Daikin RMKS112EV1A User manual

REMOVAL
PROCEDURE
SERVICE MANUAL
11.2/14.0/16.0 kW Class
Outdoor Unit
Inverter
Multi Type
Si181095

Service Manual
Removal Procedure
Outdoor Unit
zCooling Only
RMKS112EV1A
RMKS140EV1A
RMKS160EV1A
zHeat Pump
RMXS112E8V1B
RMXS140E8V1B
RMXS160E8V1B
RMXS112EVLT
RMXS140EVLT
RMXS160EVLT
RMXS112EV1A
RMXS140EV1A
RMXS160EV1A
zBP Unit
BPMKS967A2
BPMKS967A3
BPMKS967B2B
BPMKS967B3B

Si181095
Removal Procedure 1
Table of Contents
1. Outdoor Unit............................................................................................2
1.1 Removal of Outer Panels .........................................................................2
1.2 Removal of PCBs / Electrical Components ..............................................5
1.3 Removal of Outdoor Fans / Fan Motors .................................................12
1.4 Removal of Thermistors .........................................................................14
1.5 Removal of Electronic Expansion Valves / Peripheral Equipments .......15
1.6 Removal of Four Way Valve...................................................................19
1.7 Removal of Compressor.........................................................................20
2. BP Unit ..................................................................................................23
2.1 Removal of PCB Assembly ....................................................................23
2.2 Removal of Electronic Expansion Valve Coils........................................26
Note: The illustrations may be slightly different depending on the model.
The illustrations are for heat pump models as representative.

Outdoor Unit Si181095
2Removal Procedure
1. Outdoor Unit
1.1 Removal of Outer Panels
Procedure Warning Be sure to wait for 10 minutes or more after turning off all power
supplies before disassembling work.
Step Procedure Points
1
2
3
4
5
Remove the 8 screws
and remove the top
panel.
Remove the screw of
the front panel (2).
Push the front panel (2)
downward to release
the hook and remove it.
Remove the screw and
remove the piping cover
(front).
Remove the 4 screws
and remove the piping
cover (rear).
Detach the outdoor
temperature thermistor.
Remove the 6 screws
and remove the right
side panel.
It is possible to remove only
the front panel (2) without
removing the top panel.
Top panel
(R12962)
Front panel
(2)
Piping cover
(front)
Hook
(R12963)
Right side
panel
Piping cover
(rear)
(R9211)
Outdoor temperature
thermistor

Si181095 Outdoor Unit
Removal Procedure 3
6 The outdoor unit has 2
discharge grilles.
Remove the 4 screws
and unfasten the 4
hooks to remove a
discharge grille.
7 Remove the 7 screws
of the front panel (1).
Push the front panel (1)
upward and remove it.
On the rear side of the front
panel (1), a reinforce plate is
attached. Be careful not to
lose it while removing the
front panel (1).
Step Procedure Points
Front panel (1)
Discharge grille (R9213)
(R9215)
Reinforce plate

Outdoor Unit Si181095
4Removal Procedure
8 Unfasten the 3 hooks
with a flat screwdriver
and remove the suction
grille.
9 Pull the outdoor
temperature thermistor
and slide it to the right.
Detach the outdoor
temperature thermistor.
Step Procedure Points
Suction
grille
(R12964)
(R12965)
(R9218)
Outdoor
temperature
thermistor

Si181095 Outdoor Unit
Removal Procedure 5
1.2 Removal of PCBs / Electrical Components
Procedure Warning Be sure to wait for 10 minutes or more after turning off all power
supplies before disassembling work.
Step Procedure Points
1 Remove the 2 screws
of the terminal
mounting plate.
Preparation
Remove the outer panels
according to the “Removal of
Outer Panels”.
M5(3) × 12
2 Remove the screw
above the electrical
component assembly.
M5(3) × 12
3 Unfasten the clamp
from the terminal
mounting plate.
(R12966)
Terminal mounting plate
(R9220)
(R9221)

Outdoor Unit Si181095
6Removal Procedure
4 Cut off the 3 clamps.
5 Disconnect the relay
connector for the
reactor lead wire from
each other.
Step Procedure Points
(R9222)
(R9223)
(R9224)
(R9225)

Si181095 Outdoor Unit
Removal Procedure 7
6 Disconnect the 2
connectors for the fan
motor [X106A] [X107A].
7 Release the fan motor
lead wires from the
hooks.
8 Release the lead wires
of the solenoid valves
and four way valve from
the fixing plate and then
remove the electrical
component assembly.
Step Procedure Points
(R12967)
[X106A] [X107A]
(R9227)
(R9228)

Outdoor Unit Si181095
8Removal Procedure
9 Remove the 2 screws
of the insulation sheet
and then release the
compressor lead wires
(blue, red, white) and
the lead wires between
A1P and A3P (red,
blue) from the hooks.
10 Remove the 2 screws
from [LB] (red) and [NB]
(blue) on A3P and
disconnect the 2 lead
wires of condenser
(orange, gray).
M4 × 8 with spring washer
Step Procedure Points
(R9229)
(R9230)
(R12968)
Condenser (C4)
Orange
[NB]
[LB]
Gray

Si181095 Outdoor Unit
Removal Procedure 9
11 Cut the 2 clamps, for
the compressor lead
wires.
Cut the clamp for the
lead wires from A3P to
A1P (red, blue) and for
the earth (green).
Clamps (2 places) for the
compressor lead wires
Clamp for the lead wires from A3P
to A1P and for the earth
12 Push and unfasten the
2 hooks and slide the
casing to the right and
remove the casing from
the electrical
component assembly.
Step Procedure Points
(R12969)
(R9233)
(R9234)
(R9235)
Hook

Outdoor Unit Si181095
10 Removal Procedure
13 Disconnect the
connectors [X66A]
[X81A] [X5A].
14 Disconnect the reactor
lead wire connectors,
compressor lead wire
connector, and all the
other connectors from
the main PCB. [X22A]
[X21A] [X13A] [X11A]
[X12A] [X18A] [X17A]
[X32A] [X25A] [X26A]
[X27A] [X28A]
Step Procedure Points
[X66A] [X81A] [X5A]
(R12970)
X66A
X81A
X5A
X22A
X21A
X13A
X11A
X18A
X17A
X32A
X25A X26A X27A X28A LD
LE
U
V
W
X12A
(R12971)
Compressor lead
wire connector
Reactor lead
wire connectors

Si181095 Outdoor Unit
Removal Procedure 11
15 Remove the screw at
the top of the electrical
component assembly.
M4(2) × 12
16 Unfasten the 2 hooks at
the rear side.
17 The figures in the right
are PCB assembly.
Step Procedure Points
(R9238)
Hook
(R12972)
Fixing plate for the
PCB
Electrical component
mounting plate
Cool / heat selector
PCB (A4P)
(R12973)
Service PCB
(A2P)
Noise filter PCB
(A3P)
Electrical component
mounting plate
Main PCB (A1P)
(for control)

Outdoor Unit Si181095
12 Removal Procedure
1.3 Removal of Outdoor Fans / Fan Motors
Procedure Warning Be sure to wait for 10 minutes or more after turning off all power
supplies before disassembling work.
Step Procedure Points
Preparation
Remove the discharge grille,
front panels (1) and (2), and
piping cover (front),
according to the "Removal of
Outer Panels".
1Remove the nuts which
fixing the outdoor fan.
Nut size : M8
When reassembling, align
the mark of the outdoor
fan with the D-cut section of
the motor shaft.
Front panel (1)
(R9241)
Discharge
grille
Outdoor fan
Nut with a washer
(R12974)
13 mm
(R12301)

Si181095 Outdoor Unit
Removal Procedure 13
2 Cut the clamp. Pull out the connector while
supporting the fan motor and
pushing the engaging hook,
without pulling its lead wires.
When reassembling, put the
fan motor lead wire through
the back of the fan motor (so
as not to be entangled with
the outdoor fan).
Be sure to remove the lower
screws first. If the upper
screws are removed first, the
fan motor, the center of
gravity of which is toward the
front, may tilt down or fall,
getting you injured.
3 Remove the 4 screws
and remove the fan
motor.
Step Procedure Points
(R9243)
Lead wire for
fan motor
Earth wire
Clamp
D-cut
(R9244)
Fan
motor
Mount the fan motor with its mark "z"
positioned toward the bottom.
(R3249)
Lead wire Outdoor fan

Outdoor Unit Si181095
14 Removal Procedure
1.4 Removal of Thermistors
Procedure Warning Be sure to wait for 10 minutes or more after turning off all power
supplies before disassembling work.
Step Procedure Points
1 For the details of the
removal of the outdoor
temperature thermistor
(R1T), see the points
on the right column.
Preparation
Remove the front panel (2)
and the right side panel
according to the "Removal of
Outer Panels".
2 Pull out the discharge
pipe thermistor (R2T).
Removal of the outdoor
temperature thermistor
(R1T)
3 Pull out the suction pipe
thermistors (R3T)
(R5T).
4 Pull out the subcooling
thermistor (R6T) and
the liquid pipe
thermistor (R7T).
5 Pull out the outdoor
heat exchanger
thermistor (R4T).
When reassembling, pass
the outdoor temperature
thermistor through the hole
of the tube plate so as the
yellow marking comes to the
inside edge of the tube plate.
Suction pipe thermistor 2 (R5T)
Discharge pipe thermistor (R2T)
(R12975)
Subcooling
thermistor (R6T)
Suction pipe
thermistor 1 (R3T)
Liquid pipe thermistor
(R7T)
Outdoor heat exchanger
thermistor (R4T)
Hooks (2 places)
Right side panel
Notch
Fixing plate for thermistor (R1T)
Stopper
Outdoor temperature thermistor
Marking (yellow)
(R13061)
Removal
direction

Si181095 Outdoor Unit
Removal Procedure 15
1.5 Removal of Electronic Expansion Valves / Peripheral
Equipments
Procedure Warning Be sure to wait for 10 minutes or more after turning off all power
supplies before disassembling work.
Step Procedure Points
1 Pull out the 2 electronic
expansion valve coils.
2 Remove the 2 pressure
sensors.
When removing the pressure
sensor, be sure to use 2
wrench as the left figure
shows.
The pressure sensor is
equipped with a gauge port
with check valve. Therefore,
when loosening the nut,
refrigerant leak stops.
(R12996)
Electronic
expansion
valve coil
(main)
(Y1E)
Electronic
expansion
valve coil
(subcooling)
(Y3E)
(R9252)
(R12976)
High pressure sensor (S1NPH)
(R12977)
Low pressure sensor (S1NPL)

Outdoor Unit Si181095
16 Removal Procedure
3 Disconnect the lead
wires of the high
pressure switch.
4 Remove the screw and
remove the solenoid
valve coil for hot gas
bypass.
5 Remove the screw and
remove the solenoid
valve coil for unloading.
Step Procedure Points
High pressure switch (S1PH)
(R12978)
(R12979)
Solenoid valve coil for
hot gas bypass (Y2S)
Solenoid valve coil for unloading (Y3S)
(R12980)

Si181095 Outdoor Unit
Removal Procedure 17
Before working, make
sure that the refrigerant
gas is empty in the circuit.
Be sure to apply nitrogen
replacement when
heating up the brazed
part.
Warning
Be careful not to get yourself
burnt with the pipes and other
parts that are heated by the
gas brazing machine.
Warning
If the refrigerant gas leaks
during work, ventilate the
room. (If the refrigerant gas is
exposed to flames, toxic gas
may be generated.)
Caution
From the viewpoint of global
environment protection, do
not discharge the refrigerant
gas in the atmosphere. Make
sure to collect all the
refrigerant gas.
Cautions for restoration
1. Restore the piping by non-
oxidation brazing.
2. It is required to prevent the
carbonization of the oil inside
the four way valve and the
deterioration of the gaskets
affected by heat. (Keep
below 120°C.) For the sake
of this, wrap the four way
valve with wet cloth and
provide water so that the
cloth does not dry.
In case of difficulty with gas
brazing machine
1. Disconnect the brazed part
where is easy to disconnect
and restore.
2. Cut pipes on the main unit
with a tube cutter in order to
make it easy to disconnect.
6 Disconnect the brazed
part of the electronic
expansion valve.
7 Disconnect the brazed
part of the high
pressure switch.
Step Procedure Points
(R12981)
Electronic
expansion valve
(main)
Electronic
expansion valve
(subcooling)
Brazed part High pressure switch
(R13062)

Outdoor Unit Si181095
18 Removal Procedure
8 Disconnect the brazed
part of the solenoid
valve.
Note:
Do not use a metal saw for
cutting pipes by all means
because the sawdust comes
into the circuit.
When withdrawing the pipes,
be careful not to pinch them
firmly with pliers. The pipes
may get deformed.
Provide a protective sheet or
a steel plate so that the
brazing flame cannot
influence peripheries.
Step Procedure Points
(R12983)
Solenoid valve for
hot gas bypass
Solenoid valve for unloading
(R12984)