Daikin RZQ100KV4A User manual

REMOVAL
PROCEDURE
SERVICE MANUAL
Outdoor Unit
Inverter
Pair Type
4/5/6 HP Class
Si281316

Service Manual
Removal Procedure
Outdoor Unit
Applicable Models
zHeat Pump
RZQ100KV4A
RZQ125KV4A
RZQ150KV4A
RZQ160KV4A

Si281316
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 Sensor, Electronic Expansion Valve,
and Others ..............................................................................................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 Si281316
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
1For the suction grille,
pull the lower parts (in 7
places) frontward,
disengage the hooks at
the top of the grille with
a slotted screwdriver,
and then press the
overall grille downward
to disassemble it.
2For the front panel (1),
unscrew a single
mounting screw and
then press this panel
downward to remove it.
3For the top panel,
unscrew the 8 mounting
screws and then
remove this panel.
4For the front panel (1),
unscrews the 7
mounting screws and
the remove this panel.
5For the front piping
cover, unscrew a single
mounting screw and
then remove this panel.
6For the side piping
cover, unscrew the 4
mounting screws and
then remove this panel.
7For the side rear panel,
unscrew the 5 mounting
screws and then
remove this panel.
Top panel
Front panel (1)
Hooks
Suction grille
Side piping
cover
Side rear panel
Front panel (2)
Front piping
cover

Si281316 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) accordance with the
Procedure to remove
Outside Panels.
1. Remove the propeller fan
1Unscrew the 4 screws
that fix the air discharge
grille and disengage the
4 hooks at the top and
bottom of the grille, and
then remove this air
discharge grille.
2Unfasten the fan lock
nut that fixes the
propeller fan.
2. Remove the fan motor
Remove the front panel
(1) accordance with the
Procedure to remove
Outside Panels.
1Remove the connector
(X206A, X207A) for fan
motor from the PCB.
In order to disconnect the
connector, do not pull the
lead wire. Hold the
connector part and then
press the hooks.
Cautions in mounting the
motor
Be sure to fix the motor lead
wire with a clamp. Not
heeding this caution will
cause the entanglement of
the lead wire around the fan,
which will result in damage
to the fan.
2Cut the clamp 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
hooks.)
4Unfastening the 4 lock
from the fan motor,
enables the removal of
this motor.
Propeller fan
Hooks
Hooks
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 Si281316
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) accordance with the
Procedure to remove
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 sensor
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 clamp.
4Remove the clamp of
the pressure sensor
lead wire.
5Cut the clamp 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.
8Unscrew the 2 screws
that fix the terminal
block.
9Disengage the 3 hooks,
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
sensor
lead wire
Clamp
Terminal block for compressor
Terminal
cover
Upper fan
motor [X106A]
Lower fan
motor [X107A]
Electronic
expansion
valve [X21A]
Outdoor air
thermistor
[X11A]
Integrated
thermistor
[X12A]
Liquid pipe
thermistor
[X13A]
Pressure
sensor
[X17A]
Four way
valve [X25A]
Solenoid valve 1
[X26A]
Solenoid valve 2
[X27A]
Crankcase
heater [X28A]

Si281316 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)
accordance with the
Procedure to remove
Outside Panels.
1. Remove the PCB (A2P)
1Disconnect the
connector (X205A) from
the PCB.
2While pressing the 2
hooks, remove the PCB
(A2P).
2. Remove the PCB (A1P)
Remove the switch box
accordance with the
Procedure to remove the
Switch Box.
1Remove the clamp from
the compressor
harness.
2Press the hooks to
remove the terminal
block.
3Cut the 2 clamps (A).
4Extend the hooks, and
then remove the
support leg of the cover
of electrical
components.
5Disengage the 3 hooks
on the left side, and
then while pushing
down the 2 hooks on
the right side, remove
the whole cover of the
electric components.
6Cut the clamps (B). Connectors used on the
PCB
·Compressor (X102A)
·Earth wire (E1)
·Reactors (P1 and P2)
·Power supply cable (X1A)
·Indoor-Outdoor connection
cable (X803A)
7Disconnect the
connector listed in point
column.
8Remove the PCB (A1P)
together with the
radiation fin.
Connector
PCB
(A2P)
Tab of cover
of electric
components
Terminal block Tab of terminal
block mounting
section
Clamp (A) Support leg of
cover of electric
components
Compressor
harness
Tab of cover
of electric
components
Hooks
Hooks
Radiation fin thermistor
(X111A)
Clamp (B) Compressor
(X102A)
Hooks
Reactor
(P1)
Reactor
(P2)
Earth wire
(E1)
Power supply
cable (X1A)
Indoor-Outdoor
connection cable
(X803A)

Procedure to Remove Pressure Sensor, Electronic Expansion Valve, and Others Si281316
6Removal Procedure
5. Procedure to Remove Pressure Sensor,
Electronic Expansion Valve, and Others
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)
accordance with the
Procedure to remove
Outside Panels.
Before removing the
solenoid valve or the
electronic expansion valve,
be sure to recover the
refrigerant.
Precaution for mounting the
coil for the electronic
expansion valve
Align the dimple of the
electronic expansion valve and
the stopper of the electronic
expansion valve coil, and then
press them in until you hear
them click.
1. Remove the pressure
sensor
1Disconnect the
pressure sensor
connector (X17A).
2Use 2 spanners to
remove the pressure
sensor.
2. Remove the solenoid
valve
1Disconnect the solenoid
valve connector (X26A
or X27A).
2Unscrew the 1 screw
that fixes the solenoid
valve coil, and then
remove the coil.
3Remove brazing from
the 2 places, and then
remove the solenoid
valve.
3. Remove 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 sensor
Brazing
Electronic
expansion
valve coil
Electronic
expansion
valve
Stopper
Dimple

Si281316 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
accordance with the
Procedure to remove
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.
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
Mounting
spring

Procedure to Remove Four Way Valve Si281316
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 to remove
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 four way
valve coil, 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
Four way
valve coil
Brazing
Screw

Si281316 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
1 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
01/2013 Si281316 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 January 2013 but subject to change without notice.
Si281316
01/2013 AK