Johnson Controls YVAHP072B31S User manual

SM-15001
SERVICE MANUAL
INVERTER-DRIVEN MULTI-SPLIT SYSTEM
HEAT PUMP AIR CONDITIONERS
Service Manual
< Outdoor Units >
(H,Y)VAHP072B(3,4)1S to (H,Y)VAHP360B(3,4)1S
(H,Y)VAHR072B(3,4)1S to (H,Y)VAHR360B(3,4)1S
< Indoor Units >
ƔDucted High Static Type
(H,Y)IDH018B21S to (H,Y)IDH048B21S
ƔDucted Medium Static Type
(H,Y)IDM006B21S to (H,Y)IDM048B21S
ƔDucted Slim Type
(H,Y)IDS006B21S to (H,Y)IDS018B21S
Ɣ4-Way Cassette Type
(H,Y)IC4012B21S to (H,Y)IC4036B21S
Ɣ1-Way Cassette Type
(H,Y)IC1006B21S to (H,Y)IC1015B21S
ƔWall Mounted Type
TIWM006B21S to TIWM024B21S

Service Manual i
Temperature
Maximum Minimum
Cooling
Operation
Indoor 89oF DB/73oF WB (32oC DB/23oC WB) 69oF DB/59oF WB (21oC DB/15oC WB)
Outdoor 118oF DB (48oC DB) *1), *2) 14oF DB (-10oC DB) *3), *4)
Heating
Operation
Indoor 80oF DB (27oC DB) 59oF DB ( 15oC DB)
Outdoor 59oF WB (15oC WB) *5) -4oF WB (-20oC WB) *6)
DB: Dry Bulb, WB: Wet Bulb
*1) When the outdoor air temperature is 100oF DB (38oC DB) or more and the outdoor unit operation capacity
ratio is 100% or more, the outdoor unit will be Thermo-OFF to protect the compressor from failure.
*2) When the outdoor air temperature is 109oF (43oC) or more during the outdoor unit cooling operation, the
maximum connectable indoor unit capacity ratio is 100%.
*3) When the outdoor air temperature is 23oF (-5oC) or less during the outdoor unit cooling operation, the
minimum connectable indoor unit capacity is 18,000 Btu/h.
In this case, install the snow protection hood (optional).
*4) When operating the outdoor unit under the low cooling load conditions and in the low outdoor air
temperature, (applox. 50oF DB (10oC DB) or less), the indoor unit will be Thermo-OFF to prevent the heat
exchanger of the indoor unit from being frosted.
*5) When operating the outdoor unit under the low heating load conditions and the outdoor temperature is
59oF DB (15oC DB) or more, the outdoor unit will be Thermo-OFF to protect the compressor from failure.
*6) Operation in the outdoor temperature of 5~-4oF WB (-15~20oC WB) is assumed to limited conditions such
as start-up in early morning.
Long time operation in this condition may shorten the life of the compressor.
Important Notice
ƔJohnson Controls Inc. pursues a policy of continuing improvement in design and performance in its
products. As such, Johnson Controls Inc. reserves the right to make changes at any time without prior
notice.
ƔJohnson Controls Inc. cannot anticipate every possible circumstance that might involve a potential
hazard.
ƔThis heat pump air conditioning unit is designed for standard air conditioning applications only. Do not
use this unit for anything other than the purposes for which it was intended for.
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and electrical codes. The following standards may be applicable, if local regulations are not available.
International Organization for Standardization: (ISO 5149 or European Standard, EN 378). No part of
this manual may be reproduced in any way without the expressed written consent of Johnson Controls
Inc.
ƔThis heat pump air conditioning unit will be operated and serviced in the United States of America and
comes with a full complement of the appropriate Safety, Danger, and Caution, warnings.
ƔIf you have questions, please contact your distributor or dealer.
ƔThis manual provides common descriptions, basic and advanced information to maintain and service
this heat pump air conditioning unit which you operate as well for other models.
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performance and long life, operate this unit within the range limits according to the table below.
ƔThis manual should be considered as a permanent part of the air conditioning equipment and should
remain with the air conditioning equipment.

ii Service Manual
Product Inspection upon Arrival
1. Upon receiving this product, inspect it for any damages incurred in transit. Claims for damage, either
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2. Check the model number, electrical characteristics (power supply, voltage, and frequency rating), and
any accessories to determine if they agree with the purchase order.
3. The standard utilization for this unit is explained in these instructions. Use of this equipment for
purposes other than what it designed for is not recommended.
4. Please contact your local agent or contractor as any issues involving installation, performance, or
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performed by a customer without the written consent of Johnson Controls, Inc. Performing any
mechanical alterations on this product without the consent of the manufacturer will render your warranty
null and void.

Service Manual iii
1. Introduction
2. Important Safety Instructions
This manual should be considered as a permanent part of the air conditioning equipment and should
remain with the air conditioning equipment.
(Transportation/Installation Work) > (Refrigerant Piping Work) > (Electrical Wiring Work) > (Ref. Charge Work) > (Test
Run) > (User)
This manual concentrates on the Outdoor Heat Pump Unit. Read this installation and maintenance manual
carefully before installation. Read over the installation manual for the Indoor Unit also.
Signal Words
Indicates a hazardous situation that, if not avoided, could result in death or
serious injury.
Indicates a hazardous situation that, if not avoided, could result in minor or
moderate injury.
Indicates information considered important, but not hazard-related (for
example, messages relating to property damage).
General Precautions
To reduce the risk of serious injury or death, read these instructions thoroughly
and follow all warnings or cautions included in all manuals that accompanied
the product and are attached to the unit. Refer back to these safety
instructions as needed.
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against possible damage or injury that might occur in an earthquake if the unit is not installed correctly,
injuries may occur due to a falling unit.
ƔUse appropriate Personal Protective Equipment (PPE), such as gloves and protective goggles and,
where appropriate, have a gas mask nearby. Also use electrical protection equipment and tools suited
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Use care in handling, rigging, and setting of bulky equipment.
ƔWhen transporting, be careful when picking up, moving and mounting these units. Although the unit may
be packed using plastic straps, do not use them for transporting the unit from one location to another. Do
not stand on or put any material on the unit. Get a partner to help, and bend with your knees when lifting
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so wear protective gloves.
ƔDo not touch or adjust any safety devices inside the indoor or outdoor units. All safety features,
disengagement, and interlocks must be in place and functioning correctly before the equipment is put
into operation. If these devices are improperly adjusted or tampered with in any way, a serious accident
can occur. Never bypass or jump-out any safety device or switch.
ƔJohnson Controls will not assume any liability for injuries or damage caused by not following steps
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prohibited as they…
ƕMay create hazards which could result in death, serious injury or equipment damage;
ƕWill void product warranties;
ƕ 0D\LQYDOLGDWHSURGXFWUHJXODWRU\FHUWL¿FDWLRQV
ƕMay violate OSHA standards;

iv Service Manual
Take the following precautions to reduce the risk of property damage.
ƔBe careful that moisture, dust, or variant refrigerant compounds not enter the refrigerant cycle during
installation work. Foreign matter could damage internal components or cause blockages.
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ƔDo not install this unit in any place where silicon gases can coalesce. If the silicon gas molecules
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could run inside of the electrical box, possibly causing electrical failures.
ƔWhen installing the unit in a hospital or other facility where electromagnetic waves are generated
from nearby medical and/or electronic devices, be prepared for noise and electronic interference
Electromagnetic Interference (EMI). Do not install where the waves can directly radiate into the
electrical box, controller cable, or controller. Inverters, appliances, high-frequency medical equipment,
and radio communications equipment may cause the unit to malfunction. The operation of the unit
may also adversely affect these same devices. Install the unit at least 10 ft. (approximately 3m) away
from such devices.
ƔWhen a wireless controller is used, locate at a distance of at least 3.3 ft. (approximately 1 meter)
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receiving operation commands.
ƔDo not install the unit in any location where animals and plants can come into direct contact with the
outlet air stream. Exposure could adversely affect the animals and plants.
ƔDo not install the unit with any downward slope to the side of the drain adaptor. If you do, you may
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ƔBe sure the drain hose discharges water properly. If connected incorrectly, it may cause leaks.
ƔDo not install the unit in any place where oil can seep onto the units, such as table or seating areas in
restaurants, and so forth. For these locations or social venues, use specialized units with oil-resistant
features built into them. In addition, use a specialized ceiling fan designed for restaurant use. These
specialized oil-resistant units can be ordered for such applications. However, in places where large
quantities of oil can splash onto the unit, such as a factory, even the specialized units cannot be used.
These products should not be installed in such locations.
Installation Precautions
To reduce the risk of serious injury or death, the following installation
precautions must be followed.
ƔWhen installing the unit into…
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construct a strong wood or metal frame to provide added support.
ƓA room: Properly insulate any refrigerant tubing run inside a room to prevent “sweating” that can
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ƓDamp or uneven areas: Use a raised concrete pad or concrete blocks to provide a solid, level
foundation for the unit to prevent water damage and abnormal vibration.
ƓAn area with high winds: Securely anchor the outdoor unit down with bolts and a metal frame.
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ƓA snowy area: Install the outdoor unit on a raised platform that is higher than drifting snow. Provide
snow vents.
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corrosion, or product failure.
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above a kitchen stove.
ƓWhere oil (including machinery oil) may be present.
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tub or hot spring.
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ƓWhere the air quality is of high acidity.
ƓWhere harmful gases can be generated from decomposition.

Service Manual v
ƔDo not position the drain pipe for the indoor unit near any sanitary sewers where corrosive gases
may be present. If you do, toxic gases can seep into breathable air spaces and can cause respiratory
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furniture, or other possessions may result. If condensate piping becomes clogged, moisture can back
up and can drip from the indoor unit. Do not install the indoor unit where such dripping can cause
moisture damage or uneven locations: Use a raised concrete pad or concrete blocks to provide a
solid, level foundation for the unit to prevent water damage and abnormal vibration.
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nearby.
ƔPerform a test run to ensure normal operation. Safety guards, shields, barriers, covers, and protective
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clothing away from any moving parts.
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been left inside the unit being installed.
ƔDuring transportation, do not allow the backrest of the forklift make contact with the unit, otherwise,
it may cause damage to the heat exchanger and also may cause injury when stopped or started
suddenly.
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melted with remaining gas inside, the pipes will be blown off and it may cause injury.
ƔBe sure to use nitrogen gas for an airtight test. If other gases such as oxygen gas, acetylene gas or
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After installation work for the system has been completed, explain the “Safety Precautions,” the proper use
and maintenance of the unit to the customer according to the information in all manuals that came with the
system. All manuals and warranty information must be given to the user or left near the Indoor Unit.
Refrigerant Precautions
To reduce the risk of serious injury or death, the following refrigerant
precautions must be followed.
ƔAs originally manufactured, this unit contains refrigerant installed by Johnson Controls. Johnson
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or market. Johnson Controls distributors similarly are only authorized to provide refrigerants that
have been approved for use in the countries or markets they serve. The refrigerant used in this unit
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WKLVXQLWPXVWFRPSO\ZLWKWKHFRXQWU\¶VUHTXLUHPHQWVZLWKUHJDUGWRUHIULJHUDQWXVHDQGVKRXOGEH
obtained from Johnson Controls distributors. Use of any non-approved refrigerant substitutes will void
the warranty and will increase the potential risk of injury or death.
ƔIf installed in a small room, take measures to prevent the refrigerant from exceeding the maximum
allowable concentration in the event that refrigerant gases should escape. Refrigerant gases can
cause asphyxiation (0.026 lbs/ft3(0.42 kg/m3) based on ISO 5149 for R410A). Consult with your
distributor for countermeasures (ventilation system and so on). If refrigerant gas has leaked during the
installation work, ventilate the room immediately.
ƔCheck the design pressure for this product is 601 psi (4.15MPa). The pressure of the refrigerant
R410A is 1.4 times higher than that of the refrigerant R22. Therefore, the refrigerant piping for
5$VKDOOEHWKLFNHUWKDQWKDWIRU50DNHVXUHWRXVHWKHVSHFL¿HGUHIULJHUDQWSLSLQJ,IQRWWKH
refrigerant piping may rapture due to an excessive refrigerant pressure. Besides, pay attention to
the piping thickness when using copper refrigerant piping. The thickness of copper refrigerant piping
differs depending on its material.
ƔThe refrigerant R410A is adopted. The refrigerant oil tends to be affected by foreign matters such
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different refrigerant from entering the refrigerant cycle. Foreign matter can be introduced into the
cycle from such parts as expansion valve and the operation may be unavailable.
ƔTo avoid the possibility of different refrigerant or refrigerant oil being introduced into the cycle, the
sizes of the charging connections have been changed from R407C type and R22 type. It is necessary
to prepare the appropriate tools before performing installation work.
ƔUse refrigerant pipes and joints which are approved for use with R410A.
ƔA compressor/unit comprises a pressurized system. Never loosen threaded joints while the system is
under pressure and never open pressurized system parts.

vi Service Manual
ƔBefore installation is complete, make sure that the refrigerant leak test has been performed. If
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contact your service contractor. Refrigerant (Fluorocarbon) for this unit is odorless. If the refrigerant
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ƔWhen installing the unit, and connecting refrigerant piping, keep all piping runs as short as possible,
and make sure to securely connect the refrigerant piping before the compressor starts operating. If
the refrigerant piping is not connected and the compressor activates with the stop valve opened, the
refrigerant cycle will become subjected to extremely high pressure, which can cause an explosion or
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ƔWhen maintaining, relocating, and disposing of the unit, dismantle the refrigerant piping after the
compressor stops.
ƔWhen pipes are removed out from under the piping cover, after the insulation work is completed,
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covered, the unit may be damaged if snow, rain water or small animals enter the unit.
ƔDo not apply an excessive force to the spindle valve at the end of opening. Otherwise, the spindle
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otherwise, these devices will be damaged. (It is closed before shipment.)
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failure of the outdoor unit.
ƔThe refrigerant system may be damaged if the slope of the piping connection kit exceeds +15o.
Electrical Precautions
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explosion resulting in serious injury or death.
ƔHighly dangerous electrical voltages are used in this system. Carefully refer to the wiring diagram and
these instructions when wiring. Improper connections and inadequate grounding can cause serious
injury or death.
ƔPerform all electrical work in strict accordance with this installation and maintenance manual and all
the relevant regulatory standards.
ƔBefore servicing, open and tag all disconnect switches. Never assume electrical power is
disconnected. Check with meter and equipment.
ƔOnly use electrical protection equipment and tools suited for this installation.
Ɣ 8VHVSHFL¿HGFDEOHVEHWZHHQXQLWV
ƔThe new air conditioner may not function normally in the following instances:
ƓIf electrical power for the new air conditioner is supplied from the same transformer as the device*
referred to below.
ƓIf the power source cables for this device* and the new air conditioner unit are located in close
proximity to each other.
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device, arc furnace, electric furnace, large-sized induction motor and large-sized switch.
Regarding the cases mentioned above, surge voltage may be inducted into the power supply
cables for the packaged air conditioner due to a rapid change in power consumption of the
device and an activation of a switch.
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power supply for the new air conditioner unit.
ƔCommunication cabling shall be a minimum of AWG18 (0.82mm2), 2-Conductor, Stranded Copper.
Shielded cable must be considered for applications and routing in areas of high EMI and other
sources of potentially excessive electrical noise to reduce the potential for communication errors.
When shielded cabling is applied, proper bonding and termination of the cable shield is required
as per Johnson Controls guidelines. Plenum and riser ratings for communication cables must be
considered per application and local code requirements.
Ɣ 8VHDQH[FOXVLYHSRZHUVXSSO\IRUWKHDLUFRQGLWLRQHUDWWKHXQLW¶VUDWHGYROWDJH

Service Manual vii
ƔBe sure to install circuit breakers (ground fault interrupter, isolating switch, molded case circuit
EUHDNHUDQGVRRQZLWKWKHVSHFL¿HGFDSDFLW\(QVXUHWKDWWKHZLULQJWHUPLQDOVDUHWLJKWHQHGVHFXUHO\
WRUHFRPPHQGHGWRUTXHVSHFL¿FDWLRQV
ƔClamp electrical wires securely with a cable clamp after all wiring is connected to the terminal block.
In addition, run wires securely through the wiring access channel.
ƔWhen installing the power lines, do not apply tension to the cables. Secure the suspended cables at
regular intervals, but not too tightly.
ƔMake sure that the terminals do not come into contact with the surface of the electrical box. If the
terminals are too close to the surface, it may lead to failures at the terminal connection.
ƔTurn OFF and disconnect the unit from the power source when handling the service connector. Do not
open the service cover or access panel to the indoor or outdoor units without turning OFF the main
power supply.
Ɣ $IWHUFHDVLQJRSHUDWLRQEHVXUHWRZDLWDWOHDVW¿YHPLQXWHVEHIRUHWXUQLQJRIIWKHPDLQSRZHU
switch. Otherwise, water leakage or electrical breakdown may result. Disconnect the power source
completely before attempting any maintenance for electrical parts. Check to ensure that no residual
voltage is present after disconnecting the power source.
ƔDo not clean with, or pour water into, the controller as it could cause electric shock and/or damage the
unit. Do not use strong detergent such as a solvent. Clean with a soft cloth.
ƔCheck that the ground wire is securely connected. Do not connect ground wiring to gas piping, water
piping, lighting conductor, or telephone ground wiring.
ƔIf a circuit breaker or fuse is frequently activated, shut down the system and contact your service
contractor.
ƔPerform all electrical work in accordance with this manual and in compliance with all regulations and
safety standards.
Ɣ 'RQRWRSHQDVHUYLFHDFFHVVFRYHURUSDQHORIDQLQGRRURURXWGRRUXQLWZLWKRXW¿UVWWXUQLQJ2))WKH
power at the main power supply.
ƔResidual voltage can cause electric shock. At all times, check for residual voltage after disconnecting
from the power source before starting work on the unit.
ƔUse a Ground Fault Circuit Interrupter (GFCI) to reduce the chance of an electric shock.

viii Service Manual

Service Manual ix
- Table of Contents -
1. Installation..............................................................................................................................1-1
1.1 Outdoor Unit ....................................................................................................................................1-2
1.2 Change-Over Box............................................................................................................................1-92
1.3 Indoor Unit ......................................................................................................................................1-110
1.3.1 Duct Type ...............................................................................................................................1-110
1.3.1.1 High Static Type................................................................................................................1-110
1.3.1.2 Medium Static Type...........................................................................................................1-142
1.3.1.3 Slim Type ..........................................................................................................................1-174
1.3.2 4-Way Cassette Type.............................................................................................................1-206
1.3.3 1-Way Cassette Type.............................................................................................................1-245
1.3.4 Wall Mount Type.....................................................................................................................1-281
1.3.5 Decorative Panel for 4-Way Cassette ....................................................................................1-326
1.3.6 Decorative Panel for 1-Way Cassette ....................................................................................1-344
1.4 Control Device ................................................................................................................................1-359
1.4.1 Wired Controller .....................................................................................................................1-359
1.4.2 Simplified Wired Controller.....................................................................................................1-379
1.4.3 Wireless Controller.................................................................................................................1-394
1.4.4 Infrared (IR) Receiver Kit (for 4-Way Cassette Type).............................................................1-405
1.4.5 Infrared (IR) Receiver Kit (for 1-Way Cassette Type).............................................................1-417
1.4.6 Infrared (IR) Receiver Kit (for Wall Mount Type and Ducted Type) ........................................1-430
1.4.7 Motion Sensor Kit (for 1-Way Cassette Type)........................................................................1-444
1.4.8 Mini Central Controller ...........................................................................................................1-451
1.4.9 Large Central Controller.........................................................................................................1-504
1.4.10 Computerized Central Controller Management Software ......................................................1-572
1.4.11 Computerized Central Controller Software / Operation Ratio ................................................1-651
1.4.12 Computerized Central Controller Adapter ..............................................................................1-706

x Service Manual
- Table of Contents -
1.5 Optional Parts .................................................................................................................................1-729
1.5.1 For Outdoor Unit ....................................................................................................................1-729
1.5.1.1 Drain Adaptor: DBS-TP10A...............................................................................................1-730
1.5.1.2 Protection Net ...................................................................................................................1-732
1.5.1.3 Snow Protection Hood ......................................................................................................1-741
1.5.2 For Ducted Type ....................................................................................................................1-767
1.5.2.1 Air Filter: KW-PP3Q, KW-PP4Q .......................................................................................1-768
1.5.2.2 Air Filter: KW-PP7Q, KW-PP8Q, KW-PP9Q, KW-PP10Q.................................................1-769
1.5.2.3 Air Filter: KW-PP5Q, KW-PP6Q........................................................................................1-770
1.5.3 For 4-Way Cassette Type ......................................................................................................1-771
1.5.3.1 Anti-bacterial Air Filter: F-71M-K2, F-160M-K2.................................................................1-772
1.5.3.2 Filter Box: B-160H3...........................................................................................................1-774
1.5.3.3 Air Outlet Shutter Plate: PI-160LS2 ..................................................................................1-778
1.5.3.4 Fresh Air Intake Kit: OACI-160K3 .....................................................................................1-782
1.5.3.5 T-Tube Connecting Kit: TKCI-160K...................................................................................1-789
1.5.3.6 Duct Adaptor: PD-75A.......................................................................................................1-793
1.5.4 For 1-Way Cassette Type ......................................................................................................1-797
1.5.4.1 Anti-bacterial Air Filter: F-56MS-PK2 ................................................................................1-798
1.5.4.2 Duct Adaptor: PD-100 .......................................................................................................1-800
1.5.4.3 Grille for Front Discharge: DG-56SW1 .............................................................................1-802
1.5.4.4 Air Outlet Shutter Plate: PIS-56LS....................................................................................1-808
1.5.5 For Wall Mount Type ..............................................................................................................1-812
1.5.5.1 Strainer Kit: MSF-NP63A, MSF-NP112A ..........................................................................1-813
1.5.6 Piping Kit................................................................................................................................1-819
1.5.6.1 Piping Connection Kit between Outdoor Units for 2 Piping System..................................1-820
1.5.6.2 Piping Connection Kit between Outdoor Units for 3 Piping System..................................1-839
1.5.6.3 Multi-Kit between Indoor Units for 2 Piping System (Branch Type) ..................................1-859
1.5.6.4 Multi-Kit between Indoor Units for 3 Piping System (Branch Type) ..................................1-868
1.5.6.5 Multi-Kit between Indoor Units for 2 Piping System (Multi Type) ......................................1-878
1.5.6.6 Multi-Kit between Indoor Units for 3 Piping System (Multi Type) ......................................1-888
1.5.7 Control....................................................................................................................................1-898
1.5.7.1 3 Pin Connector Cable: PCC-1A.......................................................................................1-899
1.5.7.2 Remote Sensor: THM-R2A ...............................................................................................1-900
1.5.7.3 Relay and 3 Pin Connector Kit: PSC-5RA ........................................................................1-902

Service Manual xi
- Table of Contents -
2. Operation ...............................................................................................................................2-1
2.1 Indoor Unit ......................................................................................................................................2-2
2.1.1 Duct Type ...............................................................................................................................2-2
2.1.2 4-Way Cassette Type.............................................................................................................2-22
2.1.3 1-Way Cassette Type.............................................................................................................2-55
2.1.4 Wall Mount Type.....................................................................................................................2-79
2.2 Control Device ................................................................................................................................2-118
2.2.1 Wired Controller .....................................................................................................................2-118
2.2.2 Simplified Wired Controller.....................................................................................................2-163
2.2.3 Infrared (IR) Receiver Kit (for 4-Way Cassette Type).............................................................2-172
2.2.4 Infrared (IR) Receiver Kit (for 1-Way Cassette Type).............................................................2-192
2.2.5 Infrared (IR) Receiver Kit (for Wall Mount Type and Ducted Type) ........................................2-212
2.2.6 Mini Central Controller ...........................................................................................................2-231
2.2.7 Large Central Controller.........................................................................................................2-283
2.2.8 Computerized Central Controller Management Software ......................................................2-339
2.2.9 Computerized Central Controller Software / Operation Ratio ................................................2-375
3. Troubleshooting .....................................................................................................................3-1
3.1 Initial Troubleshooting .....................................................................................................................3-2
3.1.1 Checking Electrical Wiring and Power Source.......................................................................3-2
3.1.2 Location of Printed Circuit Boards (PCBs).............................................................................3-11
3.1.3 Checking Rotary Switch and DIP Switch Settings .................................................................3-16
3.1.4 Checking Wired Controller .....................................................................................................3-24
3.1.5 Checking Using 7-Segment Display.......................................................................................3-31
3.1.6 Checking Alarm Code History ................................................................................................3-37
3.1.7 Emergency Operation ............................................................................................................3-44
3.2 Troubleshooting Procedures ...........................................................................................................3-49
3.2.1 Alarm Code Table...................................................................................................................3-49
3.2.2 Troubleshooting Using Alarm Codes......................................................................................3-50
3.2.3 Abnormalities of Devices........................................................................................................3-123
3.3 Procedures for Checking.................................................................................................................3-136
3.3.1 Self-Checking of PCBs using Wired Controller......................................................................3-136
3.3.2 Self-Checking of Wired Controller..........................................................................................3-136
3.4 Test Run ..........................................................................................................................................3-137
3.4.1 Test Run Using Wired Controller............................................................................................3-138
3.4.2 Test Run from Outdoor Unit Side ...........................................................................................3-140
3.4.3 Checking the Test Run...........................................................................................................3-142
3.4.4 Checklist for Refrigerant System............................................................................................3-143
3.4.5 Automatic Judgment System for Refrigerant Amount ............................................................3-145
3.4.6 Reset for Accumulated Operation Time of Compressor 1-2 (cUJ1-cUJ2)..............................3-146

xii Service Manual
- Table of Contents -
4. Maintenance ..........................................................................................................................4-1
4.1 Maintenance of Outdoor Unit ..........................................................................................................4-2
4.2 Maintenance of Indoor Unit .............................................................................................................4-52
4.2.1 Ducted High Static Type ((H,Y)IDH018 - 048B21S)...............................................................4-52
4.2.2 Ducted Medium Static Type ((H,Y)IDM006 - 048B21S).........................................................4-66
4.2.3 Ducted Slim Type ((H,Y)IDS006 - 018B21S) .........................................................................4-78
4.2.4 4-Way Cassette Type.............................................................................................................4-88
4.2.5 1-Way Cassette Type.............................................................................................................4-103
4.2.6 Wall Mount Type.....................................................................................................................4-115
4.2.7 Cleaning Indoor Unit Heat Exchanger....................................................................................4-145
4.3 Main Parts .......................................................................................................................................4-152
4.3.1 for Outdoor Unit......................................................................................................................4-152
4.3.2 for Change-Over Box .............................................................................................................4-179
4.3.3 for Indoor Units.......................................................................................................................4-182
5. External Input/Output and Function Setting...........................................................................5-1
5.1 DIP Switch Settings of Outdoor Unit ...............................................................................................5-2
5.2 High Static Pressure Setting (DSW5-No.5: ON) .............................................................................5-3
5.3 External Input/Output and Function Setting Mode for Outdoor Unit................................................5-6
5.3.1 External Input and Output Settings ........................................................................................5-7
5.3.2 Function Setting .....................................................................................................................5-16
5.4 External Input/Output and Function Setting Mode for Indoor Unit ..................................................5-27
5.4.1 External Input and Output Settings ........................................................................................5-29
5.4.2 Function Setting .....................................................................................................................5-41
5.5 Power Saving Functions from Wired Controller ..............................................................................5-69
5.5.1 Outdoor Unit Capacity Control ...............................................................................................5-69
5.5.2 Rotation Control Function ......................................................................................................5-70
5.5.3 Intermittent Control Function..................................................................................................5-70
5.5.4 Power Saving Schedule Function ..........................................................................................5-71
5.5.5 Operation Noise Reduction Schedule Function .....................................................................5-71
5.5.6 Power Consumption Display Function ...................................................................................5-71
5.5.7 Power Saving Guide ..............................................................................................................5-71

Service Manual xiii
6. Field Work Instructions ..........................................................................................................6-1
6.1 Caution for Refrigerant Leakage .....................................................................................................6-2
6.2 Modifications of Charging Refrigerants Other than Those Specified by Johnson Controls.............6-3
6.3 Maintenance Work ..........................................................................................................................6-4
6.4 Service and Maintenance Record by 7-Segment Display ...............................................................6-5
6.5 Service and Maintenance Record by Wired Controller ...................................................................6-6
6.6 Service and Maintenance Record ...................................................................................................6-8
6.7 Saturation Curve for Refrigerant .....................................................................................................6-9
6.8 Mollier Chart for R410A...................................................................................................................6-10
7. Service Parts List...................................................................................................................7-1
7.1 Outdoor Unit ....................................................................................................................................7-2
7.2 Change-Over Box............................................................................................................................7-20
7.3 Indoor Unit ......................................................................................................................................7-22
7.3.1 Ducted Type ...........................................................................................................................7-22
7.3.1.1 High Static Type................................................................................................................7-22
7.3.1.2 Medium Static Type...........................................................................................................7-29
7.3.1.3 Slim Type ..........................................................................................................................7-38
7.3.2 4-Way Cassette Type.............................................................................................................7-44
7.3.3 1-Way Cassette Type.............................................................................................................7-48
7.3.4 Wall Mount Type.....................................................................................................................7-52
- Table of Contents -

Service Manual 1-1
INSTALLATION
1. Installation

1-2 Service Manual
INSTALLATION
1.1 Outdoor Unit
- Table of Contents -
1. Introduction ....................................................................................................................................................... 1-3
2. Important Safety Instructions ............................................................................................................................ 1-3
3. Before Installation ............................................................................................................................................. 1-8
3.1 Necessary Tools and Instrument List for Installation................................................................................ 1-8
3.2 Flaring and Joint ...................................................................................................................................... 1-10
3.3 Line-Up of Outdoor Unit ........................................................................................................................... 1-12
3.3.1 Heat Pump System ........................................................................................................................ 1-12
3.3.2 Heat Recovery System .................................................................................................................. 1-13
3.4 Combination of Indoor Unit and Outdoor Unit.......................................................................................... 1-14
3.5 Caution about Outdoor Unit Installation ................................................................................................... 1-16
3.6 Factory-Supplied Accessories.................................................................................................................. 1-17
3.7 Piping Work between Outdoor Units ........................................................................................................ 1-18
4. Outdoor Unit Installation ................................................................................................................................... 1-19
4.1 Installation Location and Precautions ...................................................................................................... 1-19
4.2 Service Space.......................................................................................................................................... 1-20
5. Transportation and Installation Work ................................................................................................................ 1-23
5.1 Transportation .......................................................................................................................................... 1-23
5.2 Handling of Outdoor Unit ......................................................................................................................... 1-25
5.3 Installation Work....................................................................................................................................... 1-26
5.3.1 Concrete Foundations.................................................................................................................... 1-26
5.3.2 Condensate Treatment................................................................................................................... 1-28
6. Refrigerant Piping Work.................................................................................................................................... 1-29
6.1 Piping Materials ....................................................................................................................................... 1-30
6.2 Piping Connection Work........................................................................................................................... 1-34
6.2.1 Stop Valve ..................................................................................................................................... 1-34
6.2.2 Piping Connection Method ............................................................................................................. 1-35
6.3 Piping Work between Outdoor Units........................................................................................................ 1-38
6.4 Piping Size between Outdoor Units ......................................................................................................... 1-41
6.4.1 Heat Pump System ........................................................................................................................ 1-41
6.4.2 Heat Recovery System .................................................................................................................. 1-44
6.5 Piping Size and Multi-Kit Selection .......................................................................................................... 1-47
6.5.1 Heat Pump System ........................................................................................................................ 1-47
6.5.2 Heat Recovery System .................................................................................................................. 1-53
6.6 Multi-Kit Connection................................................................................................................................. 1-62
7. Electrical Wiring ................................................................................................................................................ 1-63
7.1 General Check ......................................................................................................................................... 1-64
7.2 Electrical Wiring Connection .................................................................................................................... 1-64
7.3 Electrical Wiring for Outdoor Unit............................................................................................................. 1-67
7.4 Electrical Wiring Connections of Indoor Unit, Outdoor Unit, and Change-Over Box ............................... 1-68
7.5 DIP Switch Setting of Outdoor Unit.......................................................................................................... 1-71
8. Additional Refrigerant Charge .......................................................................................................................... 1-75
8.1 Airtight Test .............................................................................................................................................. 1-75
8.2 Vacuuming ............................................................................................................................................... 1-77
8.3 Charging Work ......................................................................................................................................... 1-77
8.4 Additional Refrigerant Charge Calculation............................................................................................... 1-79
8.5 Automatic Simple Judgement System for Refrigerant Amount ................................................................ 1-80
9. Test Run............................................................................................................................................................ 1-83
9.1 Before Test Run ....................................................................................................................................... 1-83
9.2 Test Run................................................................................................................................................... 1-85
10. Safety and Control Device Setting.................................................................................................................... 1-91

Service Manual 1-3
INSTALLATION
1. Introduction
2. Important Safety Instructions
This manual should be considered as a permanent part of the air conditioning equipment and should
remain with the air conditioning equipment.
(Transportation/Installation Work) > (Refrigerant Piping Work) > (Electrical Wiring Work) > (Ref. Charge Work) > (Test
Run) > (User)
This manual concentrates on the Outdoor Heat Pump Unit. Read this installation and maintenance manual
carefully before installation. Read over the installation manual for the Indoor Unit also.
Signal Words
Indicates a hazardous situation that, if not avoided, could result in death or
serious injury.
Indicates a hazardous situation that, if not avoided, could result in minor or
moderate injury.
Indicates information considered important, but not hazard-related (for
example, messages relating to property damage).
General Precautions
To reduce the risk of serious injury or death, read these instructions thoroughly
and follow all warnings or cautions included in all manuals that accompanied
the product and are attached to the unit. Refer back to these safety
instructions as needed.
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LQVWDOODWLRQFRXOGFDXVHOHDNVHOHFWULFVKRFN¿UHRUH[SORVLRQ,QDUHDVZKHUH6HLVPLFµ¶3HUIRUPDQFH
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against possible damage or injury that might occur in an earthquake if the unit is not installed correctly,
injuries may occur due to a falling unit.
ƔUse appropriate Personal Protective Equipment (PPE), such as gloves and protective goggles and,
where appropriate, have a gas mask nearby. Also use electrical protection equipment and tools suited
IRUHOHFWULFDORSHUDWLRQSXUSRVHV.HHSDTXHQFKLQJFORWKDQGD¿UHH[WLQJXLVKHUQHDUE\GXULQJEUD]LQJ
Use care in handling, rigging, and setting of bulky equipment.
ƔWhen transporting, be careful when picking up, moving and mounting these units. Although the unit may
be packed using plastic straps, do not use them for transporting the unit from one location to another. Do
not stand on or put any material on the unit. Get a partner to help, and bend with your knees when lifting
WRUHGXFHVWUDLQRQ\RXUEDFN6KDUSHGJHVRUWKLQDOXPLQXP¿QVRQWKHDLUFRQGLWLRQHUFDQFXW¿QJHUV
so wear protective gloves.
ƔDo not touch or adjust any safety devices inside the indoor or outdoor units. All safety features,
disengagement, and interlocks must be in place and functioning correctly before the equipment is put
into operation. If these devices are improperly adjusted or tampered with in any way, a serious accident
can occur. Never bypass or jump-out any safety device or switch.
ƔJohnson Controls will not assume any liability for injuries or damage caused by not following steps
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prohibited as they…
ƕMay create hazards which could result in death, serious injury or equipment damage;
ƕWill void product warranties;
ƕ 0D\LQYDOLGDWHSURGXFWUHJXODWRU\FHUWL¿FDWLRQV
ƕMay violate OSHA standards;

1-4 Service Manual
INSTALLATION
Take the following precautions to reduce the risk of property damage.
ƔBe careful that moisture, dust, or variant refrigerant compounds not enter the refrigerant cycle during
installation work. Foreign matter could damage internal components or cause blockages.
Ɣ ,IDLU¿OWHUVDUHUHTXLUHGRQWKLVXQLWGRQRWRSHUDWHWKHXQLWZLWKRXWWKHDLU¿OWHUVHWLQSODFH,IWKHDLU
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ƔDo not install this unit in any place where silicon gases can coalesce. If the silicon gas molecules
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could run inside of the electrical box, possibly causing electrical failures.
ƔWhen installing the unit in a hospital or other facility where electromagnetic waves are generated
from nearby medical and/or electronic devices, be prepared for noise and electronic interference
Electromagnetic Interference (EMI). Do not install where the waves can directly radiate into the
electrical box, controller cable, or controller. Inverters, appliances, high-frequency medical equipment,
and radio communications equipment may cause the unit to malfunction. The operation of the unit
may also adversely affect these same devices. Install the unit at least 10 ft. (approximately 3m) away
from such devices.
ƔWhen a wireless controller is used, locate at a distance of at least 3.3 ft. (approximately 1 meter)
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receiving operation commands.
ƔDo not install the unit in any location where animals and plants can come into direct contact with the
outlet air stream. Exposure could adversely affect the animals and plants.
ƔDo not install the unit with any downward slope to the side of the drain adaptor. If you do, you may
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ƔBe sure the drain hose discharges water properly. If connected incorrectly, it may cause leaks.
ƔDo not install the unit in any place where oil can seep onto the units, such as table or seating areas in
restaurants, and so forth. For these locations or social venues, use specialized units with oil-resistant
features built into them. In addition, use a specialized ceiling fan designed for restaurant use. These
specialized oil-resistant units can be ordered for such applications. However, in places where large
quantities of oil can splash onto the unit, such as a factory, even the specialized units cannot be used.
These products should not be installed in such locations.
Installation Precautions
To reduce the risk of serious injury or death, the following installation
precautions must be followed.
ƔWhen installing the unit into…
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construct a strong wood or metal frame to provide added support.
ƓA room: Properly insulate any refrigerant tubing run inside a room to prevent “sweating” that can
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ƓDamp or uneven areas: Use a raised concrete pad or concrete blocks to provide a solid, level
foundation for the unit to prevent water damage and abnormal vibration.
ƓAn area with high winds: Securely anchor the outdoor unit down with bolts and a metal frame.
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ƓA snowy area: Install the outdoor unit on a raised platform that is higher than drifting snow. Provide
snow vents.
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corrosion, or product failure.
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above a kitchen stove.
ƓWhere oil (including machinery oil) may be present.
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tub or hot spring.
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ƓWhere the air quality is of high acidity.
ƓWhere harmful gases can be generated from decomposition.