AISIN SEIKI E1 Series User manual

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

1
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.
Definition of " " and " "
Inspection Precautions
Precautions of Electrical Parts Inspection
Indicates a potentially hazardous situation that could result in death or serious injury by misuse.
If the items with this symbol shown in this manual are not adhered to, injury or damage to the unit could occur.
[Before starting inspection]
1. Be sure to switch OFF the electric leakage breaker in the outdoor control box.
If not, you could be shocked.
※If not, you could be injured because the fans may automatically start temporarily to protect the units
or maintain performance even if the GHP is stopped.
2. Close the fuel valve.
If not, gas poisoning or gas explosion could occur.
[During inspection]
1. Check for fuel gas leakage. If there is anything unusual such as gas odor, be sure to take proper safety
measures.
If not, gas poisoning or gas explosion could occur.
2. Be sure to disconnect the igniter connector before conducting corrective measures against carbon deposit
formation on the valve or valve seat.
If not, fire could occur when cranking.
1. Do not touch the engine pulley or compressor belts when the [RUN] switch is ON.
If not, injury could result.
[Before starting inspection]
1. Be sure to turn OFF the overcurrent breaker in the junction circuit and the electric leakage breaker in the
outdoor control box, and confirm the residual voltage is lower than specified value.
If not, you could be shocked, burned, or injured and the equipment could be damaged.
[Procedure of safety check before starting inspection]
1. Confirm more than 1 minute has elapsed after turning OFF the electrical leakage breaker (to allow residual
voltage to self-discharge).
2. Confirm the voltage between the following terminals is lower than 15 V DC with a voltmeter (such as circuit
tester).
between the terminal ①(red) and ③(black) of CN2 on the power PCB, or
between the terminal ①(red) and ③(black) of CN4 on the DCBL PCB.
High voltage (residual voltage higher than 250 V DC) is still charged in the electrolytic capacitor on the
DCBL PCB at the bottom of the outdoor control box even after turning OFF the electric leakage breaker.

2
Precautions of Usage
Precautions of Installation
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.
When more than 13 years or 30,000 running hours have passed since installation of the GHP outdoor unit,
serious accident might occur depending on usage profile. In such a case, be sure to consult with GHP
dealer.
Outdoor and indoor units can temporarily stop or have insufficient air conditioning performance to protect
units or maintain capacity, but the units automatically resume normal operation. In the meantime, fuel gas
or electricity consumption may temporarily increase. (For example, during defrosting.)
Leakage of oil or engine coolant could result in malfunction or secondary damage (contamination on house-
hold goods). If leakage should occur, consult with the GHP dealer.
Never install the outside unit at the indoor location.
Install the outdoor unit so that its exhaust gas does not flow into the room through the piping, intake/exhaust
port or ventilation port leading to the inside of the room. Always discharge the exhaust gas to the open air
at a location where the gas will not cause adverse effects on the surrounding area. Do not discharge the
exhaust gas into the catch basin or ditch.
If the outdoor unit is installed near the intake/exhaust port to the room, window or ventilation port, it could
cause gas poisoning or lack of oxygen.
Never share the same pipe for the exhaust drain for the outdoor unit and the exhaust water drain for the
indoor unit.
If exhaust gas flows into the building, it could cause gas poisoning or lack of oxygen.
Arrange the piping so that the exhaust gas in the exhaust drain is released into the atmosphere if :
a) The exhaust drain hose of the outdoor unit is connected to the catch basin or ditch with a lid.
b) The exhaust drain water of the outdoor unit is released at the same location as the drain water of the
indoor unit.
Otherwise, exhaust gas could flow into the room and cause gas poisoning or lack of oxygen.

3
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.......................................................................................24
2) Engine Coolant / Fuel Gas / Intake Air and Exhaust Air System Diagrams................28
PERIODIC INSPECTION
1. Inspection Items and Intervals............................................................... 38
2. Parts Requiring Periodic Replacement.................................................. 39
3. Procedure and Method of Periodic Inspection....................................... 40
1) Engine Oil Inspection / Refilling .................................................................................. 42
2) Oil Filter Replacement ................................................................................................42
3) Spark Plug Replacement ............................................................................................43
4) Air Filter Element Replacement ..................................................................................43
5) Compressor Belt Replacement...................................................................................45
6) Exhaust Water Drain Filter Inspection / Refilling.........................................................46
7) Drain Oil Filter Replacement.......................................................................................48
8) Engine Coolant Additive Refilling................................................................................50
9) Engine Coolant Amount Inspection / Refilling............................................................. 50
10) Engine Coolant Leakage Inspection ........................................................................... 51
11) Engine Oil Leak Inspection .........................................................................................51
12) Exhaust Air Leakage Inspection.................................................................................. 51
13) Exhaust Water Drain Hose Inspection ........................................................................ 52
14) Fuel Gas Hose and Fuel Gas Hose Clamp Inspection / Replacement ....................... 52
15) Fuel Gas Leak Inspection ...........................................................................................53
16) Compressor Inspection ............................................................................................... 54
17) Refrigerant Leakage Inspection .................................................................................. 54
18) Refrigerant and Engine Coolant Line Contact Inspection ...........................................55
19) Engine Valve Cleaning................................................................................................ 55
20) Engine Valve Clearance Inspection / Adjustment (8 TON only).................................. 56
21) Oil Level Switch Cleaning / Inspection ........................................................................ 57
22) Outdoor Heat Exchanger Compartment Drainage Inspection..................................... 57
23) Accumulator Condensed Water Drainage Inspection .................................................58
24) Wiring and Connector Inspection ................................................................................58
25) Anchor Bolt Inspection ................................................................................................ 58
26) Engine Startability Inspection......................................................................................59
27) Engine Mount Replacement........................................................................................59
28) Inspection for Operation Noise.................................................................................... 61
29) Inspection of the Number of Engine and Starter on/off Times ....................................61
30) Inspection of the Running Hours and Number of on/off Times of the Compressor..... 61
31) Outdoor Heat Exchanger Inspection ...........................................................................61

4
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. Replacement of Cylinder Head.............................................................. 97
4. Replacing the Compressor .................................................................. 116
CONTROL
1. System Control Functions ................................................................... 134
1) System Block Diagram..............................................................................................134
2. Control Details ..................................................................................... 135
1) Temperature Control Start / Stop..............................................................................135
2) Starting the Outdoor Unit
(Starting the Engine and Engaging the Compressor Clutch)....................135
3) Transition from Start Control to Normal Operation Control....................................... 136
4) Indicated Engine Speed............................................................................................136
5) Refrigerant Flow Volume ..........................................................................................136
6) Defrosting (In Heating Only) .....................................................................................140
7) Outdoor Fan.............................................................................................................. 141
8) Oil Bypass Control Valve .......................................................................................... 142
9) Compressor Heater...................................................................................................142
10) Drain Filter Heater / Drain Hose Heater ....................................................................142
11) Flow Chart of Backup Operation under Combined Installation
(Conceptual Chart) ................................................................................... 143
3. Function Settings................................................................................. 145
1) Outdoor unit .............................................................................................................. 145
2) Cool/Heat Switching Setting .....................................................................................148
4. System Input/Output Specifications..................................................... 150
1) Outdoor Unit Input / Output Specifications................................................................150
TROUBLESHOOTING
1. Error Code Description and Possible Cause ....................................... 154
2. Parts Characteristics ........................................................................... 177
3. Failure Phenomenon ........................................................................... 183
1) The System will not Operate..................................................................................... 183
2) Engine will not Start ..................................................................................................184
3) Engine Starts But Stalls ............................................................................................185
4) Engine Coolant Temperature Abnormality................................................................186
5) Oil Pressure Abnormality .......................................................................................... 186
6) Over Speed...............................................................................................................187
7) High Pressure Abnormality in Cooling Operation ..................................................... 187

5
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...........................................................194
14) Gas Heat Pump is Pperating but Not Heating...........................................................196
4. Procedure for Inspection and Treatment ............................................. 198
1) Check Power Supply System....................................................................................198
2) Check Control Unit....................................................................................................198
3) Locate Electric Leakage Positions............................................................................198
4) Check Remote Control System.................................................................................198
5) Inspect Starter...........................................................................................................199
6) Inspect Starter Transformer......................................................................................199
7) Operation Check of Relay.........................................................................................200
8) Inspect Fuel Gas Pressure .......................................................................................200
9) Inspect Electromagnetic Gas Valve..........................................................................200
10) Inspect Spark Plug ....................................................................................................201
11) Inspect High Voltage Cable.......................................................................................201
12) Inspect Igniter, etc..................................................................................................... 202
13) Compression Inspection............................................................................................ 203
14) Valve Clearance Inspection / Adjustment ................................................................. 204
15) Treatment for Compression Failure due to Carbon Deposit......................................205
16) Inspect Engine Throttle Valve / Fuel Gas Flow Control Valve...................................210
17) Inspect Air / Fuel Ratio.............................................................................................. 210
18) Check for Contact Failure at the Starter Drive System .............................................211
19) Inspect Exhaust Water Drain Heater......................................................................... 211
20) Inspect Engine Oil Pan Heater.................................................................................. 212
21) Check Ignition Timing................................................................................................213
22) Check Engine Coolant Circulation ............................................................................214
23) Check Engine Coolant Amount or Leakage Location ............................................... 214
24) Inspect Engine Coolant Pump...................................................................................215
25) Inspect Thermostat ...................................................................................................216
26) Check Engine Coolant Heat Dissipation Condition (in cooling).................................216
27) Inspect Outdoor Fan Motor .......................................................................................217
28) Inspect Engine Coolant Temperature Sensor ........................................................... 218
29) Inspect Radiator Cap ................................................................................................218
30) Check Engine Oil Amount .........................................................................................218
31) Check Engine Oil Leakage........................................................................................219
32) Check Engine Oil Consumption Amount...................................................................219
33) Inspect Oil Pressure.................................................................................................. 220
34) Inspect Engine Oil Pressure Switch ..........................................................................220
35) Technical Data When Replacing the Refrigerant System Parts................................ 221
36) Inspect Refrigerant Pressure (Inspect Refrigerant Amount) ..................................... 222
37) Inspection Check Valve (Refrigerant Pressure Increase) ......................................... 222
38) Inspect Refrigerant High Pressure Switch.................................................................222
39) Inspect Refrigerant High Pressure Sensor................................................................223
40) Inspect Hot Gas Bypass Valve..................................................................................223
41) Inspect Indoor Fan Motor ..........................................................................................224
42) Inspect for Blockage in the Indoor Electronic Expansion Valve ................................ 224
43) Check Environmental Conditions (Low Intake Air Temperature) ..............................224
44) Inspect Strainer ......................................................................................................... 224
45) Inspection Check Valve (Refrigerant Pressure Drop) ...............................................224

6
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.................................... 228
52) Check for Readings of the Engine Exhaust Air Temperature Sensor .......................228
53) Check for Readings of the Outdoor Temperature Sensors.......................................229
54) Inspect Subcooling Valve.......................................................................................... 230
55) Check Operation Condition .......................................................................................231
56) Check for Readings of the Indoor Temperature Sensors.......................................... 231
57) Check Indoor Air Intake Status .................................................................................231
58) Check Drain Water....................................................................................................232
59) Inspect Drain Pump................................................................................................... 232
60) Inspect Drain Float Switch ........................................................................................ 232
61) Inspect Compressor Clutch....................................................................................... 232
5. Board Maintenance Functions............................................................. 233
1) Outline of the Maintenance Function ........................................................................233
2) Code List for Each Mode .......................................................................................... 235
3) Running Hours Display Mode ................................................................................... 239
4) Monitor Mode ............................................................................................................245
5) Command Mode .......................................................................................................246
6) Check Mode..............................................................................................................247
7) Operational Procedure / Display Contents................................................................248
6. Protection Devices............................................................................... 299
7. Standard Operation Data..................................................................... 305
8. Wiring Diagram of the Outdoor Unit .................................................... 306
TECHNICAL DATA FOR REPAIR
1. Engine System .................................................................................... 310
2. Refrigerant System.............................................................................. 312
3. Engine Coolant System ....................................................................... 314
4. Thermistor Characteristics................................................................... 315

7
Introduction
Introduction
1. Product Appearance
※Refer to "Outdoor Unit Model Name Structure" for outdoor unit model name.
8 TON 15 TON
Multi zone type Combination Multi type
Outdoor unit※Outdoor unit※
AISIN
AISIN

8
Introduction
2. Product Specifications
1) Model Name Structure
[ Outdoor Unit Model Name Structure ]
Model code list
Code abcde f gh
Model name
(Example) A X G P 096 E 1 NHS
Code Item Symbol and description
a Brand A : AISIN brand
bType
X : Multi zone type
W : Combination Multi type
c Outdoor unit G : Outdoor unit
d Refrigerant type P : R410A
e Capacity
096 : 96,000 BTU/h (8 TON)
180 : 180,000 BTU/h (15 TON)
f Model change suffix A, B, … (sequential alphabet is appended)
g Minor change suffix 1, 2, … (sequential number is appended)
h Special specification categories NHS : Natural Gas, For USA