Daikin RZQ100KAVLT User manual

REMOVAL
PROCEDURE
SERVICE MANUAL
Outdoor Unit
Inverter
Pair Type
4/5/6 HP Class
Si281315E

Service Manual
Removal Procedure
Outdoor Unit
Applicable Models
zHeat Pump
RZQ100KAVLT
RZQ125KATLT
RZQ140KATLT

Si281315E
Removal Procedure 1
Table of Contents
1. Procedure to Remove Outside Panels....................................................2
2. Procedure to Remove Propeller Fan and Fan Motor ..............................3
3. Procedure to Remove Switch Box ..........................................................4
4. Procedure to Remove PCB.....................................................................5
5. Procedure to Remove Pressure Thermistor,
Solenoid Valve and Electronic Expansion Valve.....................................6
6. Procedure to Remove Thermistor ...........................................................7
7. Procedure to Remove Four Way Valve...................................................8
8. Procedure to Remove Compressor.........................................................9

Procedure to Remove Outside Panels Si281315E
2Removal Procedure
1. Procedure to Remove Outside Panels
Procedure Warning Be sure to wait for 10 minutes or more after turning off all power
supplies before disassembling work.
Step Procedure Points
1Pull the 7 tabs at the
bottom of the suction
grille to the front, and
then disengage the tabs
at the top with a
screwdriver or else.
After that, hold down
the whole suction grille
to remove it.
2Unscrew the 1 screw
that fixes the front panel
(2) (i.e., the front panel
on the side), and then
remove this front panel.
3Unscrew the 8 screws
that fix the top panel,
and then remove the
top panel.
4Unscrew the 7 screws
that fix the front panel
(1), and then remove
this front panel.
5Unscrew the 1 screw
that fix the front piping
cover bracket, and then
remove this bracket.
6Unscrew the 4 screws
that fix the side piping
cover bracket, and then
remove this bracket.
7Unscrew the 5 screws
that fix the side rear-
panel, and then remove
this panel.
Top panel
Front panel (1)
Tabs
Suction grille
Side piping cover
bracket
Side rear-panel
Front panel (2)
Front piping cover
bracket

Si281315E Procedure to Remove Propeller Fan and Fan Motor
Removal Procedure 3
2. Procedure to Remove Propeller Fan and Fan
Motor
Procedure Warning Be sure to wait for 10 minutes or more after turning off all power
supplies before disassembling work.
Step Procedure Points
Remove the front panel
(2) according to the
procedure for removing
outside panels.
1. Removing the propeller
fan
1Disengage the 4 tabs at
the top and bottom of
the discharge grille to
remove the 4 mounting
screws, and dismount
the discharge grille.
2Remove the fan setting
nut on the propeller fan.
2. Removing the fan motor
Remove the front panel
(1) according to the
procedure for removing
outside panels.
1Disconnect the
connector for fan motor
from the PCB provided
in the switch box.
To disconnect the connector,
do not pull the lead wire.
Hold the connector section
and press the tabs.
Precaution for mounting the
motor
Be sure to fix the motor lead
wires with clamps. Not doing
so may cause the lead wires
to get entangled with the fan,
thus resulting in damage to
the fan.
2Cut the cable tie of lead
wires (located on the
reverse side of the stop
valve mounting plate).
3Pull out the lead wires
through the opening of
the partition panel, and
then unclamp the 3
clamps. (Note that the
partition plate has 3
tabs.)
4Unfasten to remove the
4 bolts that fix the fan
motor, and then take
out this motor.
Propeller fan
Tabs
Tabs
Fan lock nut
Discharge grille
Front panel (1)
Stop valve
mounting plate
Opening of
partition panel
Fan
motor
Upper motor
connector (red)
Lower motor
connector (white)
Clamps (3 pcs.)
Lead wire Propeller fan

Procedure to Remove Switch Box Si281315E
4Removal Procedure
3. Procedure to Remove Switch Box
Procedure Warning Be sure to wait for 10 minutes or more after turning off all power
supplies before disassembling work.
Step Procedure Points
Remove the front panel
(2) according to the
procedure for removing
outside panels.
If the top panel cannot be
removed
Even though workability is
degraded, it is possible to pull
the switch box to the front
without removing the top panel.
The figure below shows
connectors to be
disconnected.
Precaution for mounting the
pressure thermistor
To prevent the lead wire from
hanging over the PCB, hook the
lead wire of 160 to 170 mm in
length from the front end of the
connector on the clamp.
1Disconnect each
connector on the PCB.
(Refer to the Points
column.)
2Remove the 2 faston
terminals. After that,
unscrew the 3 screws
that fix the reactor, and
then remove the
reactor.
3Cut the cable tie.
4Remove the clamp of
the pressure thermistor
lead wire.
5Cut the cable tie of the
outdoor air thermistor.
6Disconnect a set of lead
wires together from the
clamp.
7Remove the terminal
cover, and then
disconnect the 3 lead
wires from the terminal
block for the
compressor.
8
9
Unscrew the 2 screws
that fix the terminal
block.
Disengage the 3 tabs,
and then pull out the
switch box upward.
A set of
lead wires
Screws fixing
the terminal
block
Screws fixing
the reactor
Cable tie
(outdoor air
thermistor)
Pressure
thermistor
lead wire
Cable tie
Terminal block for compressor
Upper fan
motor [X106A]
Lower fan
motor [X107A]
Electronic expansion
valve [X21A]
Outdoor air
thermistor [X11A]
Integrated thermistor
[X12A]
Liquid pipe
thermistor [X13A]
Pressure
thermistor [X17A]
Four way
valve [X25A]
Solenoid valve 1
[X26A]
Solenoid valve 2
[X27A]
Crankcase
heater [X28A]

Si281315E Procedure to Remove PCB
Removal Procedure 5
4. Procedure to Remove PCB
Procedure Warning Be sure to wait for 10 minutes or more after turning off all power
supplies before disassembling work.
Step Procedure Points
Remove the top panel
and the front panel (2)
according to the
procedure for removing
outside panels.
1. Removing the PCB (A2P)
1Disconnect the
connector (X205A) from
the PCB.
2While pressing the 2
tabs, remove the PCB
(A2P).
2. Removing the PCB (A1P)
Remove the switch box
according to the
procedure for removing
the switch box.
1Remove the clamp from
the compressor
harness.
2Press the tabs to
remove the terminal
block.
3Cut the 2 cable ties (A).
4Extend the tabs, and
then remove the
support leg of the cover
of electrical
components.
5Disengage the 3 tabs on
the left side, and then
while pushing down the
2 tabs on the right side,
remove the whole cover
of the electric
components.
6Cut the cable tie (B).
7Disconnect the
connector listed in point
column.
Connectors used on the
PCB
·Compressor (X102A)
·Ground cable (E1)
·Reactors (P1 and P2)
·Power supply cable (X1A)
·Indoor-Outdoor connection
cable (X803A)
8Remove the PCB (A1P)
together with the
radiating fin.
Connector
PCB
(A2P)
Tab of cover
of electric
components
Terminal block Tab of terminal
block mounting
section
Cable tie (A) Support leg of
cover of electric
components
Compressor
harness
Tab of cover
of electric
components
Tabs
T
abs
Radiation fin thermistor
(X111A)
Cable tie (B) Compressor
(X102A)
Tabs
Reactor (P1)
Reactor (P2)
Ground cable (E1)
Power supply
cable (X1A)
Indoor-Outdoor
connection cable
(X803A)

Procedure to Remove Pressure Thermistor, Solenoid Valve and Electronic Expansion Valve Si281315E
6Removal Procedure
5. Procedure to Remove Pressure Thermistor,
Solenoid Valve and Electronic Expansion Valve
Procedure Warning Be sure to wait for 10 minutes or more after turning off all power
supplies before disassembling work.
Step Procedure Points
Remove the top panel
and the front panel (2)
according to the
procedure for removing
outside panels.
Before removing the
solenoid valve or the
electronic expansion valve,
be sure to recover the
refrigerant.
1. Removing the pressure
thermistor
1Disconnect the
pressure thermistor
connector (X17A).
2Use 2 spanners to
remove the pressure
thermistor.
2. Removing the solenoid
valve
1Disconnect the solenoid
valve connector (X26A
or X27A).
2Unscrew the 1 screw
that fixes the coil for the
solenoid valve, and
then remove the coil.
Precaution for mounting the
coil for the electronic
expansion valve
Align the dimple of the electronic
expansion valve and the stopper
of the coil for the electronic
expansion valve, and then press
them in until you hear them click.
3Remove brazing from
the 2 places, and then
remove the solenoid
valve.
3. Removing the electronic
expansion valve
1Disconnect the
electronic expansion
valve connector
(X21A).
2Pull out the coil for the
electronic expansion
valve coil upward.
3Remove brazing from
the 2 places, and then
remove the electronic
expansion valve.
Pressure thermistor
Brazing Brazing
Brazing
Coil for
solenoid valve
Coil for
electronic
expansion
valve
Coil for
solenoid valve
Electronic
expansion valve
Stopper
Dimple

Si281315E Procedure to Remove Thermistor
Removal Procedure 7
6. Procedure to Remove Thermistor
Procedure Warning Be sure to wait for 10 minutes or more after turning off all power
supplies before disassembling work.
Step Procedure Points
Remove the top panel
and the front panel (2)
and side panel according
to the procedure for
removing outside panels.
1Pull out the outdoor air
thermistor to the front,
and then slide this
thermistor to the right to
remove it.
2Pinch the mounting
spring that fixes the
discharge pipe
thermistor to pull out
this thermistor.
3Press the fixing section
of the suction pipe
thermistor to pull out
this thermistor.
4Pull the fixing bracket of
the heat exchanger’s
distribution pipe
thermistor to the front,
and then remove this
thermistor.
5Press the fixing section
of the intermediate heat
exchanger thermistor to
pull out this thermistor.
∗1
The heat exchanger’s distribution pipe thermistor,
intermediate heat exchanger thermistor, and liquid pipe
thermistor are jointed together with a single connector.
Consequently, these 3 thermistors should be replaced at
the same time.
6Press the fixing section
of the liquid pipe
thermistor to pull out
this thermistor.
Mounting
spring
Thermistor
Thermistor
Discharge pipe thermistor
(R2T)
Outdoor air thermistor
(R1T)
Intermediate heat
exchanger thermistor (R5T)
Heat exchanger distribution
pipe thermistor (R4T)
Suction pipe thermistor
(R3T)
Liquid pipe thermistor
(R6T)
Mounting
spring
thermistor
Thermistor
Thermistor

Procedure to Remove Four Way Valve Si281315E
8Removal Procedure
7. Procedure to Remove Four Way Valve
Procedure Warning Be sure to wait for 10 minutes or more after turning off all power
supplies before disassembling work.
Step Procedure Points
Recover the refrigerant.
According to the
procedure for the removal
related to the outside
panel, remove the front
panel (2) and the side
panel.
According to the
procedure for the removal
of switch box, remove the
switch box.
Be sure to remove the four
way valve only after the
refrigerant is completely
recovered.
1Unscrew the 1 screw
that fixes the coil for the
four way valve, and
then remove this coil.
2Remove brazing from
the 4 places, and then
remove the four way
valve.
(Refer to point column.)
To prevent the four way
valve from exceeding a
temperature of 120°C,
conduct brazing work while
cooling the valve with wet
cloths or else.
Brazing
Four way valve
Coil for four
way valve
Brazing
Screw

Si281315E Procedure to Remove Compressor
Removal Procedure 9
8. Procedure to Remove Compressor
Procedure Warning Be sure to wait for 10 minutes or more after turning off all power
supplies before disassembling work.
Step Procedure Points
Recover the refrigerant.
(Refer to point column.)
Remove the front panel
(2) and the front piping
cover bracket.
Be sure to remove the
compressor only after the
refrigerant is completely
recovered.
Terminal block
One out of the nuts that fix
the compressor is located
outside of the partition panel.
Be sure to cut 3 pipes by
using a pipe cutter before
disconnecting the brazed
sections of pipes. A sudden
disconnection of the brazed
sections can cause oil to
catch fire.
1Unscrew the 5 screws
that fix the stop valve
mounting plate, and
then remove this
mounting plate.
2Remove the gas piping
and the liquid piping.
3Remove the
compressor terminal
cover.
4Disconnect the lead
wires from the terminal
block.
5Loosen the 2 strings,
and then pull out the
sound insulation of the
compressor.
6Unfasten to remove the
3 nuts that fix the
compressor. (Refer to
point column.)
7Cut the suction pipe
and the discharge pipe
using a pipe cutter.
(Refer to point column.)
8Remove brazing from
the 3 places.
9Lift to pull out the
compressor.
String
String
Terminal cover
Stop valve
mounting
plate
Gas piping
Liquid piping
Compressor
lead wires
Cutting point
(suction pipe)
Cutting point
(discharge pipe)
Insulation
Nuts fixing the compressor
Brazing
W (blue)
U (red)
V (white)

Revision History
Month / Year Version Revised contents
06 / 2013 Si281315E First edition

Head Office:
Umeda Center Bldg., 2-4-12, Nakazaki-Nishi,
Kita-ku, Osaka, 530-8323 Japan
Tokyo Office:
JR Shinagawa East Bldg., 2-18-1, Konan,
Minato-ku, Tokyo, 108-0075 Japan
http://www.daikin.com/global_ac/
All rights reserved
c
Warning
zDaikin products are manufactured for export to numerous countries throughout the world. Prior to
purchase, please confirm with your local authorised importer, distributor and/or retailer whether this
product conforms to the applicable standards, and is suitable for use, in the region where the product
will be used. This statement does not purport to exclude, restrict or modify the application of any local
legislation.
zAsk a qualified installer or contractor to install this product. Do not try to install the product yourself.
Improper installation can result in water or refrigerant leakage, electrical shock, fire or explosion.
zUse only those parts and accessories supplied or specified by Daikin. Ask a qualified installer or
contractor to install those parts and accessories. Use of unauthorised parts and accessories or
improper installation of parts and accessories can result in water or refrigerant leakage, electrical
shock, fire or explosion.
zRead the User's Manual carefully before using this product. The User's Manual provides important
safety instructions and warnings. Be sure to follow these instructions and warnings.
If you have any enquiries, please contact your local importer, distributor and/or retailer.
Cautions on product corrosion
1. Air conditioners should not be installed in areas where corrosive gases, such as acid gas or alkaline gas, are produced.
2. If the outdoor unit is to be installed close to the sea shore, direct exposure to the sea breeze should be avoided. If you need to install
the outdoor unit close to the sea shore, contact your local distributor.
Organization:
DAIKIN INDUSTRIES, LTD.
AIR CONDITIONING MANUFACTURING DIVISION
Scope of Registration:
THE DESIGN/DEVELOPMENT AND MANUFACTURE OF
COMMERCIAL AIR CONDITIONING, HEATING, COOLING,
REFRIGERATING EQUIPMENT, HEATING EQUIPMENT,
RESIDENTIAL AIR CONDITIONING EQUIPMENT, HEAT
RECLAIM VENTILATION, AIR CLEANING EQUIPMENT,
COMPRESSORS AND VALVES.
Organization:
DAIKIN INDUSTRIES
(THAILAND) LTD.
Scope of Registration:
THE DESIGN/DEVELOPMENT
AND MANUFACTURE OF AIR
CONDITIONERS AND THE
COMPONENTS INCLUDING
COMPRESSORS USED FOR THEM
All of the Daikin Group’s business
facilities and subsidiaries in Japan
are certified under the ISO 14001
international standard for
environment management.
JMI-0107 JQA-1452
Dealer
z
Specifications, designs and other content appearing in this brochure are current as of June 2013 but subject to change without notice.
Si281315E
06/2013 AK