Daikin CTX Series User manual

Service
Manual
DAMA-SM-21-003
Service Manual / Inverter Multi Split Wall Mounted Type CTX(X) Series DAMA-SM-21-003
Inverter Multi Split
Wall Mounted Type CTX(X) Series
[Applied Models]
zInverter Split : Heat Pump Unit

DAMA-SM-21-003
iTable of Contents
Introduction .................................................................................... 1
1. Safety Cautions.......................................................................................2
1.1 Warnings and Cautions Regarding Safety of Workers.............................2
1.2 Warnings and Cautions Regarding Safety of Users.................................8
2. Icons Used............................................................................................10
3. Revision History....................................................................................11
Part 1 General Information .......................................................... 12
1. Applicable Models.................................................................................13
Part 2 Specifications.................................................................... 15
1. Specification Data.................................................................................16
2. Functions...............................................................................................20
Part 3 Functions and Control ....................................................... 21
1. Main Functions......................................................................................22
1.1 Temperature Control..............................................................................22
1.2 Frequency Control..................................................................................22
1.3 Airflow Direction Control.........................................................................24
1.4 Fan Speed Control for Indoor Unit .........................................................24
1.5 Dry Mode................................................................................................25
1.6 Automatic Operation...............................................................................26
1.7 Thermostat Control.................................................................................27
1.8 ECO+ Operation ....................................................................................28
1.9 Sleep Mode............................................................................................29
1.10 POWERFUL Operation..........................................................................29
1.11 Other Functions......................................................................................30
2. Thermistor Functions ............................................................................31
3. Control Specification.............................................................................32
3.1 Mode Hierarchy......................................................................................32
3.2 Frequency Control..................................................................................33
3.3 Controls at Mode Changing/Start-up......................................................35
3.4 Discharge Pipe Temperature Control.....................................................36
3.5 Input Current Control..............................................................................37
3.6 Freeze-up Protection Control.................................................................38
3.7 Heating Peak-cut Control.......................................................................39
3.8 Outdoor Fan Control...............................................................................40
3.9 Liquid Compression Protection Function................................................41
3.10 Defrost Control.......................................................................................41
3.11 Electronic Expansion Valve Control.......................................................42
3.12 Malfunctions...........................................................................................46
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DAMA-SM-21-003
Table of Contents ii
Part 4 Remote Controller ............................................................. 47
1. Applicable Remote Controller ...............................................................48
2. BRC52B63/64.......................................................................................49
Part 5 Service Diagnosis .............................................................. 50
1. General Problem Symptoms and Check Items.....................................51
2. Troubleshooting with LED.....................................................................52
2.1 Indoor Unit..............................................................................................52
2.2 Outdoor Unit...........................................................................................52
3. Error Diagnosis .....................................................................................53
3.1 To enter error diagnosis.........................................................................53
4. Troubleshooting ....................................................................................54
4.1 Error Codes and Description..................................................................54
4.2 Indoor Unit PCB Abnormality .................................................................56
4.3 Freeze-up Protection Control.................................................................57
4.4 Indoor Fan Motor (DC Motor) or Related Abnormality ...........................58
4.5 Thermistor or Related Abnormality (Indoor Unit)....................................59
4.6 Thermistor or Related Abnormality (Indoor Unit)....................................60
4.7 Low-voltage Detection or Over-voltage Detection..................................61
4.8 Signal Transmission Error (Between Indoor Unit and Outdoor Unit)......62
4.9 Installation error......................................................................................64
4.10 Outdoor Unit PCB Abnormality...............................................................65
4.11 OL Activation (Compressor Overload) ...................................................66
4.12 Compressor Lock...................................................................................68
4.13 DC Fan Lock ..........................................................................................69
4.14 Input Overcurrent Detection...................................................................70
4.15 Discharge Pipe Temperature Control.....................................................71
4.16 High Pressure Control in Cooling...........................................................72
4.17 Compressor System Sensor Abnormality ..............................................74
4.18 Position Sensor Abnormality..................................................................75
4.19 Thermistor or Related Abnormality (Outdoor Unit).................................76
4.20 Electrical Box Temperature Rise............................................................78
4.21 Radiation Fin Temperature Rise ............................................................79
4.22 Output Overcurrent Detection ................................................................80
4.23 Four Way Valve Abnormality..................................................................82
5. Actuator Check......................................................................................85
5.1 Thermistor Resistance Check................................................................85
5.2 Power Supply Waveform Check.............................................................86
5.3 Electronic Expansion Valve Check.........................................................86
5.4 Four Way Valve Performance Check.....................................................87
5.5 Inverter Unit Refrigerant System Check.................................................88
5.6 Rotation Pulse Check on the Outdoor Unit PCB....................................88
5.7 Installation Condition Check...................................................................89
5.8 Discharge Pressure Check.....................................................................89
5.9 Outdoor Fan System Check...................................................................90
5.10 Main Circuit Short Check........................................................................90
5.11 Power Module Check.............................................................................91
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DAMA-SM-21-003
iii Table of Contents
Part 6 Trial Operation and Field Settings .................................... 92
1. Pump Down Operation..........................................................................93
2. Forced Cooling Operation.....................................................................94
3. Silicone Grease on Power Transistor/Diode Bridge..............................95
Part 7 Appendix ............................................................................ 96
1. Piping Diagrams....................................................................................97
1.1 Indoor Unit..............................................................................................97
1.2 Outdoor Unit...........................................................................................97
2. Wiring Diagrams....................................................................................98
2.1 Indoor Unit..............................................................................................98
2.2 Outdoor Unit...........................................................................................98
2.3 Printed Circuit Board Connector Wiring Diagram...................................99
2.4 Printed Circuit Board Connector Wiring Diagram.................................100
3. Operation Limit....................................................................................102
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DAMA-SM-21-003
Introduction 1
1. Safety Cautions.......................................................................................2
1.1 Warnings and Cautions Regarding Safety of Workers.............................2
1.2 Warnings and Cautions Regarding Safety of Users.................................8
2. Icons Used............................................................................................10
3. Revision History....................................................................................11
Introduction
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Safety Cautions DAMA-SM-21-003
2Introduction
1. Safety Cautions
Be sure to read the following safety cautions before conducting repair work.
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.
Caution Items The caution items are classified into Warning and Caution. The Warning items are
especially important since death or serious injury can result 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.
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 in the illustration or near the symbol.
This symbol indicates an action that must be taken, or an instruction.
The instruction is shown in the illustration or near the symbol.
1.1 Warnings and Cautions Regarding Safety of Workers
This manual is for the
person in charge of
maintenance and
inspection.
This appliance is
filled with R410A.
Warning
Do not store equipment in a room with fire sources (e.g., naked
flames, gas appliances, electric heaters).
Be sure to disconnect the power cable from the socket before
disassembling equipment for repair.
Working on equipment that is connected to the power supply may cause
an electrical shock.
If it is necessary to supply power to the equipment to conduct the repair or
inspect the circuits, do not touch any electrically charged sections of the
equipment.
If refrigerant gas is discharged during repair work, do not touch the
discharged refrigerant gas.
Refrigerant gas may cause frostbite.
When disconnecting the suction or discharge pipe of the
compressor at the welded section, evacuate the refrigerant gas
completely at a well-ventilated place first.
If there is gas remaining inside the compressor, the refrigerant gas or
refrigerating machine oil discharges when the pipe is disconnected, and it
may cause injury.
If refrigerant gas leaks during repair work, ventilate the area.
Refrigerant gas may generate toxic gases when it contacts flames.
Be sure to discharge the capacitor completely before conducting
repair work.
The step-up capacitor supplies high-voltage electricity to the electrical
components of the outdoor unit.
A charged capacitor may cause an electrical shock.
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DAMA-SM-21-003 Safety Cautions
Introduction 3
Do not turn the air conditioner on or off by plugging in or
unplugging the power cable.
Plugging in or unplugging the power cable to operate the equipment may
cause an electrical shock or fire.
Be sure to wear a safety helmet, gloves, and a safety belt when
working in a high place (more than 2 m).
Insufficient safety measures may cause a fall.
In case of R410A refrigerant models, be sure to use pipes, flare nuts
and tools intended for the exclusive use with the R410A refrigerant.
The use of materials for R-22 refrigerant models may cause a serious
accident, such as a damage of refrigerant cycle or equipment failure.
Do not mix air or gas other than the specified refrigerant (R410A /
R-22) in the refrigerant system.
If air enters the refrigerant system, an excessively high pressure results,
causing equipment damage and injury.
Caution
Do not repair electrical components with wet hands.
Working on the equipment with wet hands may cause an electrical shock.
Do not clean the air conditioner with water.
Washing the unit with water may cause an electrical shock.
Be sure to provide an earth / 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 may cause injury.
Be sure to conduct repair work with appropriate tools.
The use of inappropriate tools may cause injury.
Be sure to check that the refrigerating cycle section has cooled
down enough before conducting repair work.
Working on the unit when the refrigerating cycle section is hot may cause
burns.
Conduct welding work in a well-ventilated place.
Using the welder in an enclosed room may cause oxygen deficiency.
Warning
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Safety Cautions DAMA-SM-21-003
4Introduction
Safety Checklist
Checking the area
Before beginning work, conduct safety checks to minimise the risk of ignition. When
repairing the refrigerating system, take the following precautions before work.
Work procedure
Work shall be conducted under a controlled procedure so as to minimise the risk of working
in the presence of R410A or vapour.
General working area
All maintenance staff and others working in the local area shall be instructed on the nature of
work being carried out.
Work in confined spaces shall be avoided.
The area around the workspace shall be sectioned off. Ensure that the conditions within the
area have been made safe by control of flammable materials.
Checking for presence of refrigerant
The working area shall be checked with an appropriate refrigerant detector before and
during work, to ensure the technician is aware of potentially flammable atmospheres.
Ensure that the leak detection equipment being used is suitable for use with R410A, i.e.
non-sparking, adequately sealed or intrinsically safe.
Fire extinguishing equipment
If any hot work is to be conducted on the refrigeration equipment or any associated parts,
appropriate fire extinguishing equipment shall be made available at hand. Prepare a dry
powder or CO2fire extinguisher adjacent to the working area.
No ignition sources
During work on a refrigeration system which involves exposing any piping work that contains
or has contained R410A, any sources of ignition shall not be used in a manner that may lead
to the risk of fire or explosion. All possible ignition sources, including cigarette smoking,
should be kept at a safe distance from the site of installation, repairing, or removing space.
Before starting work, the area around the equipment shall be examined to make sure that
there are no flammable hazard or ignition risks. No Smoking signs shall be displayed.
Ventilated area
Ensure that the working area is open or that it is adequately ventilated before work.
Adequate ventilation shall be maintained during the entire period of work.
The ventilation should disperse any released refrigerant and preferably discharge it into the
external atmosphere.
Checking the refrigeration equipment
Where electrical components are to be changed, the new components shall be fit for the
purpose and have the correct specifications.
The manufacturer's maintenance and service guidelines shall be followed at all times.
If there are any unclear points, consult the manufacturer's technical department for
assistance.
The following checks shall be applied to any installation work involving R410A:
The amount of charge is in accordance with the size of the room where the refrigerant
containing parts are installed;
The ventilation machinery and outlets are operating adequately and are not obstructed;
If an indirect refrigerating circuit is being used, the secondary circuit shall be checked for
the presence of refrigerant;
Marking on the equipment is visible and legible. Markings and signs that are illegible
shall be corrected;
Refrigeration pipes or components are installed in a position where they are unlikely to
be exposed to any substance which may corrode refrigerant containing components, or
the refrigerant containing components are constructed of materials which are inherently
resistant to corrosion or are suitably protected against corrosion.
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DAMA-SM-21-003 Safety Cautions
Introduction 5
Safety Checklist (con't)
Checking electrical devices
Repair and maintenance to electrical components shall include initial safety checks and
component inspection procedures. In case there is any fault that could endanger safety, no
electrical supply shall be connected to the circuit until the fault is satisfactorily dealt with.
Initial safety checks shall include:
that capacitors are discharged: this shall be done in a safe manner to avoid possibility of
sparking;
that no live electrical components and wiring are exposed while charging, recovering or
purging the system;
that the equipment is earthed at all times.
Repairs to sealed components
During repairs to sealed components, all electrical supplies shall be disconnected from the
equipment being worked upon before the removal of any sealed covers, etc. If it is absolutely
necessary to have power supplied to equipment during servicing, continuously operating
leak detection shall be installed at the most dangerous point of thesystem in order to warn of
a potentially hazardous situation.
Particular attention shall be paid to the following: ensure that working on electrical
components does not alter the casing in such a way that affects the level of protection
including damage to cables, excessive number of connections, terminals different from the
original specification, damage to seals, incorrect fitting of glands, etc.
Ensure that the equipment is mounted securely.
Ensure that seals or sealing materials have not degraded such that they no longer serve the
purpose of preventing the ingression of flammable atmospheres. Replacement parts shall be
in accordance with the manufacturer's specifications.
The use of silicon sealant may inhibit the effectiveness of some types of leak detection
equipment. Intrinsically safe components do not have to be isolated before working on them.
Repair to intrinsically safe components
Do not apply any permanent inductive or capacitance load to the circuit without ensuring that
this will not exceed the permissible voltage and current for the equipment in use.
Only intrinsically safe components can be worked on in the presence of a flammable
atmosphere.
The test apparatus shall be of correct rating.
Replace components only with parts specified by the manufacturer. Using other parts may
result in ignition of the refrigerant leaked into the atmosphere.
Wiring
Check that wiring is not subject to wear, corrosion, excessive pressure, vibration, sharp
edges or any other adverse environmental effects. The check shall also take into account
the effects of ageing or continuous vibration from sources such as compressors or fans.
Detecting of R410A
Under no circumstances shall potential sources of ignition be used in the search for or
detection of refrigerant leaks. A halide torch (or any other detector using a naked flame) shall
not be used.
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