Panasonic 2WAY Multi Series Operating manual

Applicable Models : 2WAY Multi
: 2WAY W Multi
: 3WAY Multi
Reference No. SM7110040-01
TECHNICAL & SERVICE MANUAL
TROUBLESHOOTING
Gas Heat Pump Air Conditioner
July 2012

Applicable models
< 2WAY MULTI / W MULTI >
U-16GE2E5
U-16GEP2E5
U-20GE2E5
U-20GEP2E5
U-25GE2E5
U-25GEP2E5
U-30GE2E5
< 3WAY MULTI >
U-16GF2E5
U-20GF2E5
U-25GF2E5
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Table of Contents
1. Symptoms that are not malfunctions....................................................................... I–1
2. Before troubleshooting (W MULTI series) .............................................................. II–1
(1) W MULTI series system overview ................................................................... II–1
(2) About backup operation during maintenance work ..................................... II–2
3. Malfunctions and Displays...................................................................................... III–1
(1) Malfunctions without any display.................................................................. III–1
(2) Remote Controller alarm display ................................................................... III–2
4. Error Display and Troubleshooting ........................................................................ IV–1
(1) Precautions before Troubleshooting............................................................. IV–1
(2) About the Error Detection Procedure............................................................ IV–1
(3) Engine Start Standby ...................................................................................... IV–1
(4) Troubleshooting .............................................................................................. IV–2
A01 Engine Oil Pressure Error..........................................................................................IV–2
A02 Engine Oil Error........................................................................................................ IV–4
A03 Engine High-Revolution Error................................................................................... IV–5
A04 Engine Low-Revolution Error.................................................................................... IV–6
A05 Ignition Source Error .................................................................................................IV–7
A06 Engine Start Failure.................................................................................................. IV–9
A07 Fuel Gas Valve Error ............................................................................................... IV–11
A08 Engine Stall .............................................................................................................IV–12
A10 Exhaust Gas Temperature High ..............................................................................IV–13
A14 Engine Oil Pressure Switch Error............................................................................IV–14
A15 Starter Power Source Output Short Circuit .............................................................IV–15
A16 Starter Lock.............................................................................................................IV–16
A17 CT Error (Starter Current Detection Failure)............................................................IV–17
A19 Low Coolant Temperature .......................................................................................IV–18
A20 High Coolant Temperature ......................................................................................IV–19
A21 Coolant Level Error..................................................................................................IV–21
A22 Coolant Pump Error.................................................................................................IV–23
A23 Crankshaft Angle Sensor Error ...............................................................................IV–24
A24 Camshaft Angle Sensor Error .................................................................................IV–24
A25 Clutch Error .............................................................................................................IV–25
A26 Flameout Error ........................................................................................................IV–26
A27 Catalyst Temperature Error (for only models with catalyst option) ..........................IV–27
A28 Generator Error (for only High Power Multi) ............................................................IV–28
A29 Converter Error (for only High Power Multi).............................................................IV–29
E01 Remote Controller Receive Failure......................................................................... IV–30
E02 Remote Controller Transmission Failure ................................................................ IV–33
E03 Indoor Unit Receive Failure from Remote Controller (Central) ............................... IV–34
E04 Indoor Unit Receive Failure from Outdoor Unit........................................................IV–37
E05 Indoor Unit Transmission Failure to Outdoor Unit................................................... IV–40
E06 Outdoor Unit Receive Failure from Indoor Unit........................................................IV–41
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E07 Outdoor Unit Transmission Failure to Indoor Unit................................................... IV–44
E08 Duplicated Indoor Unit Address Setting ................................................................. IV–45
E09 Multiple Main Remote Controller Units Set............................................................. IV–46
E11 Indoor Unit Receive Failure from Signal Output Board (*)...................................... IV–47
E12 Automatic Address Setting Is in Progress
: Automatic Address Setting Start is Prohibited (*)................. IV–48
E13 Indoor Unit Transmission Failure to Remote controller........................................... IV–49
E15 Automatic Address Alarm (Too Few Units)............................................................. IV–50
E16 Automatic Address Alarm (Too Many Units)........................................................... IV–52
E18 Group Control Wiring Communication Failure (*) ................................................... IV–53
E20 No Indoor Unit in Automatic Address Setting (*) .................................................... IV–54
E24 Communication Failure between Outdoor Units (for only W MULTI)...................... IV–55
E26 Inconsistencies in Number of Outdoor Units (for only W MULTI) ........................... IV–56
E31 Communication Failure between Units................................................................... IV–57
F01·02·03·10·11 Indoor Unit Temperature Sensor Error................................................ IV–58
F04·06·08·12·13·17·18/H08 Outdoor Unit Temperature Sensor Error............................ IV–60
F16 Compressor Inlet/Outlet Pressure Sensor Error..................................................... IV–61
F20 Clutch Coil Temperature Sensor Error ................................................................... IV–62
F29 Indoor Nonvolatile Memory (EEPROM) Error......................................................... IV–63
F30 Real Time Clock (RTC) Function Error................................................................... IV–64
F31 Outdoor Nonvolatile Memory (EEPROM) Error...................................................... IV–65
H07 Compressor Oil Depletion Error (for only W MULTI) .............................................. IV–66
L02 Inconsistencise in Indoor/Outdoor Unit Models
(non-GHP equipment connected) ............. IV–67
L03 Multiple Main Units Set for Group Control (*) ......................................................... IV–68
L04 Duplicate System (Outdoor Unit) Address Setting.................................................. IV–69
L05·06 Duplicate Indoor Unit Priority Setting (*)............................................................IV–70
L07 Group Control Wire Present for Individual-Control Indoor Unit (*)...........................IV–71
L08 Indoor Unit Address Not Set....................................................................................IV–72
L09 Indoor Unit Capacity Not Set (*) ..............................................................................IV–73
L10 Outdoor Unit Capacity Not Set ................................................................................IV–74
L13 Indoor Unit Model Type Setting Failure ...................................................................IV–75
L15 Defective Pairing of Indoor Units.............................................................................IV–76
L16 Faulty Water Heat Exchanger Unit Settings ............................................................IV–77
L19 Duplicated Water Heat Exchanger Unit Parallel Array Addresses ..........................IV–79
L21 Gas Type Setting Failure ........................................................................................ IV–80
P01 Indoor Fan Error/Indoor Unit Fan rpm Error (*)....................................................... IV–81
P03 High Compressor Discharge Temperature ............................................................. IV–82
P04 Refrigerant High-Pressure Switch Operation ......................................................... IV–84
P05 Power Source Error................................................................................................ IV–85
P09 Indoor Unit Ceiling Panel Connector Connection Failure (*)................................... IV–86
P10 Indoor Unit Float Switch Operation (*).................................................................... IV–87
(*) Cannot be detected when the water heat exchanger unit is connected.
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P11 Water Heat Exchanger Unit Anti-icing Sensor Error
(for only water heat exchanger unit).......................................................... IV–88
P12 Indoor DC Fan Error (DC fan motor model only) .................................................... IV–89
P13 Refrigerant circuit Error (W MULTI). ....................................................................... IV–90
P13 Refrigerant Circuit Error (3WAY) ............................................................................ IV–91
P15 Complete Refrigerant Gas Depletion...................................................................... IV–93
P18 Bypass Valve Error................................................................................................. IV–94
P19 Four-way Valve Lock Error (not detected 3WAY MULTI) ........................................ IV–95
P20 Refrigerant High-Pressure Error............................................................................. IV–96
P22 Outdoor Unit Fan Error..........................................................................................IV–101
P23 Water Heat Exchanger Unit Interlock Error (for only water heat exchanger unit) ..IV–102
P26 Clutch Connection Error ........................................................................................IV–103
P30 Group Control’s Sub Unit Error (* warning displayed only on system controller)...IV–104
P31 Group Control Error (*) ..........................................................................................IV–105
oiL Oil Change Time Alarm .........................................................................................IV–106
5. Reference Document ................................................................................................ V–1
(1) Outdoor Main Board Replacement Sequence and
Remote Controller Service Function.................... V–1
(2) Switch and LED ................................................................................................ V–3
(3) Display Component Specifications ................................................................ V–5
(4) Operation Unit Specifications .........................................................................V–6
(5) Normal Display (Level 0) .................................................................................. V–7
(6) Menu Display .................................................................................................... V–9
(8) Ignition Timing Check and Adjustment........................................................V–43
(9) Thermistor characteristic graph ................................................................... V–51
(10) Checks Prior to Automatic Addressing........................................................ V–53
(11) Indoor/outdoor control wire connection confirmation ...............................V–54
6. Outdoor Unit Electrical Wiring Diagram ................................................................ VI–1
(1) Outdoor main board........................................................................................VI–2
(2) Outdoor power board......................................................................................VI–3
(3) Converter board...............................................................................................VI–4
(4) Indoor control board for DC motor models ..................................................VI–5
(5) Outdoor Unit Electrical Wiring Diagram........................................................VI–6
(*) Cannot be detected when the water heat exchanger unit is connected.
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I–1
1. Symptoms that are not malfunctions
The following symptoms are characteristic operating conditions of this system and do not indicate malfunctions:
The fan flaps on the indoor unit operate when the unit is stopped
If the compressor outlet pressure exceeds 3.5 MPa during heating operation, the flaps on the stopped unit move to
horizontal and the fan rotates in the breeze.
When this happens, it may indicate a clogged air filter.
Inspect and clean if necessary.
Refrigerant noise is occasionally heard from the stopped indoor unit
During cooling operation of the outdoor unit, if the indoor unit is stopped for a period of time that equals the total
oil recovery time period while cooling (four hours), refrigerant will circulate in the stopped unit for four minutes,
so that refrigerant and oil can be recovered.
During heating operation of the outdoor unit, refrigerant will also flow in the stopped indoor unit, allowing
recovery of refrigerant and oil.
The fan in the outdoor unit rotates slowly
The outdoor unit fan can be completely stopped or rotated at various speeds by the control system, and will be fast
or slow as required. The fan is especially likely to stop or run slowly during cooling or heating operation when
outside temperatures are low.
During winter, the outdoor unit fan may rotate even when the engine is stopped.
The unit will not switch from cooling (dry) to heating, or from heating to cooling (dry)
• If “Being controlled by operation mode” is displayed
(When already being operated by another remote controller, the selectable operation modes are limited.)
When the following are displayed on the remote controller:
• If “Being controlled by operation mode” is displayed
(When already being operated by another remote controller, the selectable operation modes are limited.)
• If “Operation standby” is displayed
(In priority operation standby)
• If “Central control in progress” is displayed
(Operation is limited by the central control unit.)
• A display appears but then vanishes
(“Valve open” or “water circulation” has been set with the outdoor main board menu item No. 4, test operation
forced setting.)
When the engine is started, an alarm displays on the 7 segment LED display.
Engine start standby is displayed during menu item No. 0, normal display.
If the unit is in start standby and each start condition is not accomplished when the engine is started, the
uncompleted start condition is displayed on the 7 segment LED. There are 5 types of start conditions, some that
start automatically after a set time, and some that become abnormal.
* See IV -1 4.-(3) for a list of startup conditions.
The outdoor unit does not operate at all
• The temperature controller is operating (thermo-off).
Cooling is poor/heating is poor
• Is the temperature controller (remote controller temperature) properly set?
Is there too much load on the air conditioner?
• During demand control, because the unit operates at below the set fuel gas flow control value, cooling may be
slightly bad (heating may be slightly bad).
“Inspect oil” flashes on the remote controller.
When the operating hours for the gas engine reach a designated time, “Inspect oil” flashes.
Change the engine oil.
If the engine oil is not changed within 200 operating hours after flashing, warning A02 will be displayed and
operation will stop.
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II–1
2. Before troubleshooting (W MULTI series)
(1) W MULTI series system overview
W MULTI series is a system that can join up to two outdoor units to the same refrigerant tube, and control each
outdoor unit while performing air conditioning according to the operation load of the indoor unit.
Figure 1 gives an overview of the system.
In the example, the W MULTI series (refrigerant system 1) connecting to two outdoor units and 3WAY MULTI
(refrigerant system 2) are linkwired by using an operation cable for the indoor - outdoor units.
(This is an example of a dual system consisting of two refrigerant systems.)
Refrigerant System 1
Indoor/outdoor control wire
Indoor unit
1-1
Indoor unit
1-2
Indoor unit
1-48
Indoor unit
2-1
Indoor unit
2-2
Remote controller
Refrigerant tubing (main tubing)
Refrigerant
tubing
(Indoor branch
tubing)
Refrigerant tubing (Outdoor branch tubing)*1
W MULTI
outdoor unit
1
Refrigerant System 2
3WAY MULTI
outdoor unit
1
Indoor/outdoor control wire
Fig. 1 GHP System Configuration Example
Indoor/outdoor control wire
Remote controller
Remote controller
Remote controller Remote controller
Refrigerant tubing (main tubing)
W MULTI
outdoor unit
2
Refrigerant tubing
(Indoor branch tubing)
*1Refrigerant tube
Figure 1 is a simplified diagram. Actually, two refrigerant tubes consisting of a gas tube (thick tube) and a liquid
tube (thin tube) are used. Each W Multi outdoor unit is connected to an outdoor branch tube, and then connected
to the main tube. For the indoor unit, the refrigerant tubes branched from the main tube are connected to the gas
tube and liquid tube of each indoor unit.
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II–2
(2)About backup operation during maintenance work
●What is backup operation?
In the W MULTI series, multiple outdoor units are connected to the same refrigerant tube as shown in Figure 1.
Therefore, even during maintenance work of an outdoor unit, the other outdoor unit not required in maintenance
work can be used to keep the indoor operating conditions. This is called a backup operation.
●Backup operation procedure
To perform backup operation, the outdoor unit for maintenance work (hereafter referred to as “target outdoor
unit”) must be cut off from the system using the following procedure. Review content of the maintenance work
and then select the most suitable method.
Also, after the maintenance work is finished, always refer to [System recovery procedure] and then return the
system to its normal state.
[Backup operation procedure]
To turn off power of target outdoor unit and then perform maintenance work (basic operation during inspection
of outdoor unit)
<<Important>>
This is the basic operation performed during inspection work. If this operation is not performed and the power
of the outdoor unit is turned off, this will cause system fault and prevent backup operation to be carried out,
and serious malfunction will occur. If this happens, see [System recovery procedure] to recover the system, and
then once again use the following procedure to perform setup. Automatic backup operation will kick in.
<<Step 1>>
On the outdoor main board of the target outdoor unit,
set the STOP switch (S001) to “STOP”. *1
<<Step 2>>
(After confirming that the engine of the target outdoor
unit is stopped) close the valves of refrigerant gas tube,
refrigerant gas liquid tube, and balance tube.
<<Step 3>>
On the outdoor main board of the target outdoor unit,
set the STOP switch (S001) to “STOP”. Wait for three
minutes or more and then turn off the circuit breaker of
the target outdoor unit. *2
Start maintenance work.
*1) Sometimes all outdoor units may stop. If there is operation input, outdoor units other than the target one will
start operation again after approximately five minutes. (For details on the settings, see the next item.)
*2) Always carry out the following three tasks.
Check to make sure <<Step 2>> is finished. If the shutoff valve is opened, refrigerant will flow from the
other outdoor unit to the target outdoor unit, causing serious malfunction.
After three minutes has elapsed from completion of <<Step 1>>, check to make sure the outdoor main
board displays “ ” and then perform this operation. If you turn off the power immediately
after performing “STOP” setting, the entire system will stop. (Backup operation cannot be performed.) If
this happens, see [System recovery procedure], recover the system, and then start over again starting from
<<Step 1>>.
There will not be any problem whether the circuit breaker of the outdoor unit in <<Step 3>> is ON or OFF.
Select one of them according to the work required.
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II–3
[Work example] Perform maintenance on W MULTI outdoor unit 2 in refrigerant system 1 in Figure 1.
a) For the W MULTI outdoor unit 2 indicated in the left diagram, perform
<<Step 1>> to <<Step 3>> in [Backup operation procedure] in that order.
Then, perform maintenance work on W MULTI outdoor unit 2.
b) When <<Step 3>> is finished, W MULTI outdoor unit 1 is reset. It’ll stop
even if it is operating.)
c) After approximately five minutes, if there is operation input (indoor
remote controller is “Run” or test run setting on outdoor main board), W
Multi outdoor unit 1 starts up. (Backup operation starts.)
d) If test run is set from outdoor main board, W MULTI outdoor unit 1
continues to run. However, if normal operation is started by the indoor
remote controller, depending on the load, all outdoor units may stop due
to thermostat off.
[System recovery procedure]
If backup operation has been performed, by all means check the following items after the maintenance work,
and then perform settings again to return the system to its normal state.
Check to make sure all shutoff valves of refrigerant gas tube, refrigerant liquid tube, and balance tube of the
outdoor unit are opened.
Check to make sure the STOP switch (S001) on the outdoor main board is set to “NORM”.
If the power of the outdoor unit has been turned off, turn on the circuit breaker.
If “Test run” (No.4 Test- Cool/Heat) is set, cancel it.
* When adjusting to No.4 Test-Cool or Heat, if TEST/WARNING LED (D052) lights, this means “Test run” is
being set. In this state, press the SET (S007) key for one second or more. The setting will be canceled (TEST/
WARNING LED (D052) goes off.)
Refrigerant System 1
Refrigerant tubing
(main tubing)
Refrigerant tubing(Outdoor
branch tubing)
W MULTI
outdoor unit
1
Indoor/outdoor operation wiring
<Procedure 1>
<Procedure 2>
<Procedure 3>
W MULTI
outdoor unit
2
Refrigerant System 1
Refrigerant tubing
(main tubing)
Refrigerant tubing(Outdoor
branch tubing)
W MULTI
outdoor unit
1
Indoor/outdoor operation wiring
<Procedure 1>
<Procedure 2>
<Procedure 3>
W MULTI
outdoor unit
2
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III–1
3. Malfunctions and Displays
(1) Malfunctions without any display
The circuit breaker trips when power is turned on
●Short circuit or ground fault of the crankcase heater, current leakage in electrical parts
Circuit breaker trips when operated
●Current leakage or short circuit in fan or coolant pump, current leakage or short circuit in electrical parts
Poor cooling
1) Problem in refrigeration circuit
●Clog in refrigeration circuit, faulty 4-way valve, faulty electric valve in indoor/outdoor unit, compression
failure, or shortage of refrigerant.
●Shutoff valve not completely open
2) Small fan capacity
●Clogged air filter, foreign matter in air inlet, outlet
3) Other
●Insufficient refrigerant tubing insulation
Poor heating
1) Problem in refrigeration circuit
●Clog in refrigeration circuit, faulty 4-way valve, faulty electric valve in indoor/outdoor unit, compression
failure, or shortage of refrigerant.
●Shutoff valve not completely open
2) Other
●Insufficient refrigerant tubing insulation
Heating on standby does not clear
●Warm air is striking the room temperature sensor, temperature around room temperature sensor is high,
faulty indoor control board
Auto-flap does not move well
1) The flaps swing, but wind direction cannot be set
●Auto-flap limit switch is faulty or has a bad connection
2) Does not move (swing, air direction setting)
●Auto-flap is faulty, indoor control board is failed, remote controller is faulty
Loud operation noise or vibration noise
1) Noise or vibration when fan operates
●Fan is unbalanced, worn motor axis bearing, loose fan securing screw
2) Loud operation noise or vibration noise when compressor operates
●Something is coming into contact with the refrigerant tubing or compressor
Water leakage
1) Drain water leakage
●Clogged drain tube, mistake in draintube construction, insufficient draintube insulation
2) Condensation on refrigerant tubing
●Insufficient tubing insulation
3) Condensation at duct outlet
●Insufficient wind capacity, gap between duct connections
Does not stop
●Fused magnetic contactors, faulty indoor/outdoor control board, faulty remote controller
No display on the remote controller
●Remote controller wiring disconnected
●Remote controller wiring shorted
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