Daikin Ewaq016baw User manual

ESIE11-05

Service Manual

Small inverter chillers

EWAQ016BAW EWYQ016BAW

EWAQ021BAW EWYQ021BAW

EWAQ025BAW EWYQ025BAW

EWAQ032BAW EWYQ032BAW

EWAQ040BAW EWYQ040BAW

EWAQ050BAW EWYQ050BAW

EWAQ064BAW EWYQ064BAW

ESIE11-05

iTable of Contents

Table of Contents

1. Introduction .............................................................................................v

1.1 Safety Cautions ........................................................................................v

Part 1 - General Outline.................................................................. 1

1. Specifications ..........................................................................................2

1.1 Option Specifications................................................................................2

1.2 Technical Specifications...........................................................................2

1.3 Electrical Specifications............................................................................2

1.4 Nomenclature ...........................................................................................2

1.5 Operation Range ......................................................................................2

2. Refrigerant Circuit ...................................................................................3

2.1 Refrigerant Circuit ....................................................................................3

2.2 Functional Parts Layout Outdoor Unit ......................................................9

2.3 Refrigerant Flow for Each Operation Mode............................................12

3. Water Circuit .........................................................................................18

3.1 EWA/YQ016BA, 021BA, 025BA, 032BA................................................18

3.2 EWA/YQ040BA, 050BA, 064BA Module................................................20

3.3 Pressure Drop ........................................................................................22

4. Wiring Diagram .....................................................................................25

4.1 Hydrobox Wiring.....................................................................................25

4.2 Wiring Diagram - Three Phase (3N~).....................................................28

4.3 Wiring Outdoor .......................................................................................29

4.4 Field Wiring ............................................................................................38

Part 2 - Functional Description .................................................... 39

1. Function General...................................................................................40

1.1 Symbol ...................................................................................................40

1.2 Operation Mode......................................................................................41

2. Basic Control.........................................................................................42

2.1 Normal Operation ...................................................................................42

2.2 Compressor PI Control...........................................................................43

2.3 Electronic Expansion Valve PI Control...................................................44

2.4 Step Control of Outdoor Unit Fans .........................................................45

2.5 Outdoor Unit Fan Control in Cooling Operation .....................................46

3. Special Control......................................................................................47

3.1 Startup Control .......................................................................................47

3.2 Defrosting Operation ..............................................................................49

3.3 Pump-down Residual Operation ............................................................50

3.4 Standby ..................................................................................................51

3.5 Stopping Operation ................................................................................52

4. Protection Control .................................................................................53

4.1 High Pressure Protection Control...........................................................53

4.2 Low Pressure Protection Control............................................................54

4.3 Discharge Pipe Protection Control .........................................................55

4.4 Inverter Protection Control .....................................................................56

4.5 STD Compressor Overload Protection...................................................57

ESIE11-05

Table of Contents ii

5. Other Control.........................................................................................58

5.1 Emergency Operation ............................................................................58

5.2 Demand Operation .................................................................................61

6. Outline of Control (Hydrobox) ...............................................................62

6.1 Freeze Prevention ..................................................................................62

6.2 Thermostat Control.................................................................................63

6.3 Flow Control ...........................................................................................64

7. Field Setting from Outdoor Unit.............................................................65

7.1 Field Setting from Outdoor Unit..............................................................65

7.2 “Setting Mode 1”.....................................................................................70

7.3 “Setting Mode 2”.....................................................................................71

7.4 Monitor Mode .........................................................................................75

7.5 Setting of Low Noise Operation and Demand Operation .......................76

7.6 Setting of Refrigerant Recovery Mode ...................................................81

7.7 Setting of Vacuuming Mode ...................................................................82

8. Remote Controller .................................................................................83

8.1 Temperature Read Out for Remote Control ...........................................83

8.2 Field Setting ...........................................................................................84

8.3 Weekly Schedual....................................................................................97

Part 3 - Troubleshooting............................................................... 99

1. Symptom-based Troubleshooting .......................................................101

2. Malfunction Codes and Description ....................................................104

3. Malfunction Code Indication by Outdoor Unit PCB .............................106

4. Error Codes.........................................................................................110

4.1 “A1”........................................................................................................110

4.2 “A6”........................................................................................................111

4.3 “A9”........................................................................................................112

4.4 “AE”........................................................................................................114

4.5 “AJ”........................................................................................................115

4.6 “C1”........................................................................................................116

4.7 “C4”........................................................................................................117

4.8 “C9”........................................................................................................118

4.9 “CA”........................................................................................................119

4.10 “CJ”........................................................................................................120

4.11 “E1”........................................................................................................121

4.12 “E3”........................................................................................................122

4.13 “E4”........................................................................................................124

4.14 “E5”........................................................................................................126

4.15 “E6”........................................................................................................128

4.16 “E7”........................................................................................................129

4.17 “E9”........................................................................................................132

4.18 “F3”........................................................................................................134

4.19 “F6”........................................................................................................135

4.20 “H7”........................................................................................................136

4.21 “H9”........................................................................................................137

4.22 “J2”........................................................................................................138

4.23 “J3”........................................................................................................139

4.24 “J5”........................................................................................................140

4.25 “J6”........................................................................................................141

4.26 “J7”........................................................................................................142

ESIE11-05

iii Table of Contents

4.27 “J9”........................................................................................................143

4.28 “JA”........................................................................................................144

4.29 “JC”........................................................................................................145

4.30 “L4”........................................................................................................146

4.31 “L5”........................................................................................................148

4.32 “L8”........................................................................................................150

4.33 “L9”........................................................................................................152

4.34 “LC”........................................................................................................154

4.35 “P1”........................................................................................................157

4.36 “P4”........................................................................................................158

4.37 “PJ”........................................................................................................160

4.38 “U0”........................................................................................................161

4.39 “U1”........................................................................................................162

4.40 “U2”........................................................................................................163

4.41 “U3”........................................................................................................166

4.42 “U4”........................................................................................................167

4.43 “U5”........................................................................................................168

4.44 “U8”........................................................................................................169

4.45 “UA”........................................................................................................170

4.46 “UF”........................................................................................................171

4.47 “UH”........................................................................................................172

4.48 [CHECK 1]............................................................................................173

4.49 [CHECK 2]............................................................................................174

4.50 [CHECK 3]............................................................................................175

4.51 [CHECK 4]............................................................................................176

4.52 [CHECK 5]............................................................................................177

4.53 [CHECK 6]............................................................................................178

4.54 [CHECK 14]..........................................................................................179

4.55 [CHECK 15]..........................................................................................180

Part 4 - Service Procedure ......................................................... 181

1. List of Electrical and Functional Parts .................................................182

1.1 EW*Q016BA.........................................................................................182

1.2 EW*Q021BA, 025BA, 040BA Module, 050BA Module.........................183

1.3 EW*Q032BA, 064BA Module ...............................................................184

2. Thermistor Resistance / Temperature Characteristics........................185

3. Pressure Sensor .................................................................................187

4. Method of Checking the Inverter’s Power Transistors and Diode

Modules...............................................................................................188

5. Options................................................................................................190

5.1 EKRP1AHT ..........................................................................................190

5.2 DTA104A62..........................................................................................193

6. Procedure for Software Upload Hydrobox ..........................................198

6.1 What Do You Need? ............................................................................198

6.2 Software Upload Procedure .................................................................199

Part 5 - Commissioning and Test Run........................................ 207

1. Test Run..............................................................................................208

1.1 Installation Process ..............................................................................208

1.2 Procedure and Outline .........................................................................209

ESIE11-05

Table of Contents iv

1.3 Operation when Power is Turned On ...................................................212

Part 6 - Maintenance .................................................................. 213

1. Maintenance of the Main Parts ...........................................................215

Index ............................................................................................. i

Introduction ESIE11-05

1. Introduction

1.1 Safety Cautions

Cautions and

warnings

Be sure to read the following safety cautions before conducting repair work.

The caution items are classified into “ Warning” and “ Caution”. The “ Warning”

items are especially important since they can lead to death or serious injury if they are not

followed closely. The “ Caution” items can also lead to serious accidents under some

conditions if they are not followed. Therefore, be sure to observe all the safety caution items

described below.

About the pictograms

This symbol indicates an item for which caution must be exercised.

The pictogram shows the item to which attention must be paid.

This symbol indicates a prohibited action.

The prohibited item or action is shown inside or near the symbol.

This symbol indicates an action that must be taken, or an instruction.

The instruction is shown inside or near the symbol.

After the repair work is complete, be sure to conduct a test operation to ensure that the

equipment operates normally, and explain the cautions for operating the product to the

customer.

1.1.1 Caution in Repair

Warning

Be sure to disconnect the power cable plug from the plug socket before

disassembling the equipment for a repair.

Working on the equipment that is connected to a power supply can cause an

electrical shock.

If it is necessary to supply power to the equipment to conduct the repair or

inspecting the circuits, do not touch any electrically charged sections of the

equipment.

If the refrigerant gas discharges during the repair work, do not touch the

discharging refrigerant gas.

The refrigerant gas can cause frostbite.

All actions with refrigerant has to be following F-gas regulation.

If the refrigerant gas leaks during the repair work, ventilate the area. The

refrigerant gas can generate toxic gases when it contacts flames.

The step-up capacitor supplies high-voltage electricity to the electrical

components of the outdoor unit.

Be sure to discharge the capacitor completely before conducting repair work.

A charged capacitor can cause an electrical shock.

ESIE11-05 Introduction

Do not start or stop the air conditioner operation by plugging or unplugging the

power cable plug.

Plugging or unplugging the power cable plug to operate the equipment can

cause an electrical shock or fire.

Warning

Caution

Do not repair the electrical components with wet hands.

Working on the equipment with wet hands can cause an electrical shock.

Do not clean the air conditioner by splashing water.

Washing the unit with water can cause an electrical shock.

Be sure to provide the grounding when repairing the equipment in a humid or

wet place, to avoid electrical shocks.

Be sure to turn off the power switch and unplug the power cable when cleaning

the equipment.

The internal fan rotates at a high speed, and cause injury.

Do not tilt the unit when removing it.

The water inside the unit can spill and wet the furniture and floor.

Be sure to check that the refrigerating cycle section has cooled down

sufficiently before conducting repair work.

Working on the unit when the refrigerating cycle section is hot can cause burns.

Use the welder in a well-ventilated place.

Using the welder in an enclosed room can cause oxygen deficiency.

Introduction ESIE11-05

vii

1.1.2 Cautions Regarding Products after Repair

Warning

Be sure to use parts listed in the service parts list of the applicable model and

appropriate tools to conduct repair work. Never attempt to modify the

equipment.

The use of inappropriate parts or tools can cause an electrical shock,

excessive heat generation or fire.

When relocating the equipment, make sure that the new installation site has

sufficient strength to withstand the weight of the equipment. (See Installation

Operation Manual)

If the installation site does not have sufficient strength and if the installation

work is not conducted securely, the equipment can fall and cause injury.

Be sure to use an exclusive power circuit for the equipment, and follow the

technical standards related to the electrical equipment, the internal wiring

regulations and the instruction manual for installation when conducting

electrical work.

Insufficient power circuit capacity and improper electrical work can cause an

electrical shock or fire.

Do not damage or modify the power cable.

Damaged or modified power cable can cause an electrical shock or fire.

Placing heavy items on the power cable, and heating or pulling the power cable

can damage the cable.

Do not mix air or gas other than the specified refrigerant (R-410A) in the

refrigerant system.

If air enters the refrigerating system, an excessively high pressure results,

causing equipment damage and injury.

If the refrigerant gas leaks, be sure to locate the leak and repair it before

charging the refrigerant. After charging refrigerant, make sure that there is no

refrigerant leak.

If the leak cannot be located and the repair work must be stopped, be sure to

perform pump-down and close the service valve, to prevent the refrigerant gas

from leaking into the room. The refrigerant gas itself is harmless, but it can

generate toxic gases when it contacts flames, such as fan and other heaters,

stoves and ranges.

Caution

Installation of a leakage breaker is necessary in some cases depending on the

conditions of the installation site, to prevent electrical shocks.

Do not install the equipment in a place where there is a possibility of

combustible gas leaks.

If a combustible gas leaks and remains around the unit, it can cause a fire.

ESIE11-05 Introduction

viii

1.1.3 Inspection after Repair

1.1.4 Using Icons

Icons are used to attract the attention of the reader to specific information. The meaning of each

icon is described in the table below.

Warning

Check to make sure that the power cable plug is not dirty or loose, then insert

the plug into a power outlet all the way.

If the plug has dust or loose connection, it can cause an electrical shock or fire.

If the power cable and lead wires have scratches or deteriorated, be sure to

replace them.

Damaged cable and wires can cause an electrical shock, excessive heat

generation or fire.

Do not use a joined power cable or extension cable, or share the same power

outlet with other electrical appliances, since it can cause an electrical shock,

excessive heat generation or fire.

Caution

Check to see if the parts and wires are mounted and connected properly, and

if the connections at the soldered or crimped terminals are secure.

Improper installation and connections can cause excessive heat generation,

fire or an electrical shock.

If the installation platform or frame has corroded, replace it.

Corroded installation platform or frame can cause the unit to fall, resulting in

injury.

Check the grounding, and repair it if the equipment is not properly grounded.

Improper grounding can cause an electrical shock.

Be sure to measure the insulation resistance after the repair, and make sure

that the resistance is 1 Mohm or higher.

Faulty insulation can cause an electrical shock.

Introduction ESIE11-05

1.1.5 Using Icons List

Icon Type of

Information

Description

Note:

Note A “note” provides information that is not indispensable, but may

nevertheless be valuable to the reader, such as tips and tricks.

Caution

Caution A “caution” is used when there is danger that the reader, through

incorrect manipulation, may damage equipment, loose data, get

an unexpected result or has to restart (part of) a procedure.

Warning

Warning A “warning” is used when there is danger of personal injury.

Reference A “reference” guides the reader to other places in this binder or

in this manual, where he/she will find additional information on a

specific topic.

ESIE11-05

General Outline 1

Part 1

General Outline