Airwell XLF 9 Service Manual
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Airwell XLF 9 Service Manual

Xlf dci series
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REFRIGERANT
SM XLFDCI 1-A.1 GB
XLF DCI Series
Indoor Units
XLF 9
XLF 12
HEAT PUMP
NOVEMBER – 2008
CONTENTS
Outdoor Units
GC 9
GC 12
R410A

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Summary of Contents for Airwell XLF 9

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

  • Page 3: Table Of Contents

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

  • Page 4: Main Features

    General The new XLF DCI Inverter split wall mounted range comprise the RC (heat pump) models, as follows: • XLF 9 DCI • XLF 12 DCI The indoor XLF DCI units are available as LED display types, featuring esthetic design, compact dimensions, and low noise operation.

  • Page 5: Outdoor Unit

    INTRODUCTION • Coil with treated aluminum fins. • Motorized flaps. • Multi-speed motor with internal protection. • DC motor with internal protection. • Advanced electronic control box assembly. • Interconnecting wiring terminal block. • Mounting plate. Filtration The XLF DCI series presents one type of air filters:. •...
  • Page 6 Each unit is supplied with its own installation, operation and remote control manuals. 1.10 Matching Table 1.10.1 R410A INDOOR UNITS OUTDOOR UNITS MODEL REFRIGER. XLF 9 XLF 12 √ GC 9 R410A √ GC 12 R410A SM XLFDCI 1-A.1 GB...

  • Page 7: Product Data Sheet

    PRODUCT DATA SHEET PRODUCT DATA SHEET XLF 9 DCI Model Indoor Unit XLF 9 DCI Model Outdoor Unit GC 9 R410A Installation Method of Pipe Flared Characteristics Units Cooling Heating Btu/hr 8530(4780-11600) 8530(5120-15360) Capacity 2.5(1.4-3.4) 2.5(1.5-4.5) 0.658(0.45-0.98) 0.625(0.48-1.53) Power input...
  • Page 8 PRODUCT DATA SHEET XLF 12 DCI Model Indoor Unit XLF 12 DCI Model Outdoor Unit GC 12 R410A Installation Method of Pipe Flared Characteristics Units Cooling Heating Btu/hr 11940(4780-14000) 11940(5120-19100) Capacity 3.5(1.4-4.1) 3.5(1.5-5.6) 1.09(0.5-1.31) 0.969(0.53-1.94) Power input 3.21 3.61 EER (Cooling) or COP(Heating) Energy efficiency class 220-240 Power supply...

  • Page 9: Rating Conditions

    RATING CONDITIONS RATING CONDITIONS Standard conditions in accordance with ISO 5151, ISO 13253 (for ducted units) and EN 14511. Cooling: Indoor: C DB 19 C WB Outdoor: 35 C DB Heating: Indoor: C DB Outdoor: 7 C DB 6 C WB Operating Limits 3.1.1 R410A...

  • Page 10: Outline Dimensions

    OUTLINE DIMENSIONS OUTLINE DIMENSIONS Indoor Unit: XLF 9 DCI, XLF 12 DCI Outdoor Unit: GC 9, GC 12 SM XLFDCI 1-A.1 GB CONTENTS...
  • Page 11 PERFORMANCE DATA & PRESSURE CURVES PERFORMANCE DATA & PRESSURE CURVES XLF 9 DCI / GC 9 R410A 5.1.1 Cooling Mode at 7.5m Tubing Connection. 230V : Indoor Fan at High Speed. Entering Air WB/DB ID Coil( Entering Air DB Data...

  • Page 12: Performance Data & Pressure Curves

    PERFORMANCE DATA & PRESSURE CURVES 5.1.2 Heating Mode at 7.5m Tubing Connection. 230V : Indoor Fan at High Speed. ENTERING AIR DB ID COIL( ENTERING WB OD COIL( 1.32 0.53 1.27 0.56 1.22 0.59 1.42 0.54 1.37 0.57 1.32 0.60 1.51 0.55 1.46...

  • Page 13: Pressure Curves

    PERFORMANCE DATA & PRESSURE CURVES Pressure Curves. 5.3.1 Cooling. Suction Pressure VS.Outdoor Temp 14.0 15/21(WB/DB ºC) 13.0 17/24(WB/DB ºC) 19/27(WB/DB ºC) 12.0 21/29(WB/DB ºC) 11.0 23/32(WB/DB ºC) 10.0 Outdoor Temp.(DB Discharge Pressure VS.Outdoor Temp 15/21(WB/DB ºC) 17/24(WB/DB ºC) 19/27(WB/DB ºC) 21/29(WB/DB ºC) 23/32(WB/DB ºC) Outdoor Temp.(DB...
  • Page 14 PERFORMANCE DATA & PRESSURE CURVES 5.3.2 Heating. Suction Pressure VS.Outdoor Temp 12.0 11.0 10.0 15 DB (ºC) 20 DB (ºC) 25 DB (ºC) Outdoor Temp.( WB Discharge Pressure VS.Outdoor Temp 25 DB (ºC) 20 DB (ºC) 15 DB (ºC) Outdoor Temp.( WB SM XLFDCI 1-A.1 GB CONTENTS...
  • Page 15 PERFORMANCE DATA & PRESSURE CURVES XLF 12 DCI / GC 12 R410A 5.4.1 Cooling Mode at 7.5m Tubing Connection. 230V : Indoor Fan at High Speed. Entering Air WB/DB ID Coil( Entering Air DB Data OD Coil( 15/21 17/24 19/27 21/29 23/32 3.43...
  • Page 16 PERFORMANCE DATA & PRESSURE CURVES 5.4.2 Heating Mode at 7.5m Tubing Connection. 230V : Indoor Fan at High Speed. ENTERING AIR DB ID COIL( ENTERING WB OD COIL( 1.75 0.76 1.69 0.81 1.62 0.85 1.89 0.78 1.82 0.82 1.75 0.87 2.00 0.79 1.94...
  • Page 17 PERFORMANCE DATA & PRESSURE CURVES Pressure Curves. 5.6.1 Cooling. Suction Pressure VS.Outdoor Temp 14.0 15/21(WB/DB ºC) 13.0 17/24(WB/DB ºC) 19/27(WB/DB ºC) 12.0 21/29(WB/DB ºC) 11.0 23/32(WB/DB ºC) 10.0 Outdoor Temp.(DB Discharge Pressure VS.Outdoor Temp 15/21(WB/DB ºC) 17/24(WB/DB ºC) 19/27(WB/DB ºC) 21/29(WB/DB ºC) 23/32(WB/DB ºC) Outdoor Temp.(DB...
  • Page 18 PERFORMANCE DATA & PRESSURE CURVES 5.6.2 Heating. Suction Pressure VS.Outdoor Temp 11.0 10.0 15 DB (ºC) 20 DB (ºC) 25 DB (ºC) Outdoor Temp.( WB Discharge Pressure VS.Outdoor Temp 25 DB (ºC) 20 DB (ºC) 15 DB (ºC) Outdoor Temp.( WB SM XLFDCI 1-A.1 GB CONTENTS...

  • Page 19: Sound Level Characteristics

    SOUND LEVEL CHARACTERISTICS SOUND LEVEL CHARACTERISTICS Sound Pressure Level Unit Wall Mic. Figure 1 Sound Pressure Level Spectrum (Measured as Figure 1) XLF 9 DCI XLF 12 DCI -70NC -70NC -60NC -60NC -50NC -50NC -40NC -40NC -30NC -30NC APPROXIMATE APPROXIMATE...

  • Page 20: Outdoor Units

    SOUND LEVEL CHARACTERISTICS Outdoor units Unit Mic. Ground Figure 2 Sound Pressure Level Spectrum (Measured as Figure 2) GC 9 Cooling GC 9 Heating GC 12 Cooling GC 12 Heating SM XLFDCI 1-A.1 GB CONTENTS...

  • Page 21: Electrical Data

    ELECTRICAL DATA ELECTRICAL DATA Single Units MODEL XLF 9 DCI XLF 12 DCI To indoor To indoor Power Supply 1PH-230V-50Hz 1PH-230V-50Hz 10.0 10.0 Max Current, (A) 15.0 15.0 Circuit Breaker,(A) Power Supply Wiring. 3 x 1.5 mm 3 x 1.5 mm (No.

  • Page 22: Wiring Diagrams

    WIRING DIAGRAMS WIRING DIAGRAMS Units: XLF 9 DCI, XLF 12 DCI / GC 9, GC 12 R410A POWER SUPPLY SM XLFDCI 1-A.1 GB CONTENTS...

  • Page 23: Electrical Connections

    ELECTRICAL CONNECTIONS ELECTRICAL CONNECTIONS XLF 9 / GC 9, XLF 12 / GC 12 R410A Indoor unit Outdoor unit SM XLFDCI 1-A.1 GB CONTENTS...

  • Page 24: Refrigeration Diagrams

    REFRIGERATION DIAGRAMS REFRIGERATION DIAGRAMS 10.1 Heat Pump Models 10.1.1 XLF 9 DCI, XLF 12 DCI R410A 10.1.1a Cooling Mode OUTDOOR UNIT INDOOR UNIT Sensor Sensor Flared Valves connection Reverse valve Indoor coil Strainer Strainer Outdoor coil 10.1.1b Heating Mode OUTDOOR UNIT...

  • Page 25: Tubing Connections

    TUBING CONNECTIONS TUBING CONNECTIONS TUBE (Inch) ¼” ⅜” ½” ⅝” ¾” TORQUE (Nm) Flare Nuts 11-13 40-45 60-65 70-75 80-85 Valve Cap 13-20 13-20 18-25 18-25 40-50 Service Port Cap 11-13 11-13 11-13 11-13 11-13 Valve Protection Cap-end Refrigerant Valve Port (use Allen wrench to open/close) Valve Protection Cap Refrigerant Valve Service Port Cap...

  • Page 26: Control System

    CONTROL SYSTEM CONTROL SYSTEM 12.1 General Functions and Operating RulesThe DCI software parametric. All the model dependent parameters are shown in Blue color and with Italic style [parameter]. The parameters values are given in the last section of this control logic chapter of the service manual.
  • Page 27 CONTROL SYSTEM NLOAD Target Frequency Maximum Frequency 10<NLOAD<127 Interpolated value between minimum and maximum frequency Minimum frequency Compressor is sXLFped Target frequency limits as a function of outdoor air temperature (OAT): OAT Range Cooling Mode limits Heating Mode limits OAT < 6 No limit 6 ≤...
  • Page 28 CONTROL SYSTEM Turbo Speed The Turbo speed is activated during the first 30 minutes of unit operation when auto fan speed is selected and under the following conditions: Difference between set point and actual room temperature is bigger than 3 degrees. Room temperature >...
  • Page 29 CONTROL SYSTEM When compressor is switched to OFF and the heat sink temperature is above 55 degrees, the outdoor fan will remain ON in low speed for up to 3 minutes. EEV (Electronic Expansion Vavle) Control EEV Control for GC 9 / 12 EEV opening is defined as EEV = EEV + EEV is the initial EEV opening as a function of the compressor frequency, operation mode, unit...
  • Page 30 CONTROL SYSTEM Heat Mode NLOAD is calculated according to the difference between actual room temperature and user set point temperature by fuzzy control. In high/ medium/ low indoor fan user setting, unit will operate fan in selected speed. In AutoFan user setting, fan speed will be adjusted automatically according to the calculated NLOAD.
  • Page 31 CONTROL SYSTEM Dry Mode As long as room temperature is higher then the set point, indoor fan will work in low speed and compressor will work between 0 and MaxNLOADIF1C Hz. When the room temperature is lower than the set point, compressor will be switched OFF and indoor fan will cycle 3 minutes OFF, 1 minute ON.
  • Page 32 CONTROL SYSTEM Stop-Compressor Normal Control Status Compressor Temperature Increases Else Normal SXLF Rise HzDown 1 SXLF Rise HzDown 2 HzDown 1 SXLF Compressor SXLF Compressor Compressor Over Current Protection Only For DCI25/35 Stop-Compresor CCROC4 HzDown2 CCROC3 HzDown1 CCROC2 Stop-Rise CCROC1 Normal 12-7 SM XLFDCI 1-A.1 GB...
  • Page 33 CONTROL SYSTEM Heat Sink Overheating Protection Heat Sink Overheating Protection For GC 9 / 12 HST Trend Fast Decreasing Decreasing No Change Increasing Fast Increasing ≥ 90 [85, 90) [82, 85) [80, 82) Norm Norm Norm [78 , 80) < 78 Norm Outdoor Coil Deicing Protection Outdoor coil Deicing Protection For GC 9 / 12...
  • Page 34 CONTROL SYSTEM ● Deicing Operation Procedure O C T T h re s h o ld C O M P D e ic e F re q C h R V m a x. 1 2 m in u te s H E A T C O O L O F A N...
  • Page 35 CONTROL SYSTEM STAND BY Lights up when the Air Conditioner is connected to power and INDICATION ready to receive the R/C commands STBY will be indicately by the following illumination (purple color): Duty Cycle (%) ‘Unit Mode’ Heat (Red) ‘Unit Mode’ Cool (Blue) The combined color is purple (it’s not red and not blue) OPERATION INDICATION ‘Unit Mode’...

  • Page 36: Jumper Settings

    CONTROL SYSTEM Presence detector Remote controller ICOM-X command Mode Button ESF/INOIZER INDICATOR Lights up during ESF/ ionizer operation. TIMER INDICATOR Lights up during Timer and Sleep operation. FILTER INDICATOR The filer LED never lights up(even when the filer needs to be cleaned).
  • Page 37 CONTROL SYSTEM Self Test Jumper(J1) Jumper for production line check. DIP Switch Settings ● Compensation setting This setting activates the compensation to the return air temperature in heating mode. For indoor unit like cassette, the DIP switch J2 should be ON. Compensation J2(DIP1) Activated (factory setting)
  • Page 38 CONTROL SYSTEM The indoor alarm outputs are defined according to the following table: Problem ICT is disconnected ICT is shorted RAT is disconnected RAT is shorted Reserved (for MSMP used as RGT fault) ICTE shorted/disconnected (when enabled) Undefined IDU family/model No Communication No Encoder Reserved...
  • Page 39 CONTROL SYSTEM The outdoor alarm outputs are defined in the following way: Problem OCT is disconnected OCT is shorted CTT is disconnected CTT is shorted HST is disconnected (when enabled) HST is shorted (when enabled) OAT is disconnected (when enabled) OAT is shorted (when enabled) TSUC is disconnected (when enabled) TSUC is shorted (when enabled)
  • Page 40 CONTROL SYSTEM Test Mode Entering Test Mode System can enter Test mode in two ways: Automatically when the following conditions exists for 30 minutes continuously: Mode = Cool, Set point = 16, Room temperature = 27(+1/-2), Outdoor temperature = 35(+2/-1) Or Mode = Heat, Set point = 30, Room temperature = 20±1, Outdoor temperature = 7±(+1/-2) Manually when entering diagnostics with the following settings: Mode = Cool, Set point = 16...
  • Page 41 CONTROL SYSTEM SW Parameters Indoor Units SW Parameters Model dependent parameters XLF DCI Family A (XLF 9 DCI) B (XLF 12 DCI) (Reserved) (Reserved) IFVLOWC IFLOWC IFMEDC IFHIGHC IFTURBOC IFVLOWH IFLOWH IFMEDH IFHIGHH IFTURBOH Cap .Group NomLoadC NomLoadH MaxNLOADIF1C MaxNLOADIF2C...
  • Page 42 CONTROL SYSTEM Outdoor Units SW Parameters Model dependent parameters for GC 9 / GC 12 Name A Single DCI-25 B Single DCI-35 MinFreqC MaxFreqC MaxFreqCRunPhase MinFreqH MaxFreqH MaxFreqHRunPhase LoadDeadZoneC LoadDeadZoneH NormAccel NormDecel Step1Freq Step2Freq Step3Freq OFVL OFLOWC OFMEDC OFMAXC OFLOWH OFMEDH OFMAXH OFANTESTMODEC...

  • Page 43: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING 13.1 Models: XLF 9 / GC 9, XLF 12 / GC 12 ELECTRICAL & CONTROL TROUBLESHOOTING ATTENTION: check for broken or loose cable lugs first. Problem Cause Remedy Unit does not operate. Unit not connected to power Plug in the power cord...

  • Page 44: Exploded Views And Spare Parts Lists

    EXPLODED VIEWS AND SPARE PARTS LISTS EXPLODED VIEWS AND SPARE PARTS LISTS 14.1 R410A 14.1.1 Indoor Unit: XLF 9 DCI, XLF 12 DCI 21,27 14-1 SM XLFDCI 1-A.1 GB CONTENTS...
  • Page 45 EXPLODED VIEWS AND SPARE PARTS LISTS 14.1.2 Indoor Unit: XLF 9 DCI Description Quan. 465720088 Front Panel Assy. (Electra) 465720090 Front Panel Assy. (Airwell) 465720091 Front Panel Assy./silver (Electra) 465720092 Front Panel Assy. /silver(Airwell) 465720162 Front Panel Assy. /silver(Johnson) 465720099 Front Panel Assy.
  • Page 46 EXPLODED VIEWS AND SPARE PARTS LISTS 14.1.3 Indoor Unit: XLF 12 DCI Description Quan. 465720088 Front Panel Assy. (Electra) 465720090 Front Panel Assy. (Airwell) 465720091 Front Panel Assy. (Electra) 465720092 Front Panel Assy. (Airwell) 465720162 Front Panel Assy. /silver(Johnson) 465720099 Front Panel Assy.

  • Page 47: Sm Xlfdci 1-A.1 Gb Contents

    EXPLODED VIEWS AND SPARE PARTS LISTS 14.1.4 Outdoor Unit GC 9, GC 12 DCI R410A 14-4 SM XLFDCI 1-A.1 GB CONTENTS...
  • Page 48 EXPLODED VIEWS AND SPARE PARTS LISTS 14.1.5 Outdoor Unit GC 9, GC 12 DCI R410A Part No. Description 433218 A Front Panel A 4526340 Air inlet ring-420 4523060 Base Painting Assy. 4526299 Partition 4519300 Nut M5 L 463300505 Standard Valve Connect Pipe/Gas Valve/ TP2M 9.53*0.8/CON GCN ONG3 461010004 Gas Valve 3/8"...

  • Page 49: Appendix A

    APPENDIX A APPENDIX A INSTALLATION AND OPERATION MANUAL ► OPERATION MANUAL XLF 9 / GC 9, XLF 12 / GC 12 ► INSTALLATION MANUAL XLF 9 / GC 9, XLF 12 / GC 12 15-1 SM XLFDCI 1-A.1 GB CONTENTS...

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