler. Pipes 10. Remove the exhaust air heat exchanger. 1) Unscrew 2 bolts and 2 nuts to remove the exhaust pipe.
  • Page 88 REPLACEMENT OF MAIN COMPONENTS 2) Loosen a locknut and an adjustment bolt adequate- Compressor belt 3) Loosen 4 bolts in the front of the outdoor unit, and remove the compressor belt. Bolts Adjustment bolt Locknut 12. Disconnect the air intake hose and the fuel gas hose Air intake hose Fuel gas hose from the engine.
  • Page 89 REPLACEMENT OF MAIN COMPONENTS 14. Dismount the engine. Oil pan Bracket 1) Place a wooden block (thickness: approximately 2 inch (55 mm), length: 24 inch (600 mm) or longer) under the compressor bracket. 2) Place 2 wooden blocks (thickness: approximately 4-1/2 inch (115 mm), length: 24 inch (600 mm) or longer) under the oil pan.
  • Page 90 REPLACEMENT OF MAIN COMPONENTS 7) Unscrew 2 bolts to remove the bracket (front side). Bolts Front side 8) Unscrew 4 bolts to remove the bracket (rear side). Rear side Bolts (4 pieces) Dismount the engine. NOTE) When placing the engine on the floor, place wooden blocks, rag or other appropriate mate- rial on the floor and put the engine on it care- fully so that the pipes on the bottom of the oil...
  • Page 91 REPLACEMENT OF MAIN COMPONENTS [Reassembling] 1. Mount the surrounding parts on the new engine. Blow-by hose 1) Mount the gas mixer. Tighten it with a bolt and 2 nuts. NOTE) Replace the gasket before installing the gas Nuts mixer. Tightening torque 14.8 lb·ft (20.0 N·m) Bolt Gas mixer...
  • Page 92 REPLACEMENT OF MAIN COMPONENTS 2. Reassemble the engine. Bracket Oil pan 1) Place a wooden block (thickness: approximately 2 inch (55 mm), length: 24 inch (600 mm) or longer) under the compressor bracket. 2) Place 2 wooden blocks (thickness: approximately 4-1/2 inch (115 mm), length: 24 inch (600 mm) or longer) where the engine is placed.
  • Page 93 REPLACEMENT OF MAIN COMPONENTS 7) Tighten 2 bolts of engine mount bracket. Tightening torque 31.0 lb·ft (42.0 N·m) Bracket Front side Bolts 8) Mount 3 compressor brackets to the engine and tighten 11 connecting bolts (2 of the bolts are installed from the engine side).
  • Page 94 REPLACEMENT OF MAIN COMPONENTS 2) Connect the 3 exhaust water drain hoses to the box. Exhaust water drain hose 4. Connect the air intake hose and the fuel gas hose to Air intake hose Fuel gas hose the engine. 5. Mount the compressor belt. Compressor belt 1) Attach the compressor belt.
  • Page 95 REPLACEMENT OF MAIN COMPONENTS 6. Mount the front side stay and tighten 5 bolts. 31.0 ± 6.2 lb·ft Tightening torque (42.0 ± 8.4 N·m) Bolts (5 pieces) Front side 7. Reassemble the exhaust air heat exchanger. Bolts 1) Mount the bracket and tighten 2 nuts. Tightening torque 31.0 lb·ft (42.0 N·m) Exhaust air heat...
  • Page 96 REPLACEMENT OF MAIN COMPONENTS 3) Connect the 2 pipes at the outlet and inlet ports of muffler, and install the muffler. Muffler Pipes 9. Install each wire harness Gas mixer Igniter 1) Connect the 2 wire harnesses to the starter. Engine coolant 2) Connect the 2 relay connectors of the gas mixer t e mp e r a t u r e...
  • Page 97 REPLACEMENT OF MAIN COMPONENTS 12. Mount the engine mount parts. 1) Mount the stay and tighten 2 nuts. 8.9 ± 2.7 lb·ft Tightening torque (12.0 ± 3.6 N·m) Nuts 2) Mount 2 oil trays and tighten 6 bolts. Oil tray ① Tightening torque for 2.2 ±...
  • Page 98 REPLACEMENT OF MAIN COMPONENTS 14. Connect the 3 oil hoses to the engine. Oil hoses 15. Check that all the hoses are securely fixed. 16. Remove all the hose clippers clamping the hoses. Sub oil reservoir 17. Refill the engine coolant. 1) Open the radiator cap, and fill the radiator with the engine coolant to the full capacity.

  • Page 99: Replacement Of Cylinder Head

    REPLACEMENT OF MAIN COMPONENTS 3. Replacement of Cylinder Head [Necessary items] Part name Part No. Quantity Set, Cylinder Head ASSY Parts AISIN Coolant S See parts catalog AISIN Gas Engine Oil L-10000G Small amount [ 8 TON ] [Removal] 1. Drain engine coolant. 1) Clamp the engine coolant hoses at the outlet and Clamping positions inlet ports of the radiator (2 places) with 2 hose...
  • Page 100 REPLACEMENT OF MAIN COMPONENTS 2. Disconnect each wire harness. Ignition coils Gas mixer 1) Disconnect 2 relay connectors of the gas mixer wire harness. 2) Disconnect connectors from the ignition coils (3 places). 3) Disconnect a relay connector of the engine coolant temperature sensor wire harness.
  • Page 101 REPLACEMENT OF MAIN COMPONENTS 7. Remove the surrounding parts of cylinder head. 1) Unscrew a bolt to remove the blow-by hose. Bolt 2) Unscrew 6 bolts to remove the intake manifold. Bolts (6 pieces) 3) Unscrew the 3 bolts (3 places) and remove the 3 ignition coils.
  • Page 102 REPLACEMENT OF MAIN COMPONENTS 8. Remove the cylinder head. 1) Loosen 3 nuts to remove the rocker shaft ASSY NOTE) The valve stem caps stick to the rocker shaft Nuts ASSY with engine oil. Take care not to drop the valve stem caps into the engine. 2) Remove 6 valve stem caps.
  • Page 103 REPLACEMENT OF MAIN COMPONENTS [Reassembling] 1. Remove completely the gasket or dirt sticking to the sealing surface such as the cylinder block upper surface, water inlet bracketor water outlet bracket with a scraper or a gasket remover. NOTE) Make sure that dust does not enter the oil inlet, engine coolant inlet or bolt hole. Never use a gasket remover on anything other than metallic portions.
  • Page 104 REPLACEMENT OF MAIN COMPONENTS 4) Apply engine oil to the both ends of the 6 push rods, Valve stem cap and install them in the order of removal. 5) Mount the 6 valve stem caps on the valve. 6) Mount the rocker shaft so that the adjustment Rocker shaft screws come into the cup of the push rods, and tighten 3 nuts.
  • Page 105 REPLACEMENT OF MAIN COMPONENTS 4) Mount the intake manifold with 6 bolts. NOTE) Replace the gasket before mounting the Bolts (6 pieces) intake manifold. 5) Mount the blow-by hose and tighten the bolt. Tightening torque 6.3 lb·ft (8.5 N·m) Bolts 6.
  • Page 106 REPLACEMENT OF MAIN COMPONENTS 8. Install each wire harness Gas mixer Ignition coils 1) Connect the 2 relay connectors of the gas mixer wire harness. 2) Connect the 3 connectors to the ignition coils. 3) Connect the relay connector of the engine coolant temperature sensor wire harness.
  • Page 107 REPLACEMENT OF MAIN COMPONENTS 4) Check the engine coolant level in the reserve tank, and refill the engine coolant until the engine coolant Reference line reaches the reference line. 5) Run the engine coolant pump using check mode "engine coolant refill mode (code No. OA)" of the board maintenance functions.
  • Page 108 REPLACEMENT OF MAIN COMPONENTS [ 15 TON ] [Removal] 1. Drain engine coolant. Clamping positions 1) Clamp the engine coolant hoses at the outlet and inlet ports of the radiator (2 places) with 2 hose clippers. 2) Loosen the drain plug cap, and drain engine coolant from the engine.
  • Page 109 REPLACEMENT OF MAIN COMPONENTS 3. Remove the muffler. Nuts Muffler 1) Unscrew 2 nuts. 2) Disconnect the 2 pipes at the outlet and inlet ports of muffler and remove the muffler. Pipes 4. Remove the exhaust air heat exchanger. 1) Unscrew 2 bolts and 2 nuts to remove the exhaust pipe.
  • Page 110 REPLACEMENT OF MAIN COMPONENTS 6. Disconnect the air intake hose, the fuel gas hose and Oil hose the oil hose from the engine. Fuel gas hose Air intake hose 7. Disconnect the blow-by hose. Blow-by hose 8. Pull the caps to remove the cables (4 places). Spark plugs 9.
  • Page 111 REPLACEMENT OF MAIN COMPONENTS 2) Unscrew 6 bolts and 2 nuts to remove the exhaust Bolts (6 pieces) manifold. Nuts 3) Unscrew 3 bolts and 2 nuts to remove the oil return Bolts pipe. Nuts 4) Unscrew a bolt to remove the front side engine Front side hanger.
  • Page 112 REPLACEMENT OF MAIN COMPONENTS 7) Unscrew 3 bolts to remove the cylinder head cover. Bolts Cylinder head cover 11. Remove the cylinder head. 1) Loosen the bolts and nuts evenly in several rounds in the order shown right, and remove the rocker shaft assembly.
  • Page 113 REPLACEMENT OF MAIN COMPONENTS [Reassembling] 1. Remove completely the old gasket or dirt sticking to the cylinder block upper surface and sealing surface of the exhaust manifold and other parts with a scraper or a gasket remover. NOTE) Make sure that dust does not enter the oil inlet, engine coolant inlet or bolt hole. Never use a gasket remover on anything other than metallic portions.
  • Page 114 REPLACEMENT OF MAIN COMPONENTS 4. Mount the surrounding parts on the cylinder head. Bolts Cylinder head cover 1) Attach the cylinder head cover with 3 bolts. 2) Mount the water outlet bracket with 2 bolts. Bolts NOTE) Replace the gasket before mounting the water outlet bracket.
  • Page 115 REPLACEMENT OF MAIN COMPONENTS 7) Mount the igniter and 4 ignition coils with the brack- Nuts et by 2 bolts and 2 nuts. Bracket Bolts 5. Mount the 4 high voltage cables. Spark plugs 6. Mount the spark plugs with a plug wrench. (4 places) (4 places) Caps (4 places)
  • Page 116 REPLACEMENT OF MAIN COMPONENTS 9. Reassemble the exhaust air heat exchanger. 1) Mount the exhaust air heat exchanger. Tighten it with 2 nuts and 2 bolts. Bolts Bolts Tightening torque 31.0 lb·ft (42.0 N·m) Nuts Nuts 2) Mount the exhaust pipe. Tighten it with 2 nuts and 2 bolts.
  • Page 117 REPLACEMENT OF MAIN COMPONENTS 12. Mount the muffler. Nuts Muffler 1) Mount the muffler to the stay and tighten 2 nuts lightly. Tightening torque 8.9 lb·ft (12.0 N·m) 2) Tighten 2 nuts firmly. Tightening torque 8.9 lb·ft (12.0 N·m) NOTE) Be sure to tighten 2 nuts lightly and firmly. 3) Connect the 2 pipes at the outlet and inlet ports of muffler, and install the muffler.

  • Page 118: Replacing The Compressor

    REPLACEMENT OF MAIN COMPONENTS 4. Replacing the Compressor [Necessary items] Part name Part No. Quantity Compressor (supply kit) 1 / compressor 1 unit Parts Dryer filter See parts catalog Refrigerant oil (NL10) As required [ 8 TON ] Replace only the compressor that needs replacement although this section shows how to ●...
  • Page 119 REPLACEMENT OF MAIN COMPONENTS NOTE) If the liquid refrigerant accumulates in the ac- cumulator during recovery, warm and vapor- ize the liquid refrigerant with a heat gun and recover all refrigerant. Accumulator 2. Perform the following work while recovering the Oil filter Inlet side hose refrigerant.
  • Page 120 REPLACEMENT OF MAIN COMPONENTS 7) Unscrew 2 bolts and move the exhaust water drain filter not to cause an obstrustion. 8) Loosen a locknut and an adjustment bolt adequate- Bolts Lock nut Adjustment bolt 9) Take out 4 bolts. Compressor belt Bolts NOTE) When removing the mounting bolts, catch the No.
  • Page 121 REPLACEMENT OF MAIN COMPONENTS [Reassembling] 1. Remove the port cover of the new compressor. Supply the specified amount of refrigeration oil Electromagnetic compressor Discharge ports capacity valve ports through the intake and discharge ports. Refrigeration Specified amount to be supplied oil name Intake side 1.7 fl oz.
  • Page 122 REPLACEMENT OF MAIN COMPONENTS 5. Check that the steel plate and the bracket under the compressor main unit are in the correct position (see right). NOTE) Mount the steel plate so that the bent portion faces down. Bracket Bent portion Iron plate 6.
  • Page 123 REPLACEMENT OF MAIN COMPONENTS 5) Hold the 2 stays (plate-shaped) at No. 1 compres- Bolts (4 pieces) No.1 sor side under the bracket with your hand paying attention to the direction.Holding the stays, tighten 4 bolts lightly so that the No. 1 compressor moves. Stay mounting position Rounded corner Bracket side...
  • Page 124 REPLACEMENT OF MAIN COMPONENTS 9. Perform the following work while vacuuming (operat- Compressor belt ing the vacuum pump for 1 hour or longer after the pressure drops to -14.65 psi (-101 kPa, -755 mmHg) or lower). 1) Move the No. 1 compressor until the compressor belt is tight, and tighten 4 bolts lightly.
  • Page 125 REPLACEMENT OF MAIN COMPONENTS NOTE) Make sure that misalignment between the 3/8 inch or less edge line of the crank pulley groove and the Crank pulley edge line of the compressor pulley groove is 1/8 inch (3 mm) or less when measured on the Compressor pulley crankshaft axis.
  • Page 126 REPLACEMENT OF MAIN COMPONENTS 10. After finishing vacuuming, refill the specified amount of refrigerant. Standard amount of refrigerant 25.4 lbs (11.5 kg) Calculate additional refrigerant refilling amount using the formula indicated below : Refilling amount (lbs) = (l x 0.237) + (l x 0.168) + (l x 0.114) + (l x 0.074) + (l...
  • Page 127 REPLACEMENT OF MAIN COMPONENTS [ 15 TON ] Replace only the compressor that needs replacement although this section shows how to ● replace 2 compressors at the same time. [Removal] 1. Perform refrigerant recovery. (Refer to the following diagram.) Recovery from the outdoor and indoor units at the same time: Recover the refrigerant from the outdoor unit stop valves (liquid and vapor).
  • Page 128 REPLACEMENT OF MAIN COMPONENTS 2. Perform the following work while recovering the Bolts refrigerant. 1) Unscrew 15 bolts to remove the 3 stays. Stays NOTE) Unscrew bolts holding the stays with your hand to prevent the stays from falling. Bolts 2) Cut off the bundling bands fixing the compressor Compressor heater heater, compressor clutch (for only No.2 compres-...
  • Page 129 REPLACEMENT OF MAIN COMPONENTS 3. Check that no refrigerant is left in the main unit, and Discharge port Intake port perform the following work. 1) Turn the compressor pulley (clutch plate as for No. 2 compressor) a few turns by hand. 2) Loosen each 2 bolts of intake (upper side) and dis- charge ports.
  • Page 130 REPLACEMENT OF MAIN COMPONENTS [Reassembling] 1. Remove the port cover of the new compressor. Supply the specified amount of refrigeration oil Electromagnetic compressor Discharge ports capacity valve ports through the intake and discharge ports. Refrigeration Specified amount to be supplied oil name Intake side 1.7 ft oz.
  • Page 131 REPLACEMENT OF MAIN COMPONENTS 6. Check that the steel plate and the bracket under the compressor main unit are in the correct position (see right). NOTE) Mount the steel plate so that the bent portion faces down. Bracket Bent portion Steel plate 7.
  • Page 132 REPLACEMENT OF MAIN COMPONENTS 5) Hold the 2 stays (plate-shaped) at No. 1 compres- No.1 Bolts (4 pieces) sor side under the bracket with your hand paying attention to the direction. Holding the stays, tighten 4 bolts lightly so that the No. 1 compressor moves. Stay mounting direction Rounded corner Bracket side...
  • Page 133 REPLACEMENT OF MAIN COMPONENTS 10. Perform the following work while vacuuming (operat- Compressor belt ing the vacuum pump for 1 hour or longer after the pressure drops to -14.65 psi (-101 kPa, -755 mmHg) or lower). 1) Connect the oil tube to the oil tank. 2) Move the No.
  • Page 134 REPLACEMENT OF MAIN COMPONENTS NOTE) Make sure that misalignment between the edge line of the crank pulley groove and the 1/8 inch or less edge line of the compressor pulley groove is 1/8 inch (3 mm) or less when measured on the Crank pulley crankshaft axis.
  • Page 135 REPLACEMENT OF MAIN COMPONENTS =Liquid piping Ф7/8 inch total length (ft) =Liquid piping Ф22.22 mm total length (m) =Liquid piping Ф3/4 inch total length (ft) =Liquid piping Ф19.05 mm total length (m) =Liquid piping Ф5/8 inch total length (ft) =Liquid piping Ф15.88 mm total length (m) =Liquid piping Ф1/2 inch total length (ft) =Liquid piping Ф12.70 mm total length (m) =Liquid piping Ф3/8 inch total length (ft)

  • Page 136: Control

    CONTROL CONTROL 1. System Control Functions System Block Diagram...

  • Page 137: Control Details

    CONTROL 2. Control Details Temperature Control Start / Stop 1. Condition to start temperature control operation of the outdoor unit Temperature control starts when both of the following conditions are met. Condition to start temperature control shown below is met. AND The outdoor unit is not prohibited from starting.

  • Page 138: Transition From Start Control To Normal Operation Control

    CONTROL 4. Warm-up start When the remote controller starts the system, the control system gives priority to keeping engine coolant temperature at a certain level within 15 minutes after engine start. To do so, the control system controls the hot gas bypass valve with engine coolant temperature and refrigerant low pressure. For details, refer to Refer to P139, [ ④...
  • Page 139 [MEMO] << 8 TON Heating >> Electromagnetic Electromagnetic Number of operating Apparent engine Engine speed (rpm (min compressor capacity compressor capacity compressors speed (rpm (min (950P) valve 1 valve 2 3000 ERPMmax = 3000 2000 2000 1500 1500 1000 1000 1000 ERPMmin = 800 1200...
  • Page 140 CONTROL << 15 TON Heating >> Electromagnetic Electromagnetic Number of operating Apparent engine Engine speed (rpm (min compressor capacity compressor capacity compressors speed (rpm (min (3Y) valve 1 valve 2 2125 ERPMmax = 2125 1500 1500 1000 1000 ERPMmin = 600 1200 2.
  • Page 141 CONTROL Outdoor heat exchanger liquid flow control valve ② Outdoor heat exchanger liquid flow control valve controls the degree of superheat at the outlet of the outdoor heat exchanger. 1. Outdoor heat exchanger liquid flow control valve open position range In cooling : Fixed at 0 steps (without control) In heating : 60 ~ 500 steps 2.

  • Page 142: Defrosting (In Heating Only)

    CONTROL Subcooling valve control ⑤ Subcooling valve is used for the following purposes: Subcooling demand control • Subcooling demand con- trol of the outdoor heat exchanger (cooling only) • Apparent engine speed control (cooling only) • Upper limit control of the intake degree of superheat • Intake temperature avoidance lower limit control • Intake degree of superheat lower limit control (heating only) 1.

  • Page 143: Outdoor Fan

    CONTROL 3. How the system operates during defrost control The system operates as follows during defrost control. (1) Apparent engine speed is controlled by normal control in heating operation. (2) Sub heat exchanger liquid flow control valve is set to standard upper limit open position, and normal control in heating operates after that.

  • Page 144: Oil Bypass Control Valve

    CONTROL Condition to decrease fan air volume The engine compartment temperature is lower than the specified value. OR The difference between outside air temperature and low pressure equivalent temperature is smaller than the specified value and the engine coolant temperature is lower than the specified value. Oil Bypass Control Valve Oil bypass control valve is used for apparent engine speed demand control, abnormal compressor intake temperature avoidance control, and abnormal compressor intake degree of superheat avoidance control.

  • Page 145: (Conceptual Chart)

    CONTROL Flow Chart of Backup Operation under Combined Installation (Conceptual Chart) (1) When 2 outdoor units is operating This chart is a general conceptual flow chart. Backup operation may not start depending on error type. The number of retries until backup operation varies depending on error type. Backup operation is reset when the outdoor unit detects an error (determinate error) during backup operation.
  • Page 146 CONTROL (2) When 1 outdoor units is operating This chart is a general conceptual flow chart. Backup operation may not start depending on error type. The number of retries until backup operation varies depending on error type. Backup operation is reset when the outdoor unit detects an error (determinate error) during backup operation. The reset of the remote controller may not be possible depending on error type.

  • Page 147: Function Settings

    CONTROL 3. Function Settings Outdoor unit Various function settings The outdoor unit has EEPROM dip switches on the outdoor control PCB. The contents and the factory defaults are as follows. Be sure to set #4 pin of #1 EEPROM dip switch to "Enabled" if the deodorant kit is installed. If not, the protection device may not work properly and result in smoke, fire or damage to the unit.
  • Page 148 CONTROL EEPROM dip switch 2 (Setting can be changed with check code No. 81) Factory Pin No. Functions default Setting of cool/heat OFF : Indoor unit ON : Outdoor unit switching (※3) OFF: Master OFF: Pro- Dependent Individual Master control (※3) collec- hibited collective...
  • Page 149 CONTROL EEPROM dip switch 5 (Setting can be changed with check code No. 84) Pin No. Functions Factory default － － － － － － － － － － － － － － － － EEPROM dip switch 6 (Setting can be changed with check code No. 85) Pin No.

  • Page 150: Cool/Heat Switching Setting

    CONTROL Cool/Heat Switching Setting There are the following 5 methods to switch between cooling and heating. The indoor unit remote controller sets cooling or heating for individual outdoor unit system. The cool/heat selector sets cooling or heating for individual outdoor unit system. The indoor unit remote controller sets cooling or heating for multiple outdoor unit systems collectively in accordance with the collective master outdoor unit.
  • Page 151 CONTROL 4) Set DS2 and DS1 of the outdoor external control adapter so that they agree with the cooling / heating collective address of the outdoor control PCB with the check mode code No. dA. (Factory set addresses are all "OFF".) 5) Set SS 2 of the outdoor external control adapter to "ON".

  • Page 152: System Input/Output Specifications

    CONTROL 4. System Input/Output Specifications Outdoor Unit Input / Output Specifications Name Functions Specifications Connector No. DCBL PCB FM1: CN7[1]-[2]-[3] CN10[1]- Outdoor fan Heat exchange of refrigerant and cooling the Rated: 280 V DC [2]-[3]-[4]-[5] FM2: motor engine coolant DC brushless CN8[1]-[2]-[4] CN12[1]- [2]-[3]-[4]-[5] 1.
  • Page 153 CONTROL Name Functions Specifications Connector No. IGN1: CN8[1]-[3] IGN2: CN8[2]-[3] To generate high voltage necessary for the Ignition coil Rated: 12 V DC spark plugs IGN3: CN8[7]-[3] IGN4※2: CN8[8]-[3] Exhaust water To turn ON to prevent freezing of exhaust Cold district PCB drain heater water drain filter and exhaust water drain Rated : 200 V AC...
  • Page 154 CONTROL Name Functions Specifications Connector No. 1. Control of outdoor heat exchanger liquid Outdoor heat Refer to P177 and af- flow control valve in heating operation exchanger ter, [Parts Character- THG: CN4[17]-[18] vapor tempera- 2. Detection of disconnection or short circuit istics].
  • Page 155 CONTROL Name Functions Specifications Connector No. 1. Engine coolant temperature maintaining control at engine start 2. Refrigerant high pressure avoidance Hot gas bypass control Rated : 200 V AC BV: CN11[1]-[7] valve 3. Freezing prevention control in cooling operation 4. Pressure equalizing control at system stop To turn ON in heating NOTE) To switch the mode at the start of Reversing valve...

  • Page 156: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING 1. Error Code Description and Possible Cause Error code Contents Error detection / Judgment Outdoor control PCB display Code Sub code n (Air net Indoor drain failure The float switch repeats ON and OFF 5 times or more while the address) temperature control is OFF.
  • Page 157 TROUBLESHOOTING Method of diagnosis / repair Error Treatment frequency Display until error Possible major causes Diagnosis / Repair display ※ ※ Warning 1. Drain system failure Refer to P232, 58)Check Drain Water 2. Water supply/drain water system failure 2. Check humidifier for water leak of the humidifier 3.
  • Page 158 TROUBLESHOOTING Error code Contents Error detection / Judgment Outdoor control PCB display Code Sub code n (Air net Indoor remote controller sensor Indoor remote controller sensor disconnection or short circuit address) failure during operation. n (Air net Indoor unit transmission failure Communication failure between indoor PCBs address) (Indoor control PCB - fan PCB,...
  • Page 159 TROUBLESHOOTING Method of diagnosis / repair Error Treatment frequency Display until error Possible major causes Diagnosis / Repair display ※ ※ Alert 1. Connector contact failure 1. Check connector connection 2. Indoor remote controller sensor failure 2. Inspect indoor remote controller sensor 3.
  • Page 160 TROUBLESHOOTING Error code Contents Error detection / Judgment Outdoor control PCB display Code Sub code Engine coolant pump starting 10 seconds after starting of the engine coolant pump, the pump failure speed is lower than 1,400 rpm (min Engine coolant pump speed When any of the following occurs at engine coolant pump failure operation:...
  • Page 161 TROUBLESHOOTING Method of diagnosis / repair Error Treatment frequency Display until error Possible major causes Diagnosis / Repair display ※ ※ 15 in a row Error 1. Connector contact failure 1. Check connector connection 2. Engine coolant pump failure Refer to P215, 24)Inspect Engine 3.
  • Page 162 TROUBLESHOOTING Error code Contents Error detection / Judgment Outdoor control PCB display Code Sub code All fan motor starting failure or No fan motor can operate due to starting failure or abnormal speed failure speed. (Refer to the following for details.) Fan motor 1 starting failure The fan motor speed is lower than 50 rpm (min ) after 10 sec-...
  • Page 163 TROUBLESHOOTING Method of diagnosis / repair Error Treatment frequency Display until error Possible major causes Diagnosis / Repair display ※ ※ Error 1. Connector of fan motor contact failure 1. Check connector of fan motor connec- 2. Fan motor failure tion 3.
  • Page 164 TROUBLESHOOTING Error code Contents Error detection / Judgment Outdoor control PCB display Code Sub code ℉ Excessive compressor intake The compressor intake temperature sensor detects 140 ℃ temperature ) or higher for 10 minutes during compressor operation. Insufficient degree of superheat After a compressor kicks in, length of time described below for compressor intake ℉...
  • Page 165 TROUBLESHOOTING Method of diagnosis / repair Error frequen- Treatment cy until error Display Possible major causes Diagnosis / Repair display ※ ※ 2/10 hours Error 1. Connector of compressor intake temper- 1. Check for connector of compressor ature sensor contact failure intake temperature sensor connection 2.
  • Page 166 TROUBLESHOOTING Error code Contents Error detection / Judgment Outdoor control PCB display Code Sub code Engine oil pressure switch The engine oil pressure switch OFF is detected for 5 seconds disconnection at starting. (At the first and second times of failure detection, the engine is driven for 3 seconds and stops.
  • Page 167 TROUBLESHOOTING Method of diagnosis / repair Error frequen- Treatment cy until error Display Possible major causes Diagnosis / Repair display ※ ※ 5 in a row Error 1. Connector contact failure 1. Check connector connection 2. Engine oil pressure switch failure Refer to P220, 34)Inspect Engine Oil 3.
  • Page 168 TROUBLESHOOTING Error code Contents Error detection / Judgment Outdoor control PCB display Code Sub code Outdoor heat exchanger vapor The outdoor heat exchanger vapor temperature sensor detects ℉ ℃ temperature sensor disconnec- lower than -38 (-39 ) for 1 minute. tion Outdoor heat exchanger vapor The outdoor heat exchanger vapor temperature sensor detects...
  • Page 169 TROUBLESHOOTING Method of diagnosis / repair Error frequen- Treatment cy until error Display Possible major causes Diagnosis / Repair display ※ ※ Error C, E 1. Connector connection failure 1. Check connector connection 2. Outdoor heat exchanger vapor tempera- 2. Inspect outdoor heat exchanger vapor ture sensor failure pipe temperature sensor (Refer to...
  • Page 170 TROUBLESHOOTING Error code Contents Error detection / Judgment Outdoor control PCB display Code Sub code Engine speed control failure When 15 seconds or more have past after the start of the compressor, 1. Engine speed of lower than minimum engine speed muinus 50 rpm (min ) is detected for 60 seconds.
  • Page 171 TROUBLESHOOTING Method of diagnosis / repair Error frequen- Treatment cy until error Display Possible major causes Diagnosis / Repair display ※ ※ 3 in a row Error 1. Intake and exhaust air system failure 1. Check connector connection 2. Ignition system failure Refer to P184, 2)Engine will not Start 3.
  • Page 172 TROUBLESHOOTING Error code Contents Error detection / Judgment Outdoor control PCB display Code Sub code n (Air net Refrigerant system is not set / Indoor unit system has no outdoor unit setting. address) Improper wiring For example, indoor unit is connected to outdoor - outdoor unit line.
  • Page 173 TROUBLESHOOTING Method of diagnosis / repair Error frequen- Treatment cy until error Display Possible major causes Diagnosis / Repair display ※ ※ Error Improper wiring Check wiring Error Signal wire between indoor and outdoor Check signal wire between indoor and units improper wiring outdoor units Error...
  • Page 174 TROUBLESHOOTING Error code Contents Error detection / Judgment Outdoor control PCB display Code Sub code Communication failure between <Automatic address setting failure> outdoor units 2 Master unit: When any of the following occurs. 1. Memorized address of the outdoor unit connected to the indoor unit is a dependent unit address.
  • Page 175 TROUBLESHOOTING Method of diagnosis / repair Error Treatment frequency Display until error Possible major causes Diagnosis / Repair display ※ ※ Error 1. Power supply is OFF during operation. Refer to P198, 1)Check Power Supply (Power failure, open phase) System 2.
  • Page 176 TROUBLESHOOTING Error code Contents Error detection / Judgment Outdoor control PCB display Code Sub code Communication failure between <Usual communication failure under combined installation> outdoor units 7 Master unit: Among the following list, the same thing occurs 3 times or more within 10 seconds. 1.
  • Page 177 TROUBLESHOOTING Error Method of diagnosis / repair Treatment frequency Display until error Possible major causes Diagnosis / Repair display ※ ※ Error B, E 1. Power supply is OFF during operation. Refer to P198, 1)Check Power Supply (Power failure, open phase) System 2.
  • Page 178 TROUBLESHOOTING NOTE) Start prohibition control after "LF" (start failure) is displayed Depending on the starter signal ON time, the start failure reset is restricted. Start failure reset is restricted in order to prevent starter overheating. (Unable to reset the "LF" indication) In that case, try to reset the error with appropriate intervals.

  • Page 179: Parts Characteristics

    TROUBLESHOOTING 2. Parts Characteristics [Outdoor unit system] Inspection item Measurement point Normal voltage (V) Normal resistance value (Ω) Remark Electric leakage breaker Red-White-Black 1-2-3 (ELB) Red-White-Black R-S-T Terminal block 1 (for power NOTE) Measure the voltage at CN13[1]-[2] Red-White 200 V AC supply) (TB1) R-S (Red-White).
  • Page 180 TROUBLESHOOTING [Engine system] Inspection item Measurement point Normal voltage (V) Normal resistance value (Ω) Remark Throttle valve (STM) CN6[16] Brown CN6[18] Red 120 Ω ℉ ℃ CN6[19] Blue -30 ~ +30 V DC pulse wave CN6[21] Orange CN6[15] Yellow 240 Ω ℉...
  • Page 181 TROUBLESHOOTING Inspection item Measurement point Normal voltage (V) Normal resistance value (Ω) Remark Ignition coils 1 ~ 4 (IG1 ~ 4) 1; CN8[1]-[3] White-Black Primary resistance value ℉ ℃ (IG4 is 15 TON only) 2; CN8[2]-[3] Yellow-Black 13~15 VDC 3; CN8[7]-[3] Blue-Black 8 TON 2.8 Ω...
  • Page 182 TROUBLESHOOTING Inspection item Measurement point Normal voltage (V) Normal resistance value (Ω) Remark Compressor discharge pipe 1: CN4[27]-[28] Temperature Resistance • Disconnection temperature is ℉ ℃ ℉ temperature sensors 1, 2 (Ω) detected (lower than 41 White-White ℃ (C/P T1, C/P T2) 2: CN4[25]-[26] 32 (0) 182.9 k...
  • Page 183 TROUBLESHOOTING Inspection item Measurement point Normal voltage (V) Normal resistance value (Ω) Remark Refrigerant high pressure CN30[1]-[2] Red-Red An error is detected when the switches 1, 2 (HLSW1, 2) sensor detects 551 psi. (3.8 (HLSW2 is 15 TON only) MPa) (OFF). Normal state is resumed at the detection of 421 psi (2.9 MPa) (ON).
  • Page 184 TROUBLESHOOTING Inspection item Measurement point Normal voltage (V) Normal resistance value (Ω) Remark Oil bypass control valve CN5[8] Red Red-White (OVEV) CN5[6] Brown Red-Orange CN5[1] Blue 46 ± 4 Ω NOTE) When the elecrtonic Brown-Yellow expansion valve is 5 cores CN5[3] Orange 11 ~ 13 V DC (without brown), substitute...

  • Page 185: Failure Phenomenon

    TROUBLESHOOTING 3. Failure Phenomenon The System will not Operate Problem Possible Cause Specific Example Inspection and Treatment Error in connecting the power Refer to P198, 1)Check Power Supply supply wires System Contact failure / disconnection Power supply system failure No operation. Control unit failure Refer to P198, 2)Check Control Unit No display on the remote...

  • Page 186: Engine Will Not Start

    TROUBLESHOOTING Engine will not Start Problem Possible Cause Specific Example Inspection and Treatment Pinion drive coil failure Refer to P199, 5)Inspect Starter pinion does not work Starter Starter unit failure Transformer failure Refer to P199, 6)Inspect P8 (74-1) error Starter Transformer Starter drive system terminal contact failure Starter drive system failure Refer to P200, 7)Operation...

  • Page 187: Engine Starts But Stalls

    TROUBLESHOOTING Engine Starts But Stalls Problem Possible Cause Specific Example Inspection and Treatment Refer to P200, 8)Inspect Fuel Gas Fuel gas pressure failure Pressure Electromag- Electromagnetic gas valve Fuel gas netic gas valve failure Refer to P200, 9)Inspect Electromag- operation netic Gas Valve Output failure failure...

  • Page 188: Engine Coolant Temperature Abnormality

    TROUBLESHOOTING Engine Coolant Temperature Abnormality Problem Possible Cause Specific Example Inspection and Treatment Refer to P214, 22)Check Engine Coolant Circulation Insufficient engine coolant Refer to P214, 23)Check Engine Coolant Amount or Leakage Location Engine coolant circulation failure Engine coolant pump Engine coolant Refer to P215, 24)Inspect Engine Cool- failure...

  • Page 189: Over Speed

    TROUBLESHOOTING Over Speed Problem Possible Cause Specific Example Inspection and Treatment Engine throttle valve failure Stuck engine throttle valve Refer to P210, 16)Inspect En- Engine system Gas mixer operation P8 (82) error gine Throttle Valve / Fuel Gas Fuel gas flow control valve failure failure Flow Control Valve...

  • Page 190: High Pressure Abnormality In Heating Operation

    TROUBLESHOOTING High Pressure Abnormality in Heating Operation Problem Possible Cause Specific Example Inspection and Treatment Obstacle Clean up obstacle (contact with other objects) Indoor fan motor Indoor fan motor failure operation failure Refer to P224, 41)Inspect Indoor Indoor fan capacitor failure Fan Motor Heat exchange Output failure...

  • Page 191: Refrigerant Low Pressure Abnormality

    TROUBLESHOOTING Refrigerant Low Pressure Abnormality Problem Possible Cause Specific Example Inspection and Treatment Obstacle Clean up obstacle (contact with other objects) Indoor fan motor Indoor fan motor failure operation failure Refer to P224, 41)Inspect In- Indoor fan capacitor failure door Fan Motor Output failure Heat exchange at the evaporator...

  • Page 192: Overheated Refrigerant Discharge Temperature In Cooling Operation

    TROUBLESHOOTING Overheated Refrigerant Discharge Temperature in Cooling Operation Problem Possible Cause Specific Example Inspection and Treatment Obstacle Clean up obstacle (contact with other objects) Outdoor fan motor operation failure Outdoor fan motor failure Refer to P217, 27)Inspect Outdoor Fan Motor Heat exchange Output failure at the condenser...

  • Page 193: Overheated Refrigerant Discharge Temperature In Heating Operation

    TROUBLESHOOTING Overheated Refrigerant Discharge Temperature in Heating Operation Problem Possible Cause Specific Example Inspection and Treatment Obstacle Clean up obstacle (contact with other objects) Indoor fan motor Indoor fan motor failure operation failure Refer to P224, 41)Inspect Indoor Indoor fan capacitor failure Fan Motor Heat exchange Output failure...

  • Page 194: Communication Failure / Indoor Unit System Failure

    TROUBLESHOOTING Communication Failure / Indoor Unit System Failure Problem Possible Cause Specific Example Inspection and Treatment Refer to P232, 58)Check Drain Drain system failure Water AF (30) error Indoor drain failure Water supply/drain water system Humidifier failure Check humidifier for water leak failure of the humidifier Drain pump failure Drain pump...
  • Page 195 TROUBLESHOOTING Problem Possible Cause Specific Example Inspection and Treatment Refer to P198, 1)Check Power Power of some of the indoor units is OFF, when one Supply System remote controller controls multiple indoor units. Check fuse and transformer Remote controller Block noise path and shield the line failure Noise in remote controller wiring U5 (1) error...

  • Page 196: Gas Heat Pump Is Operating But Not Cooling

    TROUBLESHOOTING Gas Heat Pump is Operating but Not Cooling Problem Possible Cause Specific Example Inspection and Treatment Compressor clutch failure Compressor clutch Refer to P232, 61)Inspect Compressor Contact failure operation failure Clutch Output failure Indoor intake air temperature sensor malfunc- tion (Sensor judges the room temperature compressor lower than the actual value and the tempera-...
  • Page 197 TROUBLESHOOTING Problem Possible Cause Specific Example Inspection and Treatment Refer to P187, 7)High Pressure Abnor- Refrigerant high pressure avoidance control mality in Cooling Operation Refer to P190, 10)Overheated Refriger- During avoidance The unit is under control to avoid excessive ant Discharge Temperature in Cooling Engine speed control, etc.

  • Page 198: Gas Heat Pump Is Pperating But Not Heating

    TROUBLESHOOTING Gas Heat Pump is Pperating but Not Heating Problem Possible Cause Specific Example Inspection and Treatment Compressor clutch failure Compressor Refer to P232, 61)Inspect Compressor clutch operation Contact failure Clutch failure Output failure compressor Indoor intake air temperature sensor malfunction clutch is not (Sensor judges the room temperature higher than engaged...
  • Page 199 TROUBLESHOOTING Problem Possible Cause Specific Example Inspection and Treatment Refer to P188, 8)High Pressure Ab- Refrigerant high pressure avoidance control normality in Heating Operation Refer to P190, 10)Overheated Refrig- During avoidance The unit is under control to avoid excessive erant Discharge Temperature in Cool- control, etc.

  • Page 200: Procedure For Inspection And Treatment

    TROUBLESHOOTING 4. Procedure for Inspection and Treatment Check Power Supply System 1. Check that the power supply wires of the indoor and outdoor units are correctly connected as specified in the installation manual. 2. Check that the power supply voltage (230 V AC or 208 V AC) is applied to indoor and outdoor units at the power supply terminal.

  • Page 201: Inspect Starter

    TROUBLESHOOTING Inspect Starter 1. Check output voltage applied to the starter 1) Output voltage applied to the starter motor. (1) Select "Actuators output condition/individual actuating (code No. 20)" in the check mode of the board maintenance functions. Then turn ON "Main side output permission", "Engine side output permission", and "Starter transformer"...

  • Page 202: Operation Check Of Relay

    TROUBLESHOOTING Operation Check of Relay 1. Check operation of starter relay (RY1) 1) Select "Actuators output condition/individual actuating (code No. 20)" in the check mode of the board mainte- nance functions. Then check that "starter ON" is displayed. 2) Check that 12 V DC is applied at CN10[4]-[6] on the main PCB. If 12 V DC is not applied, the output circuit of the main PCB is considered to be faulty.

  • Page 203: Inspect Spark Plug

    TROUBLESHOOTING Inspect Spark Plug 1. Spark check of spark plug 1) Close the fuel gas valve. 2) Pull the caps to remove the cables. NOTE) Do not pull the cable. 3) Remove the spark plugs with a plug wrench. 4) Attach the spark plug to the high voltage a cable, and make the spark plug body (screw part) contact to the engine.

  • Page 204: Inspect Igniter, Etc

    TROUBLESHOOTING [ 8 TON ] [ 15 TON ] Standard resistance value Standard resistance value High voltage cable #1 5.7 ± 2.2 kΩ High voltage cable #1 High voltage cable #2 4.6 ± 1.8 kΩ High voltage cable #2 1.9 ~ 5.0 kΩ High voltage cable #3 3.5 ±...

  • Page 205: Compression Inspection

    TROUBLESHOOTING 3. Inspect engine speed sensor 1) Turn OFF the electric leakage breaker. 2) Measure the resistance value between both terminals of the engine speed sensor. [ 8 TON ] [ 15 TON ] Standard resistance value (68 ℉ (20 ℃ )) Standard resistance value (68 ℉...

  • Page 206: Valve Clearance Inspection / Adjustment

    TROUBLESHOOTING Valve Clearance Inspection / Adjustment [ 8 TON only ] 1. Close the fuel gas valve. 2. Hold and pull the cap to remove the cables (3 places). NOTE) Do not pull the cable. 3. Remove 3 spark plugs with a plug wrench. Caps 4.

  • Page 207: Treatment For Compression Failure Due To Carbon Deposit

    TROUBLESHOOTING 7. Check that the intake rocker arm of No. 1 cylinder No.3 exhaust No.3 intake does not move when the crank pulley is turned ap- proximately 60˚ clockwise and counterclockwise. Rear side (Set No. 1 cylinder to the top dead center.) Front side NOTE) If the intake rocker arm of No.
  • Page 208 TROUBLESHOOTING 4. Disconnect the connector for the igniter. Be sure to disconnect the igniter connector before Igniter valve cleaning. Failure to do so may cause a fire. 5. Move a clamp to remove the air intake hose. Air intake hose Nuts Clamp 6.
  • Page 209 TROUBLESHOOTING 16. Remove the blow-by hose at the cylinder head Cylinder head cover cover side. 17. Run the engine. 18. Supply 1/2 can of valve cleaner to the gas mixer through the hose disconnected. Blow-by hose NOTE) Supply valve cleaner intermittently while making sure that there is no engine stall or over speed.
  • Page 210 TROUBLESHOOTING 7. Turn the crankshaft by hand and set it at the posi- Rear side tion where the intake and exhaust valves of No. 1 No.4 intake cylinder do not move, when the crankshaft is No.4 exhaust turned 60˚ clockwise and counterclockwise. No.3 exhaust (Set No.
  • Page 211 TROUBLESHOOTING 19. Reconnect the blow-by hose to the head cover and keep the engine running until no more white smoke is emitted from the exhaust port. Then stop the engine. 20. Check if the compression has recovered sufficient pressure. (Refer to P203, [Compression Inspection]) If the compression does not recover, repeat steps 1.

  • Page 212: Inspect Engine Throttle Valve / Fuel Gas Flow Control Valve

    TROUBLESHOOTING Inspect Engine Throttle Valve / Fuel Gas Flow Control Valve [Engine throttle valve] 1. Turn OFF the electric leakage breaker. 2. Disconnect the engine throttle valve relay connector and measure resistance between each pair of termi- nals of the stepping motor. Motor coil resistance Connector terminal arrangement...

  • Page 213: Check For Contact Failure At The Starter Drive System

    TROUBLESHOOTING Check for Contact Failure at the Starter Drive System A contact failure at the terminal of the starter drive system may lead to an engine stall caused by noise. Check for looseness. In particular; ① Capacitor connection terminals (2 places) ②...

  • Page 214: Inspect Engine Oil Pan Heater

    TROUBLESHOOTING 3. Check temperature sensor readings 1) Check outside air temperature and engine compart- Code No. ment temperature with the monitor mode of the Outside air temperature No. 4d board maintenance functions. Engine compartment No. 50 2) Measure actual temperature with a thermometer, temperature and check for the sensor reading's extreme devia- Measure point (on main PCB)

  • Page 215: Check Ignition Timing

    TROUBLESHOOTING 3. Check temperature sensor readings 1) Check outside air temperature and engine compart- Code No. ment temperature with the monitor mode of the Outside air temperature No. 4d board maintenance functions. Engine compartment No. 50 2) Measure actual temperature with a thermometer, temperature and check for the sensor reading's extreme devia- Measure point (on main PCB)

  • Page 216: Check Engine Coolant Circulation

    TROUBLESHOOTING Check Engine Coolant Circulation Reduction of engine coolant circulation amount due to blockage in the piping or other causes will cause a large difference between the radiator inlet and outlet temperatures. 1. Check temperature difference between radiator Temperature difference inlet and outlet to judge if the engine coolant circu- lation is normal.

  • Page 217: Inspect Engine Coolant Pump

    TROUBLESHOOTING When refilling engine coolant, be sure to use AISIN Coolant S. When refilling engine coolant, be sure to mix with the following balance 50 ~ 60 vol% (engine coolant: 0.55, water: 0.45). 8 TON 3.96 gal (15 L) Amount of engine coolant 15 TON 6.87 gal (26 L) Inspect Engine Coolant Pump...

  • Page 218: Inspect Thermostat

    TROUBLESHOOTING 3) Check output current from the DCBL PCB (1) Select "Engine coolant refilling (code No. 0A)" in the check mode of the board maintenance functions. Then turn the engine coolant pump ON. (2) Check power supply current value for the engine coolant pump at CN9[1], [2], and [3] on the DCBL PCB with a clamp tester.

  • Page 219: Inspect Outdoor Fan Motor

    TROUBLESHOOTING Inspect Outdoor Fan Motor 1. Inspect outdoor fan motor body [Check during operation] 1) Check the outdoor fan motor body for abnormal noise. 2) Check the outdoor fan motor body for abnormal vibra- tion. 3) Select "Outdoor fan motor 1 speed (code No. 25)" and "Outdoor fan motor 2 speed (code No.

  • Page 220: Inspect Engine Coolant Temperature Sensor

    TROUBLESHOOTING Inspect Engine Coolant Temperature Sensor 1. Check the relay connector for the engine coolant temperature for looseness or contact failure. 2. Check for disconnection or short circuit at CN6[11]- [12] on the main PCB and relay connector. Resistance value Condition ∞...

  • Page 221: Check Engine Oil Leakage

    TROUBLESHOOTING Check Engine Oil Leakage 1. Check the engine block and the gasket for oil leakage. 2. Check if the engine oil hose clamps are attached securely. Sub oil reservoir 3. Check the engine oil hoses and hose connections for leakage.

  • Page 222: Inspect Oil Pressure

    TROUBLESHOOTING Inspect Oil Pressure Oil pressure does not rise if oil supply is not normal due to causes such as oil strainer blockage. 1. Measure oil pressure with an oil pressure gauge attached to the mounting hole (PT 1/8) of the engine oil pres- sure switch during operation.

  • Page 223: Technical Data When Replacing The Refrigerant System Parts

    TROUBLESHOOTING Technical Data When Replacing the Refrigerant System Parts NOTE) Refer to the followings when you replace the refrigerant system parts. Flare nuts tightening torque 1/4 inch (6.35 mm) 10 ~ 13 lb·ft (14 ~ 18 N·m) 3/8 inch (9.52 mm) 25 ~ 31 lb·ft (34 ~ 42 N·m) Nominal outer 1/2 inch (12.70 mm)

  • Page 224: Inspect Refrigerant Pressure (Inspect Refrigerant Amount)

    TROUBLESHOOTING Inspect Refrigerant Pressure (Inspect Refrigerant Amount) 1. Operate all indoor units. Reference values of refrigerant pressure during operation 2. Measure the refrigerant pressure at the pressure Refrigerant low Refrigerant high detection port provided in the engine compartment. Mode pressure pressure If the measured pressure deviates from the reference value, there is a problem in heat exchange at the...

  • Page 225: Inspect Refrigerant High Pressure Sensor

    TROUBLESHOOTING Inspect Refrigerant High Pressure Sensor 1. Check for contact failure of connectors on the main PCB Select "Refrigerant high pressure 1 (code No. 40)" in the monitor mode of the board maintenance functions, and check if the pressure is displayed again when you disconnect and connect the refrigerant high pressure sensor connector of CN4 on the main PCB.

  • Page 226: Inspect Indoor Fan Motor

    TROUBLESHOOTING Inspect Indoor Fan Motor Check the motor coil resistance and output voltage at the indoor fan motor connector. Inspect for Blockage in the Indoor Electronic Expansion Valve Make judgment by checking if the temperature difference of the pipes at each end of the electronic expansion valve is normal.

  • Page 227: Inspect Sub Heat Exchanger Liquid Flow Control Valve

    TROUBLESHOOTING 3. Check output voltage of the refrigerant low pressure sensor 1) Measure output voltage with a tester on low-pressure sensor at CN4[11]-[12] on the main PCB. Then refer to the figure to read the standard pressure. 2) Make sure the valve compared with low-pressure gauge is not much different.

  • Page 228: Inspect Outdoor Heat Exchanger Liquid Flow Control Valve

    TROUBLESHOOTING Inspect Outdoor Heat Exchanger Liquid Flow Control Valve 1. Check if the mechanical part of the outdoor heat exchanger liquid flow control valve is locked. When the valve is driven with the mechanical part locked, the motor idles, making a soft clicking sound. 1) Turn ON the electric leakage breaker.

  • Page 229: Inspect Reversing Valve

    TROUBLESHOOTING Inspect Reversing Valve If the slide valve is locked at the middle position due to the operation failure of the reversing valve, the hot gas leaks into the inlet side, increasing the intake temperature and eventually, increases of the discharge temperature.

  • Page 230: Check For Readings Of The Outside Air Temperature Sensor

    TROUBLESHOOTING Check for Readings of the Outside Air Temperature Sensor 1. Select "Outside air temperature (code No. 4d)" in the monitor Temperature Standard resistance value mode of the board maintenance functions to check outside air -4 ℉ (-20 ℃ ) 39.6 kΩ...

  • Page 231: Check For Readings Of The Outdoor Temperature Sensors

    TROUBLESHOOTING Check for Readings of the Outdoor Temperature Sensors 1. Check each outdoor temperature with the monitor mode of the board maintenance functions. 2. Measure actual temperature with a thermometer, and check for the sensor reading's extreme deviation from the actual temperature.

  • Page 232: Inspect Subcooling Valve

    TROUBLESHOOTING Code No. Measure point (on main PCB) Compressor intake temperature No. 44 CN4[23]-[24] Accumulator outlet temperature No. 45 CN4[13]-[14] Outdoor heat exchanger vapor pipe temperature No. 49 CN4[17]-[18] Outdoor heat exchanger liquid temperature No. 4A CN4[19]-[20] Outdoor liquid pipe temperature No.

  • Page 233: Check Operation Condition

    TROUBLESHOOTING 2. Check motor coil resistance Standard resistance value 1) Turn OFF the electric leakage breaker. Blue-Brown 2) Measure the resistance between each coils. Brown-Yellow 46 ± 4 Ω ※ When the electronic expansion valve is 5 cores Orange-Red (without brown), substitute red core for brown Red-White core.

  • Page 234: Check Drain Water

    TROUBLESHOOTING Check Drain Water 1. Put water into the drain pan gradually taking care [EX. AXCP type] so that electric parts do not get wet. Drain pipe 2. Start the cooling operation and operate the drain pump. Pump 3. Check the operating sound of the drain pump mo- tor, and confirm water comes out of the drain port.

  • Page 235: Board Maintenance Functions

    TROUBLESHOOTING 5. Board Maintenance Functions Outline of the Maintenance Function Arrangement of the LEDs and buttons for board maintenance functions LED display is assigned as follows unless otherwise stated. LED 1 ~ 4: Data display. LED 5 ~ 6: Code number display (code No.00 ~ E7) Alternate display of code number and indoor unit number (code No.E8 ~ FF) Display after turning the power ON...
  • Page 236 TROUBLESHOOTING Function and display of each mode Mode indicator LED Mode Main functions During maintenance set- Check mode Normal ting (setting from a PC) Running hours Running hours and other Repeat of 5 red-green Repeat of 3-second red display information display flashes/off lighting up/off Repeat of 3-second red...

  • Page 237: Code List For Each Mode

    TROUBLESHOOTING Code List for Each Mode Code No. Functions Monitor Command Check Remark Available only in automatic Ⅲ ※ communication forced master setting ○ ○ address setting Only indoor unit re-wiring recognition during automatic ※ Indoor / outdoor unit re-wiring recognition ○...
  • Page 238 TROUBLESHOOTING Code No. Functions Monitor Command Check Remark ℃ Compressor intake temperature ( ● ℃ Accumulator outlet temperature ( ● ℃ Compressor 1 discharge pipe temperature ( ● ℃ Compressor 2 discharge pipe temperature ( ● ℃ Outdoor heat exchanger vapor pipe temperature ( ●...
  • Page 239 TROUBLESHOOTING Code No. Functions Monitor Command Check Remark Electronic expansion valve open position of the indoor ○ unit whose is stopped in heating mode (steps) Electronic expansion valve open position of the indoor unit whose temperature control is stopped in heating ○...
  • Page 240 TROUBLESHOOTING Code No. Functions Monitor Command Check Remark Indoor electronic expansion valve actual open posi- ○ tion Remote controller unit number / Remote controller ○ code Indoor unit air net address number ○ Indoor unit capacity (0.1 kW) ○ ℃ Indoor heat exchanger vapor pipe temperature ( ○...

  • Page 241: Running Hours Display Mode

    TROUBLESHOOTING Running Hours Display Mode Running hours display mode shows the following in accordance with system status. System status Display contents Normal (other than below) Engine running hours ⇔ Central control setting status※ During automatic address Automatic address progress status ※...
  • Page 242 TROUBLESHOOTING Switch Functions / 7-segment LEDs display The following shows warning with code "80-0" LED 4 display Error : Middle ― Warning, Alert : Lower ＿ ※ As for the dependent unit's failure, 100 is added to the sub code. (80 - 0 →...
  • Page 243 TROUBLESHOOTING Switch Functions / 7-segment LEDs display Displays the indoor unit on/off status while the switch is pressed Indoor unit 18 ＋ n Indoor unit 2 ＋ n Indoor unit 0 ＋ n Indoor unit 1 ＋ n Indoor unit group Indoor unit Run/Stop status Indoor unit 15 ＋...
  • Page 244 TROUBLESHOOTING Switch Functions / 7-segment LEDs display Displays output status with 7-segment LEDs while the switch is pressed The segment corresponding to the working component lights up, LED 6 shows "o" [SET] switch Resetting errors Pressing [UP] + [CLEAR] switches simultaneously for 1 second cancels the error and displays the following [UP] + [CLEAR] switches pressed simultaneously...
  • Page 245 TROUBLESHOOTING During automatic address During automatic address, the system displays the progress as follows. ※ Error display by [UP] or [DOWN] switch is possible as "■ Normal display". 1) During connection check of the indoor unit During automatic address Elapsed time from automatic address start (by 0.1 minutes) P: Master unit, c: Dependent unit, －...
  • Page 246 TROUBLESHOOTING 4) When connection status is determined When the outdoor unit is determined as the master unit, the display shows as follows. Alternately displayed Indoor unit Number of connected units Outdoor unit Number of connected units (If the number of connected units is 1, these is no dependent unit) When the outdoor unit is determined as the dependent unit, the display shows as follows.

  • Page 247: Monitor Mode

    TROUBLESHOOTING Monitor Mode Monitor mode monitors various input/output status and stored data such as temperature or running hours. Use this mode by selecting the code number with [UP] or [DOWN] switch. Refer to P235 and after, [Code List for Each Mode] for available code numbers.

  • Page 248: Command Mode

    TROUBLESHOOTING Command Mode Command mode changes a part of operation status such as engine indicated speed during GHP operation, and conducts system operation check. Normally, use this mode with the procedure shown below. 1. Select command 1) Select the code number with [UP] or [DOWN] switch. Select the indoor unit with [INDOOR UNIT] switch. 2) Proceed to "2.

  • Page 249: Check Mode

    TROUBLESHOOTING Check Mode Check mode overwrites various stored data such as running hours, and checks operation of various parts. Normally, use this mode with the procedure shown below. 1. Select command 1) Select the code number with [UP] or [DOWN] switch. Select the dip switch number or other with [INDOOR UNIT] switch.

  • Page 250: Operational Procedure / Display Contents

    TROUBLESHOOTING Operational Procedure / Display Contents Operation for each code number after mode/code number selection is shown below. Code No. / Operational procedure / display contents functions Command mode, check mode D Ⅲ communication forced master setting is set. This setting makes automatic address setting time shorter.
  • Page 251 TROUBLESHOOTING Code No. / Operational procedure / display contents functions Command mode, check mode Indoor / outdoor unit re-wiring recognition is set. Only indoor unit re-wiring recognition during automatic address setting is available in command mode. Example) Method of indoor unit re-wiring recognition setting Select command (Initial display) Indoor unit re-wiring recognition Outdoor unit re-wiring recognition...
  • Page 252 TROUBLESHOOTING Code No. / Operational procedure / display contents functions Monitor mode Displays cooling pump down operation (code No. 03) / heating pump-down operation (code No. 04). In the case of operation mode "Cooling" and status "Pump down in progress" Operation modes are as follows C : Cooling H : Heating...
  • Page 253 TROUBLESHOOTING Code No. / Operational procedure / display contents functions Monitor mode Displays status of refrigerant recovery [vacuuming] setting. When refrigerant recovery setting is in progress Refrigerant recovery [vacuuming] display LED 4 shows "V" (looks like inverted 4). It is always displayed. Status are as follows rtn: Refrigerant recovery setting in progress Status...
  • Page 254 TROUBLESHOOTING Code No. / Operational procedure / display contents functions Monitor mode Displays status of forced defrosting. When forced defrosting is in progress Display of defrosting LED 4 shows "d" (looks like inverted 4). It is always displayed. Status are as follows Frc : Forced defrosting in progress Defrosting Status...
  • Page 255 TROUBLESHOOTING Code No. / Operational procedure / display contents functions Monitor mode Displays status of the energy saving test operation. When energy saving test operation is in progress Display of energy save "E" is always displayed. Status are as follows tSt : Energy saving test operation in progress Energy save Status...
  • Page 256 TROUBLESHOOTING Code No. / Operational procedure / display contents functions Monitor mode Retrofit setting status is displayed. When status is standard specification Status Std : Standard specification rEn : Retrofit specification Retrofit check Status When status is retrofit specification...
  • Page 257 TROUBLESHOOTING Code No. / Operational procedure / display contents functions Monitor mode Displays engine coolant refilling status. When engine coolant refilling is in progress Engine coolant refilling status are as follows on : Engine coolant refilling in progress oFF : Engine coolant refilling OFF When engine coolant refilling is OFF Check mode Programs engine coolant refilling setting.
  • Page 258 TROUBLESHOOTING Code No. / Operational procedure / display contents functions Monitor mode Displays indicated engine speed (code No. 12) / apparent engine speed (code No. 13). When indicated engine speed is 1,200 rpm (min Command mode Switches between forced setting and automatic setting (cancelling forced setting) of indicated engine speed (code No.
  • Page 259 TROUBLESHOOTING Code No. / Operational procedure / display contents functions Monitor mode Displays 1/10 of total apparent engine speed. When total apparent engine speed is 10,350 rpm (min Command mode Switches between forced setting and automatic setting (cancelling forced setting) of total apparent engine speed.
  • Page 260 TROUBLESHOOTING Code No. / Operational procedure / display contents functions Monitor mode Displays engine throttle valve open position (code No. 15) / fuel gas flow control valve open position (code No. 16). When fuel gas flow control valve open position is 238 steps Check mode Programs forced setting of engine throttle valve open position (code No.
  • Page 261 TROUBLESHOOTING Code No. / Operational procedure / display contents functions Change the flashing digit data ↓ with [UP] or [DOWN] switch. (with digit up/down) (Continued) Engine throttle Press [SET] switch ↓ valve open (all digits start flashing) position Fuel gas ↓...
  • Page 262 TROUBLESHOOTING Code No. / Operational procedure / display contents functions Monitor mode Displays engine coolant pump flow volume. When engine coolant pump flow volume is 80 % Check mode Programs forced setting of engine coolant pump flow volume. Method of engine coolant pump flow volume setting Select command (Initial display) During automatic operation During forced setting (100 →...
  • Page 263 TROUBLESHOOTING Code No. / Operational procedure / display contents functions Press [SET] switch ↓ (all digits start flashing) (Continued) ↓ ↓ Engine Press [SET] switch Press [SET] switch coolant Return to select command (setting is completed) pump flow volume Engine coolant pump flow volume setting Completed Automatic setting is completed.
  • Page 264 TROUBLESHOOTING Code No. / Operational procedure / display contents functions Monitor mode Displays actuators output status. When output 3 (starter transformer) is ON Output status are as follows on : Output ON oF : Output OFF When output 12 (reversing valve) is OFF ※...
  • Page 265 TROUBLESHOOTING Code No. / Operational procedure / display contents functions Check mode Conducts single forced actuator operation. ※ To drive the starter, turn ON " ① Main side output permission", " ② Engine side output permis- sion", and " ③ Starter transformer" in order. Then turn ON " ⑥ Starter". ※...
  • Page 266 TROUBLESHOOTING Code No. / Operational procedure / display contents functions Monitor mode Displays outdoor fan motor 1 speed (code No. 25) / outdoor fan motor 2 speed (code No. 26) When outdoor fan motor 2 speed is 628 rpm (min Command mode, check mode Programs forced setting of outdoor fan motor 1 speed (code No.
  • Page 267 TROUBLESHOOTING Code No. / Operational procedure / display contents functions Change the flashing digit data ↓ with [UP] or [DOWN] switch. (with digit up/down) Press [SET] switch (all digits ↓ start flashing) (Continued) Change the flashing digit data ↓ with [UP] or [DOWN] switch. Outdoor fan (with digit up/down) motor 1...
  • Page 268 TROUBLESHOOTING Code No. / Operational procedure / display contents functions Monitor mode Displays subcooling valve open position (code No. 28) / outdoor heat exchanger liquid flow control valve open position (code No. 29) / sub heat exchanger liquid flow control valve open position (code No.
  • Page 269 TROUBLESHOOTING Code No. / Operational procedure / display contents functions Change the flashing digit data ↓ with [UP] or [DOWN] switch. (with digit up/down) (Continued) Press [SET] switch (Flashing ↓ digit moves to the right) ↓ ↓ Press [SET] switch Press [SET] switch Return to select command (setting is completed) Outdoor heat exchanger liquid flow control valve open position setting Completed...
  • Page 270 TROUBLESHOOTING Code No. / Operational procedure / display contents functions Monitor mode Displays abnormal engine speed avoidance control status with "ON" or "OFF". When control to avoid abnormal refrigerant high pressure is in progress Abnormal engine speed avoidance control status are as follows on : Control in progress oF : Control off When control to avoid abnormal engine coolant temperature is OFF...
  • Page 271 TROUBLESHOOTING Code No. / Operational procedure / display contents functions Monitor mode Displays motor-operated valve control status for abnormality avoidance with "ON" or "OFF". During avoidance of freezing of the sub heat exchanger liquid flow control valve. Motor-operated valve control status for abnormality avoidance are as follows on : Control in progress oF : Control off...
  • Page 272 TROUBLESHOOTING Code No. / Operational procedure / display contents functions Monitor mode Displays protection operation status with "ON" or "OFF". When compressor protection control is in progress Protection operation status on: During protect operation oF: Protection operation OFF When defrosting operation is OFF ※...
  • Page 273 TROUBLESHOOTING Code No. / Operational procedure / display contents functions Monitor mode Displays outdoor unit input status with "ON" or "OFF". When output monitor of electromagnetic gas valve is ON Outdoor unit input status on : Input ON oF : Input OFF When refrigerant high pressure switches 1 and 2 is OFF Outdoor ※...
  • Page 274 TROUBLESHOOTING Code No. / Operational procedure / display contents functions Monitor mode Displays selected temperature. (Refer to code number table below) When compressor intake temperature 1 is 12 ℃ When engine compartment temperature is -5 ℃ ※ Code number table (excerpt from the code number list) Code No.
  • Page 275 TROUBLESHOOTING Code No. / Operational procedure / display contents functions Monitor mode Displays starter voltage. When starter voltage is 8.7 V Starter voltage Monitor mode Displays igniter voltage. When igniter voltage is 13.1 V Igniter voltage Monitor mode Displays starter transformer voltage. When starter transformer voltage is 10.7 V Starter transformer...
  • Page 276 TROUBLESHOOTING Code No. / Operational procedure / display contents functions Monitor mode Displays engine running hours (code No. 60) / last periodical inspection time (code No. 61) / compressor 1 running hours (code No. 62) / compressor 2 running hours (code No. 63) in hours. When compressor 1 running hours are 17,824 hours Alternately displayed →...
  • Page 277 TROUBLESHOOTING Code No. / Operational procedure / display contents functions (Continued) ↓ Press [SET] switch (Flashing digit moves to the right) Engine running Digit of 10 hours is flashing hours ↓ Change the flashing digit data with [UP] or [DOWN] switch. (with digit up/down) Last periodical inspection...
  • Page 278 TROUBLESHOOTING Code No. / Operational procedure / display contents functions Monitor mode Displays the number of starter on/off times (code No. 68) / the number of engine on/off times (code No. 69) / the number of compressor 1 on/off times (code No. 6A) / the number of compressor 2 on/ off times (code No.
  • Page 279 TROUBLESHOOTING Code No. / Operational procedure / display contents functions ↓ Press [SET] switch (Flashing digit moves to the right) (Continued) Digit of 100 times is flashing Number of starter on/off times ↓ Change the flashing digit data with [UP] or [DOWN] switch. (with digit up/down) Number of engine on/off times...
  • Page 280 TROUBLESHOOTING Code No. / Operational procedure / display contents functions Monitor mode OEM code is displayed on LED 1. In the case of AISIN brand / DAIKIN indoor unit OEM code ※ OEM code table OEM code Corresponding brand / indoor unit AISIN brand / DAIKIN indoor unit DAIKIN brand / DAIKIN indoor unit Monitor mode...
  • Page 281 TROUBLESHOOTING Code No. / Operational procedure / display contents functions Monitor mode Additional function is displayed with "ON" or "OFF". When it is with cold district specification Additional function with/ without are as follows on : With additional function oF: Without additional function When it is without high power ※...
  • Page 282 TROUBLESHOOTING Code No. / Operational procedure / display contents functions Monitor mode Displays main microcomputer programming version. Main micro- When main microcomputer programming version is 15 computer program- ming version Monitor mode Displays engine microcomputer programming version. Engine When engine microcomputer programming version is 1 microcom- puter pro- gramming...
  • Page 283 TROUBLESHOOTING Code No. / Operational procedure / display contents functions Monitor mode Displays periodical inspection status. Before periodical inspection time Remaining time until next periodical inspection is displayed (In this case, periodical inspection alert will be sent 1,134 hours later.) On or after periodical inspection time "oVEr"...
  • Page 284 TROUBLESHOOTING Code No. / Operational procedure / display contents functions Monitor mode Displays EEPROM dip switch 1 status (code No. 80) / EEPROM dip switch 2 status (code No. 81) / EEPROM dip switch 3 status (code No. 82) / EEPROM dip switch 4 status (code No .83) / EEPROM dip switch 5 status (code No.
  • Page 285 TROUBLESHOOTING Code No. / Operational procedure / display contents functions Monitor mode Displays Tc set value (code No. 98) / Te set value (code No. 99) / heating indoor SC target set value (code No. 9c). (display range : -20 ~ 60 ℃ ) When Tc set value is -1 ℃...
  • Page 286 TROUBLESHOOTING Code No. / Operational procedure / display contents functions Monitor mode Displays heating hot start high pressure value. (display range : 1.00 ~ 3.50 MPa) When heating hot start high pressure value is 2.86 MPa Heating hot start high pressure When heating hot start high pressure value is not set value...
  • Page 287 TROUBLESHOOTING Code No. / Operational procedure / display contents functions Monitor mode Displays address under combined installation In the case of master outdoor unit Address under Address under combined installation combined 0 : Master outdoor unit installation 1 : Dependent outdoor unit 1 2 : Dependent outdoor unit 2 Monitor mode Displays number of connected units under combined installation.
  • Page 288 TROUBLESHOOTING Code No. / Operational procedure / display contents functions Monitor mode Displays the number of connected terminals in the same D Ⅲ net that were set with automatic address. ※ This data is displayed only when EX4 address is 0 in the code No. d0. Number of When 16 indoor units are connected in D Ⅲ...
  • Page 289 TROUBLESHOOTING Code No. / Operational procedure / display contents functions Monitor mode Displays air net address number. When air net address is 105 Check mode Programs forced setting of air net address number. (Setting range of air net address number is 0 ~ 63.) Method of air net address number setting Select command (Initial display) When the address is not set...
  • Page 290 TROUBLESHOOTING Code No. / Operational procedure / display contents functions Monitor mode Displays setting status of cooling/heating collective address number (code no. dA) / low noise address number (code No. db). In the case of cooling/heating collective address setting status "Pin 4 ON" Setting status are as follows on : ON oF : OFF...
  • Page 291 TROUBLESHOOTING Code No. / Operational procedure / display contents functions Monitor mode Shows current method of indoor unit number display. When indoor unit number is displayed by air net address Method of indoor unit number display Air : Air net address cnt : Order of indoor unit registration Command mode Switches the method of indoor unit number display.
  • Page 292 TROUBLESHOOTING Code No. / Operational procedure / display contents functions Monitor mode Displays forced setting status of indoor electronic expansion valve open position in shutdown status (code No. E8) / temperature control is OFF (code No. E9) / temperature control is ON (code No.
  • Page 293 TROUBLESHOOTING Code No. / Operational procedure / display contents functions [ Display when all indoor units are selected ] Alternately displayed? → (Continued) ← Display of all indoor Indoor ※ After this, LED 6 and 5 display code number and indoor unit number alternately. electronic In this figure, code number is displayed.
  • Page 294 TROUBLESHOOTING Code No. / Operational procedure / display contents functions Monitor mode Displays forced setting status of indoor fan air volume in shutdown status (code No. Eb) / when temperature control is OFF (code No. Ec) / when temperature control is ON (code No. Ed). Indoor fan air volume forced setting during thermostat OFF : When the setting of indoor unit No.
  • Page 295 TROUBLESHOOTING Code No. / Operational procedure / display contents functions [ Display when all indoor units are selected ] Alternately displayed → ← Display of all indoor unit selection (Continued) ※ After this, LED 6 and 5 display code number and indoor unit number alternately. In this figure, code number is displayed.
  • Page 296 TROUBLESHOOTING Code No. / Operational procedure / display contents functions Monitor mode Displays indoor electronic expansion valve actual open position. When the open position of indoor unit No. 3 is 470 steps Alternately displayed → Indoor ← electronic expansion valve actual ※...
  • Page 297 TROUBLESHOOTING Code No. / Operational procedure / display contents functions Monitor mode Displays indoor unit air net address number When air net address of indoor unit No. 34 is No. 158 Alternately displayed? → Indoor unit air ← net address number ※...
  • Page 298 TROUBLESHOOTING Code No. / Operational procedure / display contents functions Monitor mode Displays status of indoor heat exchanger vapor pipe temperature (code No. Fc) / indoor heat exchanger liquid pipe temperature (code No. Fd) / indoor intake air temperature (code No. FE). When indoor heat exchanger vapor pipe temperature of inddor unit No.
  • Page 299 TROUBLESHOOTING Code No. / Operational procedure / display contents functions Monitor mode Displays indoor unit operation status. When operation status of indoor unit No. 14 is temperature setting 27 ℃ in cooling Alternately displayed → ← Operation mode Operation mode Temperature control Set temperature Set temperature...
  • Page 300 TROUBLESHOOTING Code No. / Operational procedure / display contents functions Command mode Programs test operation setting. (Simultaneous operation or stop of all indoor units is possible) Method of test operation setting Select command (Initial display) In the case of change "Test operation stopped → Cooling test operation" Display modes are as follows Hcr : During heating test operation Ccr : During cooling test operation...

  • Page 301: Protection Devices

    TROUBLESHOOTING 6. Protection Devices 8 TON FRONT SIDE Engine coolant temperature sensor Engine oil pressure switch REAR SIDE Oil level switch Figure 1 Engine and related parts...
  • Page 302 TROUBLESHOOTING PANEL SIDE Outdoor liquid pipe temperature sensor Accumulator outlet temperature sensor Outdoor heat exchanger liquid temperature sensor ENGINE SIDE Outdoor heat exchanger Sub heat exchanger liquid vapor temperature sensor temperature sensor Refrigerant high pressure sensor 1 Refrigerant low pressure sensor Compressure discharge pipe temperature sensor 1 Refrigerant high...
  • Page 303 TROUBLESHOOTING Eelectric leakage breaker ENLARGE Figure 3 In control box Radiator cap Engine compartment temperature sensor (attached to the 1F top panel) Outside air temperature sensor Figure 4 Overhead view...
  • Page 304 TROUBLESHOOTING 15 TON FRONT SIDE Engine coolant temperature sensor Engine oil pressure switch Oil level switch Figure 1 Engine and related parts...
  • Page 305 TROUBLESHOOTING PANEL SIDE Outdoor liquid pipe temperature sensor Refrigerant high pressure switch 1 Accumulator outlet temperature sensor ENGINE SIDE Outdoor heat exchanger liquid temperature sensor Outdoor heat exchanger vapor temperature sensor Sub heat exchanger liquid temperature sensor Refrigerant low pressure sensor Refrigerant high pressure sensor 1 Compressure discharge...
  • Page 306 TROUBLESHOOTING Eelectric leakage breaker ENLARGE Figure 3 In control box Radiator cap Outside air temperature sensor Engine compartment temperature sensor (attached to the 1F top panel) Figure 4 2F...

  • Page 307: Standard Operation Data

    TROUBLESHOOTING 7. Standard Operation Data 8 TON Overloaded cooling Rated cooling Rated heating (outside air 115℉(46℃) Engine speed rpm (min 1700 (1700) 1500 (1500) 1750 (1750) Number of compressors Compressor intake pressure psi (MPa) 133 (0.92) 146 (1.01) 113 (0.78) Compressor intake temperature ℉...

  • Page 308: Wiring Diagram Of The Outdoor Unit

    TROUBLESHOOTING 8. Wiring Diagram of the Outdoor Unit 8 TON Electronic expansion valve is 5 cores (without brown) or 6 cores (with brown). Heat exchanger compartment Unit with drain heater kit only Engine compartment Engine compartment C/P2 Compressor clutch Reversing valve Engine oil pan heater Outdoor heat exchanger liquid flow Electromagnetic compressor...
  • Page 309 TROUBLESHOOTING Heat exchanger Unit with deodorant kit only compartment Unit with drain heater kit only NOTE) The status of contact point shown in the diagram is when the system is shut down. Ignition coil 1 EMC-PCB EMC PCB Igniter Communication control Ignition coil 2 IF-PCB Cold district PCB...
  • Page 310 TROUBLESHOOTING 15 TON Electronic expansion valve is 5 cores (without brown) or 6 cores (with brown). Engine compartment Heat exchanger compartment Unit with drain heater kit only Engine compartment C/P2 Compressor clutch OVEV Oil bypass control valve Compressor discharge pipe Outdoor heat exchanger liquid Exhaust water drain heater C/P T1...
  • Page 311 TROUBLESHOOTING Heat exchanger Unit with deodorant kit only compartment Unit with drain heater kit only NOTE) The status of contact point shown in the diagram is when the system is shut down. Igniter EMC-PCB EMC PCB Reactor Reversing valve Eelectric leakage breaker Cold district PCB KR-PCB (unit with drain heater kit only)

  • Page 312: Technical Data For Repair

    TECHNICAL DATA FOR REPAIR TECHNICAL DATA FOR REPAIR 1. Engine System Item Standard value Remark Each cylinder 203 psi (1.4 MPa) or higher Compression Compression limit 160 psi (1.1 MPa) Compression When the engine 0.014 ± 0.002 inch (0.35 ± 0.05 mm) system is hot Valve clearance...
  • Page 313 TECHNICAL DATA FOR REPAIR Item Standard value Remark Engine oil pan heater 833 Ω On the PCB 421 Ω (combined value) 8 TON Drain filter 833 Ω Electric Unit with drain Drain hose 851 Ω Exhaust water resistance heater kit only drain heater On the PCB 476 Ω...

  • Page 314: Refrigerant System

    TECHNICAL DATA FOR REPAIR 2. Refrigerant System Item Standard value Remark It's vary according to In cooling ΔT=18 ~ 27 ℉ (10 ~ 15 ℃ ) Indoor unit temper- the envitonmental con- ature difference ditions or indoor units. (Intake-Discharge) The values are only for In heating ΔT=27 ~ 36 ℉...
  • Page 315 TECHNICAL DATA FOR REPAIR Item Standard value Remark Compressor heaters 1, 2 registance value 1.67 kΩ ± 7 % Type NL10 Refilling of refrigerant Refrigerant oil Standard amount 1.06 gal (4 L) oil at the time of instal- lation is not necessary. When replacing the parts that do not When doing refrigerant pump down...

  • Page 316: Engine Coolant System

    TECHNICAL DATA FOR REPAIR 3. Engine Coolant System Item Standard value Remark Starts 140 ℉ (60 ℃ ) opening at Opened 140℉ (60 ℃ ) 163 ℉ (73 ℃ ) fully at open Thermostat valve lift 0.33 inch (8.5 mm) amount Thermostat valve Starts...

  • Page 317: Thermistor Characteristics

    TECHNICAL DATA FOR REPAIR 4. Thermistor Characteristics Outdoor unit Engine coolant temperature sensor resistance Temperature Standard value value 122 ℉ (50 ℃ ) 17.6 kΩ 176 ℉ (80 ℃ ) 6.1 kΩ 212 ℉ (100 ℃ ) 3.3 kΩ 230 ℉ (110 ℃ ) 2.5 kΩ...

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