Daikin VRV R-407C PLUS Series User manual

System
R-407C PLUS Series
Service
Manual
SiE 00-07

SiE 00-07
Table of Contents i
Inverter K Series
R-407C PLUS Series
1. Introduction .............................................................................................v
1.1 Safety Cautions....................................................................................... v
1.2 PREFACE................................................................................................ix
Part 1 General Information R-407C PLUS Series .........................1
1. Product Outline .......................................................................................2
1.1 Year 2000 Models Using New Refrigerant..............................................2
1.2 Outline of New Series Products............................................................... 3
1.3 Model Configuration and Combination....................................................5
Part 2 Specifications R-407C PLUS Series...................................7
1. Specifications..........................................................................................8
1.1 Outdoor Unit............................................................................................8
1.2 Indoor Unit.............................................................................................12
Part Function R-407C PLUS Series.......................................... 1
1. Outdoor Unit Refrigerant System Diagram ...........................................32
1.1 Outdoor Unit Refrigerant System Diagram............................................ 32
1.2 Flow of Refrigerant in Each Operating Mode ........................................ 35
2. List of Safty Device and Function Parts Setting Value..........................39
2.1 Outdoor Unit..........................................................................................39
2.2 Indoor Unit.............................................................................................40
3. Outline of Control (Outdoor Unit) ..........................................................43
3.1 Compressor PI Control.......................................................................... 43
3.2 Motorized Valve PI Control.................................................................... 44
3.3 Defrost Control ...................................................................................... 45
3.4 Low Outside Temperature Cooling Control...........................................47
3.5 Compressor Capacity Control ............................................................... 49
3.6 Demand Control .................................................................................... 51
3.7 Restart Standby..................................................................................... 52
3.8 Startup Control ...................................................................................... 53
3.9 Oil Equalization Operation..................................................................... 54
3.10 Oil Return Operation.............................................................................. 55
3.11 Low Pressure Protection Control........................................................... 58
3.12 High Pressure Protection Control..........................................................59
3.13 Discharge Pipe Temperature Control.................................................... 61
3.14 Inverter Protection Control..................................................................... 63
3.15 Crankcase Heater Control.....................................................................64
3.16 Gas Shortage Warning..........................................................................65
3.17 Heating Pump-Down Residual Operation.............................................. 66
3.18 Backup Operation.................................................................................. 67
3.19 Fan Location and Fan Tap .................................................................... 68

SiE 00-07
ii Table of Contents
4. Outline of Control (Indoor Unit).............................................................69
4.1 Drain Pump Control...............................................................................69
4.2 Louver Control for Preventing Ceiling Dirt............................................. 71
4.3 Thermostat Sensor in Remote Controller.............................................. 72
4.4 Freeze Prevention.................................................................................74
Part 4 Test Operation R-407C PLUS Series................................75
1. Test Operation................................................................................................ 76
1.1 Procedure and Outline...........................................................................76
1.2 Operation When Power is Turned On ................................................... 78
1.3 Outdoor Unit PC Board Ass’y................................................................79
1.4 Setting Modes........................................................................................81
1.5 Cool / Heat Mode Selection................................................................... 88
1.6 Low Noise Operation.............................................................................93
1.7 Demand Control .................................................................................... 94
1.8 Sequential Start.....................................................................................95
1.9 Wiring Check Operation ........................................................................ 96
1.10 Additional Refrigerant Charge Operation .............................................. 97
1.11 Refrigerant Recovery Mode................................................................... 98
1.12 Indoor Field Setting ............................................................................... 99
1.13 Centralized Control Group No. Setting................................................105
1.14 Contents of Control Modes.................................................................. 107
Part 5 Troubleshooting R-407C PLUS Series ...........................109
1. Operation Flowcharts....................................................................................111
1.1 Indoor Unit Operation Flowchart.......................................................... 111
2. Troubleshooting by Remote Controller ...............................................116
2.1 The INSPECTION / TEST Button........................................................ 116
2.2 Self-diagnosis by Wired Remote Controller......................................... 117
2.3 Self-diagnosis by Wireless Remote Controller....................................118
2.4 Operation of The Remote Controller’s Inspection /
Test Operation Button ......................................................................... 122
2.5 Remote Controller Service Mode ........................................................ 123
2.6 Remote Controller Self-Diagnosis Function ........................................ 125
3. Troubleshooting ..................................................................................128
3.1 Indoor Unit: Error of External Protection Device.................................. 128
3.2 Indoor Unit: PC Board Defect..............................................................128
3.3 Indoor Unit: Malfunction of Drain Level Control System (33H)............ 129
3.4 Indoor Unit: Fan Motor (M1F) Lock, Overload..................................... 130
3.5 Indoor Unit: Malfunction of Swing Flap Motor (M1S)........................... 131
3.6 Indoor Unit: Malfunction of Moving Part of Electronic Expansion Valve
(Y1E)132
3.7 Indoor Unit: Drain Level above Limit ................................................... 133
3.8 Indoor Unit: Malfunction of Capacity Determination Device................134
3.9 Indoor Unit: Malfunction of Thermistor (R2T) for Liquid Pipe..............134
3.10 Indoor Unit: Malfunction of Thermistor (R3T) for Gas Pipes ............... 135
3.11 Indoor Unit: Malfunction of Thermistor (R1T) for Air Inlet.................... 135
3.12 Indoor Unit: Malfunction of Thermostat Sensor
in Remote Controller............................................................................ 136
3.13 Outdoor Unit: Actuation of Safety Device............................................136
3.14 Outdoor Unit: PC Board Defect...........................................................137

SiE 00-07
Table of Contents iii
3.15 Outdoor Unit: Actuation of High Pressure Switch................................ 137
3.16 Outdoor Unit: Actuation of Low Pressure Sensor................................ 138
3.17 Outdoor Unit: Malfunction of
Moving Part of Electronic Expansion Valve (Y1E)............................... 139
3.18 Outdoor Unit: Abnormal Discharge Pipe Temperature........................ 140
3.19 Outdoor Unit: Malfunction of Thermistor for Outdoor Air (R1T)........... 141
3.20 Outdoor Unit: Malfunction of Discharge Pipe Thermistor (R3T).......... 142
3.21 Outdoor Unit: Malfunction of Thermistor (R4T) for Suction Pipe......... 143
3.22 Outdoor Unit: Malfunction of Thermistor (R2T) for Heat Exchanger ... 144
3.23 Outdoor Unit: Malfunction of Discharge Pipe Pressure Sensor........... 145
3.24 Outdoor Unit: Malfunction of Suction Pipe Pressure Sensor............... 146
3.25 Low Pressure Drop Due to Refrigerant Shortage
or Electronic Expansion Valve Failure................................................. 147
3.26 Reverse Phase, Open Phase..............................................................148
3.27 Malfunction of Transmission
Between Indoor Units..........................................................................149
3.28 Malfunction of Transmission
Between Remote Controller and Indoor Unit....................................... 150
3.29 Malfunction of Transmission
Between Outdoor Units ....................................................................... 151
3.30 Malfunction of Transmission
Between Master and Slave Remote Controllers.................................. 152
3.31 Malfunction of Transmission
Between Indoor and Outdoor Units in the Same System....................153
3.32 Excessive Number of Indoor Units......................................................154
3.33 Address Duplication of Central Remote Controller.............................. 155
3.34 Refrigerant System not Set, Incompatible Wiring/Piping..................... 155
3.35 Malfunction of System, Refrigerant System Address Undefined......... 156
4. Failure Diagnosis for Inverter System...........................................................157
4.1 Points of Diagnosis.............................................................................. 157
4.2 How to Use The Monitor Switch on The Inverter PC Board................158
5. Troubleshooting (Inverter)...................................................................159
5.1 Outdoor Unit: Malfunction of
Inverter Radiating Fin Temperature Rise ............................................ 159
5.2 Outdoor Unit: Inverter Instantaneous Over-Current ............................ 160
5.3 Outdoor Unit: Inverter Thermostat Sensor, Compressor Overload.....161
5.4 Outdoor Unit: Inverter Stall Prevention, Compressor Lock.................. 162
5.5 Outdor Unit: Malfunction of Transmission
Between Inverter and Control PC Board.............................................163
5.6 Power Supply Insufficient or Instantaneous Failure ............................ 164
5.7 Outdoor Unit: Inverter Over-Ripple Protection..................................... 165
5.8 Outdoor Unit: Malfunction of
Inverter Radiating Fin Temperature Rise Sensor................................ 166
6. Troubleshooting (OP: Central Remote Controller)..............................167
6.1 Malfunction of Transmission
Between Central Remote Controller and Indoor Unit..........................167
6.2 PC Board Defect..................................................................................168
6.3 Malfunction of Transmission
Between Optional Controllers for Centralized Control......................... 168
6.4 Improper Combination of Optional Controllers
for Centralized Control......................................................................... 169
6.5 Address Duplication, Improper Setting................................................170

SiE 00-07
iv Table of Contents
7. Troubleshooting (OP: Schedule Timer)...............................................171
7.1 Malfunction of Transmission
Between Central Remote Controller and Indoor Unit..........................171
7.2 PC Board Defect..................................................................................172
7.3 Malfunction of Transmission
Between Optional Controllers for Centralized Control......................... 172
7.4 Improper Combination of Optional Controllers
for Centralized Control......................................................................... 173
7.5 Address Duplication, Improper Setting................................................174
8. Troubleshooting (OP: Unified ON/OFF Controller) .............................175
8.1 Operation Lamp Blinks........................................................................175
8.2 Display “Under Host Computer Integrate Control” Blinks
(Repeats Single Blink).........................................................................176
8.3 Display “Under Host Computer Integrate Control” Blinks
(Repeats Double Blink)........................................................................ 178
Part 6 Special Service Mode R-407C PLUS Series...................179
1. Backup and Emergency Operation...............................................................180
1.1 Backup and Emergency Operation......................................................180
2. Pump Down Operation .................................................................................182
2.1 Pump Down Operation........................................................................182
Part 7 Appendix R-407C PLUS Series.......................................18
1. Piping Diagram....................................................................................184
1.1 Outdoor Unit........................................................................................184
1.2 Indoor Unit...........................................................................................186
2. Wiring Diagram ...................................................................................187
2.1 Outdoor Unit........................................................................................187
2.2 Indoor Unit...........................................................................................189
3. Characteristics.............................................................................................. 201
3.1 R-407C Characteristics ....................................................................... 201
3.2 Thermistor Resistance / Temperature Characteristics........................202
3.3 Pressure Sensor.................................................................................. 204
3.4 Method of Replacing The Inverter’s Power Transistors
and Diode Modules..............................................................................205
4. Precautions in Servicing The Models with New-type Refrigerant................. 207
4.1 Tools Required....................................................................................207
4.2 Notes for Work Procedures.................................................................208
Index .............................................................................................i
Drawings & Flow Charts ................................................................v

SiE 00-07 Introduction
v
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
shook.
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.
When disconnecting the suction or discharge pipe of the compressor at the welded
section, release the refrigerant gas completely at a well-ventilated place first.
If there is a gas remaining inside the compressor, the refrigerant gas or refrigerating
machine oil discharges when the pipe is disconnected, and it can cause injury.
If the refrigerant gas leaks during the repair work, ventilate the area. The refrigerant gas
can generate toxic gases when it contacts flames.
Thestep-upcapacitor supplieshigh-voltageelectricityto theelectricalcomponentsof the
outdoor unit.
Be sure to discharge the capacitor completely before conducting repair work.
A charged capacitor can cause an electrical shock.
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.

Introduction SiE 00-07
vi
1.1.2 Cautions Regarding Products after Repair
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.
Warning
Besuretousepartslistedintheserviceparts 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.
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 install the product correctly by using the provided standard installation frame.
Incorrect use of the installation frame and improper installation can cause the equipment
to fall, resulting in injury.
For integral units only
Be sure to install the product securely in the installation frame mounted on a window
frame.
If the unit is not securely mounted, it can fall and cause injury.
For integral units only
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.
Be sure to use the specified cable to connect between the indoor and outdoor units.
Make the connections securely and route the cable properly so that there is no force
pulling the cable at the connection terminals.
Improper connections can cause excessive heat generation or fire.

SiE 00-07 Introduction
vii
1.1.3 Inspection after Repair
When connecting the cable between the indoor and outdoor units, make sure that the
terminal cover does not lift off or dismount because of the cable.
If the cover is not mounted properly, the terminal connection section can cause an
electrical shock, excessive heat generation 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-407C) 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.
When replacing the coin battery in the remote controller, be sure to disposed of the old
battery to prevent children from swallowing it.
If a child swallows the coin battery, see a doctor immediately.
Warning
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.
Be sure to install the packing and seal on the installation frame properly.
If the packing and seal are not installed properly, water can enter the room and wet the
furniture and floor.
For integral units only
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.

Introduction SiE 00-07
viii
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:
1.1.5 Using Icons List
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.
Be sure to check the drainage of the indoor unit after the repair.
Faulty drainage can cause the water to enter the room and wet the furniture and floor.
Caution
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.

SiE 00-07 Introduction
ix
1.2 PREFACE
Thank you for your continued patronage of Daikin products.
This is the new service manual for Daikin's Year 2000 R-407C VRV PLUS series.
Daikin offers a wide range of models to respond to building and office air conditioning needs. We are
confident that customers will be able to find the models that best suit their needs.
This service manual contains information regarding the servicing of the R-407C VRV PLUS series.
The following technical documents are also available from Daikin. Please use these documents together
with this manual to conduct efficient servicing.
Design & Installation instruction Si33-003 Nov. 2000
Oct. 2000
After Sales Service Division