Airwell GC 12 DCI User manual

BS DCI Series
Indoor Units Outdoor Units
BS 12 DCI GC 12 DCI
OCTOBER – 2008
REFRIGERANT
R410A HEAT PUMP
SM BS DCI 1-A.1 GB
CONTENTS

A
LIST OF EFFECTIVE PAGES
SM BS DCI 1- A.1 GB
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.
Dates of issue for original and changed pages are:
Original ....... 0 ........ May 2005
Total number of pages in this publication is 68 consisting of the following:
Page
No.
Revision
No. #
Page
No.
Revision
No. #
Page
No.
Revision
No. #
Title....................... 1
A ........................... 1
i............................. 1
1-1 - 1-3................ 1
2-1 ........................ 1
3-1 ........................ 1
4-1 ........................ 1
5-1 - 5-5................ 1
6-1 - 6-2................ 1
7-1 ........................ 1
8-1 ........................ 1
9-1 ........................ 1
10-1 ...................... 1
11-1-11-16............. 1
12-1-12-6.............. 1
13-1-13-5.............. 1
Appendix -A...........1
•Zero in this column indicates an original page.
*Due to constant improvements please note that the data on this service manual can be modified
with out notice.
**Photos are not contractual
CONTENTS

i
TABLE OF CONTENTS
SM BS DCI 1- A.1 GB
Table of Contents
1. INTRODUCTION ...................................................................................................1-1
2. PRODUCT DATA SHEET......................................................................................2-1
3. RATING CONDITIONS..........................................................................................3-1
4. OUTLINE DIMENSIONS .......................................................................................4-1
5. PERFORMANCE DATA & PRESSURE CURVES ...............................................5-1
6. AIRFLOW CURVES ..............................................................................................6-1
7. ELECTRICAL DATA..............................................................................................7-1
8. WIRING DIAGRAMS .............................................................................................8-1
9. REFRIGERATION DIAGRAMS.............................................................................9-1
10. TUBING CONNECTIONS......................................................................................10-1
11. CONTROL SYSTEM .............................................................................................11-1
12. TROUBLESHOOTING ..........................................................................................12-1
13. EXPLODED VIEWS AND SPARE PARTS LISTS.................................................13-1
14. APPENDIX A .........................................................................................................14-1

1-1
INTRODUCTION
SM BS DCI 1- A.1 GB
1. INTRODUCTION
1.1 General
The new BS 12 DCI ducted Unit is another completion to the DC inverter units range,
Which includes several types such as wall mounted, floor /ceiling, cassettes, and multi
splits.
1.2 Main Features
The BS 12 DCI benefits from the most advanced technological innovations, namely :
● DC Inverter Technology.
● R410A.
● Microprocessor control.
● Infrared remote control with liquid crystal display.
● High COP.
● Pre-Charged units up to the max allowing tubing distance.
● Cooling operation at outdoor temperature down to -10ºC.
● Heating operation at outdoor temperature down to -15ºC.
● Advanced test and diagnostics mode.
● M2L diagnostics softwear cable port (for PC)
● Network connectivity.
● The Indoor unit can be easily modified to a vertical or horizontal installation up
to 4 different air inlet and discharge applications.
● Base heater connection.
● Easy installation and service.
1.3 Indoor Unit
The indoor unit is a Low Silhouette ducted unit, and can be easily fitted to many types
of residential and commerciaBS applications.
It includes:
● Casing with interchangeable metal sheet paneBS, allowing verticality between
vertical and horizontal installation.
● Two centrifugal indoor fans.
● Coil with treated aluminum fins.
● Advanced electronic control box assembly.
● Interconnecting wiring terminal block.
● Easily accessible, and re-usable pre-filters (mesh).
CONTENTS

1-2
INTRODUCTION
SM BS DCI 1- A.1 GB
1.4 Control
The microprocessor indoor controller, and an infrared remote control, supplied as
standard, provide complete operating function and programming. For further detaiBS
please refer to the Operation Manual, Appendix A.
1.5 Outdoor Unit
The GC 12 DCI outdoor unit can be installed as floor or wall mounted by using a
wall supporting bracket. The metal sheets are protected by anti- corrosion paint work
allowing long life resistance. All outdoor units are pre-charged.
For further information please refer to the Product Data Sheet, Chapter 2.
It includes :
● Single DC inverter Rotary Compressor mounted in a soundproofed
compartment
● DC Inverter Outdoor Fan Motor
● Advanced controller.
● Axial fan.
● Outdoor coil with hydrophilic louver fins.
● Outlet air fan grill.
Outdoor Unit Features:
Feature GC 12 DCI
Diagnostics
Display 3 LED’s
Base Heater Optional
Outdoor Fan Variable speed DC Inverter
M2L cable Port No
1.6 Tubing Connections
Flare type interconnecting tubing to be produced on site.
For further detaiBS please refer to the Installation Manual, Appendix A
1.7 Inbox Documentation
Each unit is supplied with its own installation and operation manuaBS,
CONTENTS

1-3
INTRODUCTION
SM BS DCI 1- A.1 GB
1.8 Matching Table
R410A
OUTDOOR UNITS
INDOOR UNITS
MODEL REFRIGER. WNG25 WNG35 K25 K35 PXD25 PXD35 BS 12 DCI
GC 9 DCI R410A √√ √
GC 12 DCI R410A √√ √ √
The above table lists outdoor units and BS DCI indoor unit which can be matched together.
In addition the listed outdoor units can be matched with other types of indoor units such as
cassettes and wall mounted.
For further information please refer to the relevant Service Manual.
CONTENTS

2-1
PRODUCT DATA SHEET
SM BS DCI 1- A.1 GB
(1) Rating conditions in accordance with ISO 5151 and ISO 13253 (for ducted units) and EN 14511.
(2) Airflow in ducted units; at nominal external static pressure.
(3) Sound power in ducted units is measured at air discharge.
(4) Sound pressure level measured at 1 meter distance from unit.
2. PRODUCT DATA SHEET
2.1 BS 12 DCI / GC 12 DCI R410A
Model Indoor Unit BS 12 DCI
Model Outdoor Unit GC 12 DCI
Installation Method of Pipe Flared
Characteristics Units Cooling Heating
Capacity (1) Btu/hr 11940(5118-15686) 14663(5118-18760)
kW 3.5(1.5-4.6) 4.3(1.6-5.5)
Power input (1) kW 0.96 (0.42-1.45) 1.34(0.4-1.8)
EER (Cooling) or COP(Heating) (1) W/W 3.65 3.21
Energy efficiency class A C
Power supply V/Ph/Hz 220-240V/Single/50Hz
Rated current A 4.3 5.8
Starting current A 10.5
Circuit breaker rating A 12
INDOOR
Fan type & quantity Centrifugal x 2
Fan speeds H/M/L RPM 1150/1000/760
Air flow (2) H/M/L m3/hr 830/700/530
External static pressure Min-Max Pa 25
Sound power level (3) H/M/L dB(A) 59/55/52
Sound pressure level(4) H/M/L dB(A) 42/38/35
Moisture removal l/hr 1.3
Condensate drain tube I.D mm 16
Dimensions WxHxD mm 860x245x680
Weight kg 30
Package dimensions WxHxD mm 1055x305x728
Packaged weight kg 33.5
Units per pallet units 6 units per pallet
Stacking height units 6 leveBS
OUTDOOR
Refrigerant control EEV
Compressor type, model Single Rotary DC Inverter, Panasonic 5RS0102XAB
Fan type & quantity Propeller(direct) x 1
Fan speeds H/L RPM 830
Air flow H/L m3/hr 1780
Sound power level H/L dB(A) 62
Sound pressure level (4) H/L dB(A) 52
Dimensions WxHxD mm 795x610x290
Weight kg 38
Package dimensions WxHxD mm 945X655X395
Packaged weight kg 42.5
Units per pallet Units 9 units per pallet
Stacking height units 3 leveBS
Refrigerant type R410A
Refrigerant chargless distance kg/m 1.2 /7.5m
Additional charge per 1 meter g/m No need
Connections between
units
Liquid line In.(mm) 1/4”(6.35)
Suction line In.(mm) 3/8”(9.53)
Max.tubing length m. Max.20
Max.height
difference m. Max. 10
Operation control type Remote control
Heating elements kW
Others
CONTENTS

3-1
RATING CONDITIONS
SM BS DCI 1- A.1 GB
3. RATING CONDITIONS
Rating conditions in accordance with ISO 5151 and ISO 13253 (for ducted units).
Cooling:
Indoor: 27oC DB 19oC WB
Outdoor: 35 oC DB
Heating:
Indoor: 20oC DB
Outdoor: 7oC DB 6oC WB
3.1 Operating Limits
3.1.1 R410A
Indoor Outdoor
Cooling Upper limit 32oC DB 23oC WB 46oC DB
Lower limit 21oC DB 15oC WB -10oC DB
Heating Upper limit 27oC DB 24oC DB 18oC WB
Lower limit 10oC DB -15oC DB -16oC WB
Voltage 198 – 264 V
CONTENTS

4-1
OUTLINE DIMENSIONS
SM BS DCI 1- A.1 GB
4. OUTLINE DIMENSIONS
4.1 Indoor Unit: BS 12 DCI
4.2 Outdoor Unit: GC 12 DCI
CONTENTS

5-1
PERFORMANCE DATA & PRESSURE CURVES
SM BS DCI 1- A.1 GB
5. PERFORMANCE DATA
5.1 BS 12 DCI
5.1.1 Cooling Capacity (kW) - Run Mode
230[V] : Indoor Fan at High Speed.
ID COIL ENTERING AIR DB/WB TEMPERATURE [oC]
OD COIL
ENTERING AIR DB
TEMPERATURE [oC]
DATA 22/15 24/17 27/19 29/21 32/23
-10 - 20
(protection range)
TC 80 - 110 % of nominal
SC 80 - 105 % of nominal
PI 25 - 50 % of nominal
25
TC 3.38 3.60 3.83 4.05 4.27
SC 2.65 2.70 2.75 2.81 2.86
PI 0.75 0.77 0.78 0.80 0.81
30
TC 3.22 3.44 3.66 3.88 4.11
SC 2.58 2.63 2.69 2.74 2.79
PI 0.84 0.86 0.87 0.89 0.90
35
TC 3.06 3.28 3.50 3.72 3.94
SC 2.51 2.57 2.62 2.67 2.73
PI 0.93 0.95 0.96 0.97 0.99
40
TC 2.89 3.12 3.34 3.56 3.78
SC 2.45 2.50 2.55 2.61 2.66
PI 1.02 1.03 1.05 1.06 1.08
46
TC 2.70 2.92 3.14 3.36 3.58
SC 2.37 2.42 2.47 2.53 2.58
PI 1.13 1.14 1.15 1.17 1.18
LEGEND
TC – Total Cooling Capacity, kW
SC – Sensible Capacity, kW
PI – Power Input, kW
WB – Wet Bulb Temp., (oC)
DB – Dry Bulb Temp., (oC)
ID – Indoor
OD – Outdoor
5.1.2 Capacity Correction Factors
Cooling Capacity Ratio Vs. Outdoor Temperature
0.50
0.60
0.70
0.80
0.90
1.00
1.10
1.20
20 25 30 35 40 45
Outdoor Temperature [deg C]
Capacity Ratio
CONTENTS

5-2
PERFORMANCE DATA & PRESSURE CURVES
SM BS DCI 1- A.1 GB
5.1.3 Heating Capacity (kW) - Run Mode)
230[V] : Indoor Fan at High Speed
ID COIL ENTERING AIR DB TEMPERATURE [oC]
OD COIL ENTERING
AIR DB/WB
TEMPERATURE [oC]
DATA 15 20 25
-15/-16 TC 2.74 2.55 2.35
PI 0.80 0.89 0.97
-10/-12 TC 3.05 2.86 2.66
PI 0.97 1.05 1.13
-7/-8 TC 3.28 3.09 2.90
PI 1.09 1.17 1.26
-1/-2 TC 3.39 3.20 3.01
PI 1.16 1.24 1.32
2/1 TC 3.47 3.28 3.09
PI 1.20 1.28 1.36
7/6 TC 4.49 4.30 4.11
PI 1.26 1.34 1.42
10/9 TC 4.74 4.55 4.36
PI 1.33 1.42 1.50
15/12 TC 4.99 4.80 4.60
PI 1.41 1.49 1.57
15-24 TC 85 - 105 % of nominal
(Protection Range) PI 80 - 120 % of nominal
LEGEND
TH – Total Heating Capacity, kW
PI – Power Input, kW
WB – Wet Bulb Temp., (oC)
DB – Dry Bulb Temp., (oC)
ID – Indoor
OD – Outdoor
5.1.4 Capacity Correction Factors
Heating Capacity Ratio Vs. Outdoor Temperature
0.50
0.60
0.70
0.80
0.90
1.00
1.10
1.20
-15 -10 -5 0 5 10 15
Outdoor WB Temperature [deg C]
Capacity Ration
CONTENTS

5-3
PERFORMANCE DATA & PRESSURE CURVES
SM BS DCI 1- A.1 GB
5.1.5 Capacity Correction Factor Due to Tubing Length
BS 12 DCI: Cooling
5.1.6 Heating
0.91
0.92
0.93
0.94
0.95
0.96
0.97
0.98
0.99
1.00
1.01
3 4 5 6 7 8 9 1011121314151617181920
Tubing Length [m]
Capacity Ratio
0.90
0.92
0.94
0.96
0.98
1.00
1.02
3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Tubing Length [m]
Capacity Ratio
CONTENTS

5-4
PERFORMANCE DATA & PRESSURE CURVES
SM BS DCI 1- A.1 GB
5.2 Pressure Curves
5.2.1. Model: BS 12 DCI Cooling — Test Mode
Suction Pressure Vs.Outdoor Temp.
500
600
700
800
900
1000
1100
1200
1300
1400
10 15 20 25 30 35 40 45
Outdoor DB Temperature [ºC ]
Suction Pressure [kPa]
22/15
24/17
27/19
29/21
32/23
Indoor
DB/WB
Discharge Pressure Vs.Outdoor Temp.
1000
1250
1500
1750
2000
2250
2500
2750
3000
3250
3500
3750
4000
10 15 20 25 30 35 40 45
Outdoor DB Temperature [ºC ]
Discharge Pressure [kPa]
22/15
24/17
27/19
29/21
32/23
Indoor
DB/WB
CONTENTS

5-5
PERFORMANCE DATA & PRESSURE CURVES
SM BS DCI 1- A.1 GB
5.2.2. Heating — Test Mode
Suction Pressure Vs.Outdoor Temp.
200
300
400
500
600
700
800
900
1000
1100
1200
1300
-15 -10 -5 0 5 10 15
Outdoor WB Temperature [ºC]
Suction Pressure [kPa]
15
20
25
indoor DB
Discharge Pressure Vs.Outdoor Temp.
1000
1250
1500
1750
2000
2250
2500
2750
3000
3250
3500
3750
4000
-15 -10 -5 0 5 10 15
Outdoor WB Temperature [ºC]
Discharge Pressure [kPa]
15
20
25
Indoor DB
CONTENTS

6-1
AIRFLOW CURVES
SM BS DCI 1- A.1 GB
6. AIRFLOW CURVES
Model: BS 12 DCI
Airflow Correction Factors (Test Mode, at nominal rating conditions)
Air Flow Rate [% of nominal]
60% 70% 80% 90% 100%
Cooling
TC 0.88 0.91 0.94 0.97 1.00
SC 0.78 0.84 0.89 0.95 1.00
PI 0.95 0.97 0.98 0.99 1.00
Heating PI 0.90 0.92 0.95 0.97 1.00
TC 1.07 1.05 1.03 1.02 1.00
LEGEND
TC –Total Capacity
SC –Sensible Capacity
PI – Power Input
Airflow Vs. External Static Pressure S DCI
0
10
20
30
40
50
60
300 400 500 600 700 800 900 1000 1100 1200
Air Flow Rate, [m^3/hr]
External Static Pressure, [Pa]
Super High
High
Medium
Low
Nominal System Resistance
Max.System Resistance
Curve's colors according to
fan motor wires colors
The System characteristics defines
recommended motor speeds range
vs.static pressure
Point for Performance test
Operating range
CONTENTS

7-1
ELECTRICAL DATA
SM BS DCI 1- A.1 GB
7. ELECTRICAL DATA
7.1 Single Phase Unit
MODEL BS 12 DCI
Power Supply To indoor
1PH-230V-50Hz
Max Current, A 10
Inrush Current A 35
Starting Current A 10.5
Circuit Breaker A 16
Power Supply Wiring No. X Cross Section mm23x1.5 mm2
Interconnecting Cable No. X Cross Section mm24x1.5 mm2
(a) Inrush current is the current when power is up (charging the DC capacitors
at outdoor unit controller).
(b) Starting current is the current at compressor start up.
NOTE
Power wiring cord should comply with local lows and electrical
regulations requirements.
CONTENTS

8-1
WIRING DIAGRAMS
SM BS DCI 1- A.1 GB
8. WIRING DIAGRAMS
8.1 Model: BS 12 DCI
Display
POWER SUPPLY
magnetic ring
Brown
Y/G
Red
Blue
Red
L-F
L
N-F
N
COM COM FUSE
Y/G
Y/G
Black EARTH
EMI filter PCB
EARTH NCOM Red
L/4
N/3
C/5
Blue
Brown
EEV
Y/G
P21
OFAN
Yellow Vsp
Outdoor unit controller PCB
Orange
Black
Red
P14
P12
EARTH
L
P10
N-COM
NCOM
P3 P13P9 P11
UVW
JP9
42
135
6
P1P4
11
2
P17P16 P18
2
Choke coil
Red
Blue
White
Brown
Black
COMP
Vcc
Vdc
EARTH
1 2 3 4
Base heater
valve
Reverse
Blue
P7
654321
megatool
2
1
P6 34
P19
P2
P22
2
121
P8P20
2
12
1
FG
5 6
OCT
OAT SUCTCTT
OUTDOOR UNIT CIRCUIT DIAGRAM
Y/G
Brown
Blue
Red
CONTENTS

9-1
REFRIGERATION DIAGRAMS
SM BS DCI 1- A.1 GB
9. REFRIGERATION DIAGRAMS
9.1 Heat Pump Models
9.1.1 BS 12 DCI
EEV
EEV
CONTENTS

10-1
TUBING CONNECTIONS
SM BS DCI 1- A.1 GB
10. TUBING CONNECTIONS
TUBE (Inch)
TORQUE (Nm)
¼” ⅜” ½” ⅝” ¾”
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
1. Valve Protection Cap-end
2. Refrigerant Valve Port (use Allen wrench to open/close)
3. Valve Protection Cap
4. Refrigerant Valve
5. Service Port Cap
6. Flare Nut
7. Unit Back Side
8. Copper Tube
When the outdoor unit is installed above the indoor unit an oil trap is required every 5m along the suction
line at the lowest point of the riser. Incase the indoor unit is installed above the outdoor, no trap is
required.
CONTENTS

11-1
CONTROL SYSTEM
SM BS DCI 1- A.1 GB
11. CONTROL SYSTEM
11.1 General Functions and Rules (for single split models)
The DCI software is fully parametric.
All the model dependent parameters are shown in Blue color and with Italic st
y
[parameter].
The parameters values are given in the last section of this control logic chapt
e
service manual.
11.2 System Operation Concept
The control function is divided between indoor and outdoor unit control
l
Indoor unit is the system ‘Master’, requesting the outdoor unit for cooling/he
a
capacity supply. The outdoor unit is the system ‘Slave’ and it must supply
required capacity unless it enters into a protection mode avoiding it
f
supplying the requested capacity.
The capacity request is transferred via indoor to outdoor communication, a
n
represented by a parameter called ‘NLOAD’. NLOAD is an integer number
w
values between 0 and 127, and it represents the heat or cool load felt by
indoor unit.
11.3 Compressor Frequency Control
11.3.1 NLOAD setting
The NLOAD setting is done by the indoor unit controller, based on a PI contr
o
scheme.
The actual NLOAD to be sent to the outdoor unit controller is based on the
preliminary LOAD calculation, the indoor fan speed, and the power shedding
function.
NLOAD limits as a function of indoor fan speed:
Indoor Fan Speed Maximum NLOAD Cooling Maximum NLOAD Heating
Low Max NLOADIF1C 127
Medium Max NLOADIF2C 127
High Max NLOADIF3C 127
Turbo Max NLOADIF4C 127
Auto Max NLOADIF5C 127
NLOAD limits as a function of power shedding:
CONTENTS