Transcript
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2004
SPLIT-TYPE, HEAT PUMP AIR CONDITIONERS
No. OC309
TECHNICAL & SERVICE MANUAL Series PKFY Wall Mounted Indoor unit [Model names]
R410A
R407C
R22
[Service Ref.]
PKFY-P20VAM-E PKFY-P25VAM-E
PKFY-P20VAM-E PKFY-P25VAM-E
CONTENTS
INDOOR UNIT
1. SAFETY PRECAUTION ·····················2 2. PART NAMES AND FUNCTIONS······6 3. SPECIFICATION·································8 4. OUTLINES AND DIMENSIONS ·······10 5. WIRING DIAGRAM···························11 6. REFRIGERANT SYSTEM DIAGRAM···12 7. TROUBLESHOOTING······················12 8. DISASSEMBLY PROCEDURE·········19 9. PARTS LIST ·····································22
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SAFETY PRECAUTION
CAUTIONS RELATED TO NEW REFRIGERANT Cautions for units utilizing refrigerant R407C
Do not use the existing refrigerant piping.
Use liquid refrigerant to seal the system.
The old refrigerant and lubricant in the existing piping contains a large amount of chlorine which may cause the lubricant deterioration of the new unit.
If gas refrigerant is used to seal the system, the composition of the refrigerant in the cylinder will change and performance may drop.
Use “low residual oil piping”
Do not use a refrigerant other than R407C.
If there is a large amount of residual oil (hydraulic oil, etc.) inside the piping and joints, deterioration of the lubricant will result.
If another refrigerant (R22, etc.) is used, the chlorine in the refrigerant may cause the lubricant deterioration.
Store the piping to be used during installation indoors with keep both ends sealed until just before brazing. (Store elbows and other joints in a plastic bag.) If dust, dirt, or water enters the refrigerant cycle, deterioration of the oil and compressor trouble may result.
Use a vacuum pump with a reverse flow check valve. The vacuum pump oil may flow back into the refrigerant cycle and cause the lubricant deterioration.
Ventilate the room if refrigerant leaks during operation. If refrigerant comes into contact with a flame, poisonous gases will be released.
Use ESTR , ETHER or HAB as the lubricant to coat flares and flange connection parts. If large amount of mineral oil enter, that can cause deterioration of refrigerant oil etc.
[1] Cautions for service ·After recovering the all refrigerant in the unit, proceed to working. ·Do not release refrigerant in the air. ·After completing the repair service, recharge the cycle with the specified amount of liquid refrigerant.
[2] Refrigerant recharging (1) Refrigerant recharging process 1Direct charging from the cylinder. ·R407C cylinder are available on the market has a syphon pipe. ·Leave the syphon pipe cylinder standing and recharge it. (By liquid refrigerant)
Unit
Gravimeter (2) Recharge in refrigerant leakage case ·After recovering the all refrigerant in the unit, proceed to working. ·Do not release the refrigerant in the air. ·After completing the repair service, recharge the cycle with the specified amount of liquid refrigerant.
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[3] Service tools Use the below service tools as exclusive tools for R407C refrigerant. No. 1
Tool name Gauge manifold
Specifications ·Only for R407C. ·Use the existing fitting SPECIFICATIONS. (UNF7/16) ·Use high-tension side pressure of 3.43MPa·G or over.
2
Charge hose
·Only for R407C. ·Use pressure performance of 5.10MPa·G or over.
3
Electronic scale
4
Gas leak detector
·Use the detector for R134a or R407C.
5
Adapter for reverse flow check.
·Attach on vacuum pump.
6
Refrigerant charge base.
7
Refrigerant cylinder.
·For R407C
·Top of cylinder (Brown)
·Cylinder with syphon 8
Refrigerant recovery equipment.
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Cautions for units utilizing refrigerant R410A
Do not use the existing refrigerant piping.
Use a vacuum pump with a reverse flow check valve.
The old refrigerant and lubricant in the existing piping contains a large amount of chlorine which may cause the lubricant deterioration of the new unit.
Vacuum pump oil may flow back into refrigerant cycle and that can cause deterioration of refrigerant oil etc.
Use “low residual oil piping”
Use the following tools specifically designed for use with R410A refrigerant. The following tools are necessary to use R410A refrigerant.
If there is a large amount of residual oil (hydraulic oil, etc.) inside the piping and joints, deterioration of the lubricant will result.
Gauge manifold Charge hose Gas leak detector Torque wrench
Store the piping to be used during installation indoors and keep both ends of the piping sealed until just before brazing. (Leave elbow joints, etc. in their packaging.) If dirt, dust or moisture enter into refrigerant cycle, that can cause deterioration of refrigerant oil or malfunction of compressor.
Tools for R410A Flare tool Size adjustment gauge Vacuum pump adaptor Electronic refrigerant charging scale
Keep the tools with care. If dirt, dust or moisture enter into refrigerant cycle, that can cause deterioration of refrigerant oil or malfunction of compressor.
Use ester oil, ether oil or alkylbenzene oil (small amount) as the refrigerant oil applied to flares and flange connections.
Do not use a charging cylinder.
If large amount of mineral oil enter, that can cause deterioration of refrigerant oil etc.
If a charging cylinder is used, the composition of refrigerant will change and the efficiency will be lowered.
Charge refrigerant from liquid phase of gas cylinder. If the refrigerant is charged from gas phase, composition change may occur in refrigerant and the efficiency will be lowered.
Ventilate the room if refrigerant leaks during operation. If refrigerant comes into contact with a flame, poisonous gases will be released.
Do not use refrigerant other than R410A. If other refrigerant (R22 etc.) is used, chlorine in refrigerant can cause deterioration of refrigerant oil etc.
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[1] Cautions for service (1) Perform service after collecting the refrigerant left in unit completely. (2) Do not release refrigerant in the air. (3) After completing service, charge the cycle with specified amount of refrigerant. (4) When performing service, install a filter drier simultaneously. Be sure to use a filter drier for new refrigerant.
[2] Additional refrigerant charge When charging directly from cylinder · Check that cylinder for R410A on the market is syphon type. · Charging should be performed with the cylinder of syphon stood vertically. (Refrigerant is charged from liquid phase.)
Unit
Gravimeter
[3] Service tools Use the below service tools as exclusive tools for R410A refrigerant. No. 1
Specifications Gauge manifold
·Only for R410A ·Use the existing fitting specifications. (UNF1/2) ·Use high-tension side pressure of 5.3MPa·G or over.
2
Charge hose
·Only for R410A ·Use pressure performance of 5.09MPa·G or over.
3
Electronic scale
4
Gas leak detector
·Use the detector for R134a, R407C or R410A.
5
Adaptor for reverse flow check
·Attach on vacuum pump.
6
Refrigerant charge base
7
Refrigerant cylinder
8
Refrigerant recovery equipment
·Only for R410A
Top of cylinder (Pink) Cylinder with syphon
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PART NAMES AND FUNCTIONS
● Indoor Unit
PKFY-P20VAM-E PKFY-P25VAM-E Air intake
Air intake grille
Filter
Auto Vane Guide vane
Air Outlet
● MA remote controller [PAR-20MAA] ● Once the operation of the unit is set, subsequent operations can only be performed by pressing the ON/OFF button repeatedly. ● Operation buttons
TEMP. ADJUSTMENT button This sets the room temperature. The temperature setting can be performed in 1: units Setting range Cooler 19: to 30: Heater 17: to 28:
TIME SETTING button
AIR SPEED button
This sets the current time, start time and stop time.
This sets the ventilation fan speed.
ON/OFF button This switches between the operation and stop modes each time it is pressed. The lamp on this button lights during operation.
TIMER button
1Hr.
CENTRALLY CONTROLLED ON
This switches between continuous operation and the timer operation.
OFF
˚C
CLOCK
CHECK
˚C STAND BY DEFROST
ERROR CODE
NOT AVAILABLE
TEMP.
FILTER CHECK MODE TEST RUN FUNCTION
ON/OFF
AIR DIRECTION button This adjusts the vertical angle of the ventilation.
FILTER
OPERATION SWITCH button Press this button to switch the cooler, electronic dry (dehumidify), automatic and heater modes.
CHECK TEST
PAR-20MAA
FILTER button
TIMER SET
This resets the filter service indication display
LOUVER button
CHECK-TEST RUN button
This switch the horizontal fan motion ON and OFF.
Only press this button to perform an inspection check or test operation. Do not use it for normal operation.
(Not available for this model.)
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● Display CENTRALLY CONTROLLED display This indicates when the unit is controlled by optional features such as central control type remote controller.
In this display example on the bottom left, a condition where all display lamps light is shown for explanation purposes although this differs from actual operation.
CLOCK display The current time , start time and stop time can be displayed in ten second intervals by pressing the time switch button. The start time or stop time is always displayed during the timer operation.
AIR DIRECTION display TIMER display
This displays the air direction.
This indicates when the continuous operation and time operation modes are set. It also display the time for the timer operation at the same time as when it is set.
AIR SPEED display The selected fan speed is displayed.
ROOM TEMPERATURE 1Hr.
CENTRALLY CONTROLLED
OPERATION MODE display This indicates the operation mode.
ON
OFF
˚C
CLOCK
CHECK
˚C STAND BY DEFROST
ERROR CODE
TEMP.
NOT AVAILABLE
FILTER CHECK MODE TEST RUN FUNCTION
ON/OFF
display
The temperature of the suction air is displayed during operation. The display range is 8°C to 39°C. The display flashes 8°C when the actual temperature is less than 8°C and flashes 39°C when the actual temperature is greater than 39°C.
FILTER
STANDBY display The [STANDBY] symbol is only displayed from the time the heating operation starts unit the heated air begins to blow.
CHECK TEST
PAR-20MAA
TIMER SET
Operation lamp This lamp lights during operation, goes off when the unit stops and flashes when a malfunction occurs.
CHECK MODE TEST RUN
DEFROST display
display
This display lights in the check mode or when a test operation is performed.
This indicates when the defrost operation is performed.
FILTER display This lamp lights when the filter need to be cleaned.
CHECK display This indicates when a malfunction has occurred in the unit which should be checked.
SET TEMPERATURE display
POWER display
This displays the selected setting temperature.
This lamp lights when electricity is supplied to the unit.
Caution ● Only the Power display lights when the unit is stopped but power is supplied to the unit. ● When the central control remote control unit, which is sold separately, is used the ON-OFF button, operation switch button and TEMP. adjustment button do not operate. ● “NOT AVAILABLE” is displayed when the Air speed button are pressed.This indicates that this room unit is not equipped with the fan direction adjustment function and the louver function. ● When power is turned ON for the first time, it is normal that “H0” is displayed on the room temperature indication (For max. 2minutes). Please wait until this “H0” indication disappear then start the operation.
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SPECIFICATION
3-1. Specification Item
Unit [,V,Hz
Power
PKFY-P20VAM-E PKFY-P25VAM-E Single phase, 220-230-240V, 50Hz Single phase, 220V, 60Hz
Cooling capacity
kW
2.2
2.8
Heating capacity
kW
2.5
3.2
kW
0.04
Heating
kW
0.04
Cooling
A
0.20
Heating
A
0.20
—
Plastic munsell : <2.60Y 8.66/0.69>
Height
mm
295
Width
mm
815
Depth
mm
158
—
Cross fin
Fan ✕ No.
—
Lineflow fan ✕ 1
Air flow w 2
K/min
5.9-5.6-5.2-4.9
External static pressure
Pa
0
Fan motor output
kW
0.017
Insulator
—
Polyethylene sheet
Air filter
—
PP honey comb
Electric
characteristic
Cooling Power Supply
Starting Current
Exterior
Out dimensions
Heat exchanger
Fan
Pipe dimensions
Gas side [mm(in.)
12.7 (1/2")
Liquid side [mm(in.)
6.35 (1/4")
[mm
PVC pipe VP-16 connectable (I.D. 16)
Noise level w 2
dB
36-35-33-32
Product weight
kg
8.5
Unit drain pipe size
Note 1. Rating conditions (JIS B 8615-1) Cooling : Indoor D.B. 27°C W.B. 19°C Outdoor D.B. 35°C Heating : Indoor D.B. 20°C Outdoor D.B. 7°C W.B. 6°C w 2. Air flow and the noise level are indicated as High – Middium1 – Middium2 – Low.
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3-2. Electrical parts specifications Model Symbol
PKFY-P20VAM-E
PKFY-P25VAM-E
Parts name Room temperature thermistor
TH21
Resistance 0:/15k", 10:/9.6k", 20:/6.3k", 25:/5.4k", 30:/4.3k", 40:/3.0k"
Liquid pipe thermistor
TH22
Resistance 0:/15k", 10:/9.6k", 20:/6.3k", 25:/5.4k", 30:/4.3k", 40:/3.0k"
Gas pipe thermistor
TH23
Resistance 0:/15k", 10:/9.6k", 20:/6.3k", 25:/5.4k", 30:/4.3k", 40:/3.0k"
Fuse (Indoor controller board)
FUSE
250V 6.3A
Fan motor (with thermal fuse)
MF
4-Pole Output 17W / RC4V17
Fan motor capacitor
C1
1.5µF ✕ 440V
Vane motor (with limit switch)
MV
MSFBC20A76 DC12V
Linear expansion valve
LEV
DC12V Stepping motor drive Port [3.2 (0~2000pulse)
Power supply terminal block
TB2
(L, N, ;) 250V 20A
Transmission terminal block
TB5
(M1, M2) 250V 10A
9
3
24.4
5
5 R1
R8
45
295
Knock out hole for the remote controller wiring
Knock out hole for under piping
Knock out hole for left - hand side piping
45
16
R8
B
91.5
2.5
10
C
54
R1
2.5
10
R8
34
A
B
146
150
116
110
60
25.5 Air intake dimension
D
Primary
Secondary
D
Air intake
260
190 159 155 120 205 175 170
225
328 328
295
Installation plate
235
3 Address board is protected by the plastic cover. For the setting, remark 1-screw using the screw driver.
Dip switch
Lotary switch(self address)
Lotary switch(part No.)
Terminal block
Address board
A
5
85
0
12- 2.8
10 0 10
100 or more
4- 9
155
180 190
170 175 205
87- 5.1
225 235
120
85
130 or more
35 10 0 27.5 40 53 65 87 113 128
135 125 110
168
pipe hole 65
4-4.5✕37 4-4.5✕40
407.5
Gas pipe
Connection inner dimension [16
Flare connection 1/2F
Liquid pipe Flare connection 1/4F
Drain pipe
Refrigerant pipe
Note1. For the installation, be sure to leave some space in case there is fringe at edge of the ceiling. Note2. Use the M10 or W3/8 bolt for the installation plate. Note3. Refer for the specification table it below .
Unit transplant parts
Installation space
Knock out hole
260
Position detail of the tapping screw and bats at pipe intake 4-11✕20 Center of gravity hole for installation
8- 4.3
: There is no terminal board for MA remote controller. : In case of connecting MA remote controller, use the cable with the connector attached to the indoor unit. Please connect the cable with the connector with the lead wire and connector (Relay connector) for the MA remote controller of indoor controller board.
Terminal block for transmission
Terminal block for power supply
Detail of address board
Air outlet dimension
70.3
158
407.5
4-4.5✕35
90 102.5 124
159 133 122.5 97.5 85 72.5 60 47.5 22.5 0 15
Installation plate
80
Air outlet direction
Air outlet angle
Terminal block for transmission Address board
Terminal block for power supply
13 Detail of Terminal block
Knock out hole for the remote controller wiring
Knock out hole for right - hand side piping
450 Gas pipe 520 Liquid pipe
660 Drain pipe length
695 Air outlet dimension
60
247.5 Air intake dimension 13
815
630 Air intake dimension
21.5
Detail of knock out hole (A B C)
50
Air intake dimension
30 45 50 44
783
16
C
45 5
10
50
2
R1
4
10 17
2.5
37.4
30
20 or more
298 298
4
1 20 or more
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1 54 or more for left or left back piping
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OUTLINES AND DIMENSIONS
PKFY-P20VAM-E PKFY-P25VAM-E Unit : mm
R1 5
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WIRING DIAGRAM
PKFY-P20VAM-E PKFY-P25VAM-E Symbol TH23
Name Indoor controller board
Remote switch HA terminal-A Centrally control Remote indication Switch Capacity code Mode selection Thermistor Room temperature,detection (0:/15T,25:/5.4T) Pipe temperature,detection/liquid (0:/15T,25:/5.4T)
CN32
Connector
CN41 CN51 CN52 SW2 SW3 TH21 TH22
Symbol
Transmission Circuit board Address board block
Indoor power board
A.B
ZNR
Varistor
FUSE
Fuse (6.3A)
SW1 Switch SW5 SW11 SW12 SW14
F.C
Fan phase control
MF
Fan motor
C1
Capacitor(fan motor)
MV
Vane motor
LEV
Linear expansion valve
RED PNK BLU ORN YLW
Address setting 1st digit Address setting 2nd digit Connection No.
{
5
1 2 3 4 5
Mode selection Voltage selection
TO OUTDOOR UNIT TO MA-REMOTE BC CONTROLLER CONTROLLER M-NET REMOTE CONTROLLER DC8.7-13V DC24-30V
TH23 TH22 TH21 6
Name Power supply
Terminal
{
LEV
6 5 4 3 2 1
BRN RED BLU ORN YLW WHT
P.B
Name
Thermistor Pipe temperature,detection/Gas TB2 (0:/15T,25:/5.4T) TB5
M1 M2
MV
SW5 220V
(RED) ADDRESS CN43
240V SW1
0
0
3RD 2ND 1ST DIGIT DIGIT DIGIT
(WHT)
(GRN)
(RED)
LED2
(RED)
1 3
1 2
CN3A (BLU)
CN20 INTAKE (RED)
BLU RED
CND 1 3 (RED)
4 6
1 2 3
CN35P
C1
MICON BOARD
(BLU)
ZNR
5 CN53P 4 MICON 3 BOARD 2 1 (RED)
CN53M POWER BOARD 1 2 3 4 5 (RED)
SW2
See fig: w1
CN51 CN52 1 2 3 4 1 2 3 4 5 6 7 8 CENTRALLY REMOTE CN42 CN81 INDICATION ADDRESS ADDRESS CONTROL
8
FAN 1 1 2 CN2M (GRN) M-NET (BLU)
1 2 3 4 5
SW3
SW12 SW11
1 2 3 4 5
1 2 3 4 5 6 7 8 910 1 2 3 4
1 2 3 4 5 6 7 8 910
(RED) ADDRESS 8 7 CN82 6 5 SW14 4 0 3 2 1 CONNECTION NO.
4
0N 0FF
ON OFF
4 3 2 1
1 2
BLK
1 2
RED
1 2 3
WHT
1 2 3
CN32 CN34 CN29 CN21 HA REMOTE (GRN) GAS LIQUID CN41 SWITCH (BLK) (WHT) (WHT) (WHT) ORN
A.B
1 2 3 4
BLU
BLU
CN5V (BLU)
ORN
1 2 3 4 5
CN60 LEV (WHT)
CN35M POWER BOARD 1 2 3 (BLU)
F.C
LED1
P.B M.B
Note 1. At servicing for outdoor unit, always follow the wiring diagram of outdoor unit. 2. In case of connecting MA-remote controller, please connect MA remote controller cable in an accessorie to the connector 1 2 . (Remote controller wire is non-polar.) 3. In case of using M-NET, please connect to TB5. (Transmission line is non-polar.) : connecter. 4. Symbols used in wiring diagram above are, : terminal block, 5. The setting of the SW2 dip switches differs in the capacity. For the detail, refer to the fig: w1. 6. Please set the switch SW5 according to the power supply voltage. Set SW5 to 240V side when the power supply is 230 and 240 volts. When the power supply is 220 volts, set SW5 to 220V side. LED on indoor board for service Mark
Meaning
Function
Main power supply(Indoor unit:220-240V) power on lamp is lit Power supply for Power supply for MA-Remote controller LED2 MA-Remote controller on lamp is lit
Models
LED1 Main power supply
11
PKFY-P20VAM
SW2 ON OFF
Models PKFY-P25VAM
1234
TB2 L N
PULL BOX
TB5
1 2
MF
1 2 3 4 5 6
TO NEXT INDOOR UNIT
GRN/YLW
Legend Symbol M.B
SW2 ON OFF
1234
FUSE 250V 6.3A
FUSE (15A)
BREAKER (15A)
POWER SUPPLY ~/N 220-230-240V 50Hz ~/N 220V 60Hz
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REFRIGERANT SYSTEM DIAGRAM
PKFY-P20VAM-E PKFY-P25VAM-E
Gas pipe temperature thermistor TH23 Gas pipe
Strainer (#50mesh)
Flare
Liquid pipe temperature thermistor TH22 Liquid pipe Heat exchanger
Linear expansion valve Strainer (#100mesh)
Room temperature thermistor TH21
Models Item
7
PKFY-P20VAM-E PKFY-P25VAM-E
Gas pipe
{12.7 (1/2”)
Liquid pipe
{6.35 (1/4”)
TROUBLESHOOTING
7-1. How to check PKFY-P20VAM-E PKFY-P25VAM-E Parts name
Check points
Room temperature thermistor (TH21) Liquid pipe temperature thermistor (TH22) Gas pipe temperature thermistor (TH23)
Vane motor
Disconnect the connector then measure the resistance using a tester. (Surrounding temperature 10:~30:) Normal
Abnormal
4.3k"~9.6k"
Open or short
Refer to the next page for the details.
Measure the resistance between the terminals using a tester. (Surrounding temperature 25:)
3 Blue
Normal
M
1-2 Red-Pink
5 Yellow 1 Red
Orange Pink Connect pin No.
4
Normal 1-3 Red-Blue
1-4 Red-Orange
Abnormal 1-5 Red-Yellow
1 Measure the resistance between the terminals using a tester. (Surrounding temperature 20:)
Fan motor
Abnormal
Normal FAN White Red Black
Brown
3
1 4 6
Gray Yellow
2
1
White-Black
195"
Red-Black
200"
Normal
CN34
Linear expansion valve CN60 White Yellow Orange Blue Red Brown
1 2 3 4 5 6
Open or short
2 Without disassembling the parts, measure the electrical pressure of the gray wire (Signal line) and brown wire (GND) while the power is on.
Abnormal
LEV
Open or short
200" ±7%
2
(1) At first, check if the electrical pressure is 12V between the brown wire (GND) and yellow wire (VCC). (2) Slowly start running the fan. It is normal if while the fan rotate once, the electrical pressure change from 0V to12V then go back to 0V. If the electrical pressure stay at around 0V or 10V, it means the fan motor has the defects.
Disconnect the connector then measure the resistance valve using a tester. (Coil temperature 20:) Normal
Abnormal
(1)-(5) (2)-(6) (3)-(5) (4)-(6) White-Red Yellow-Brown Orange-Red Blue-Brown
Open or short
150" ±10%
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Thermistor for lower temperature
< Thermistor for lower temperature > 50
Room temperature thermistor(TH21) Liquid pipe temperature thermistor(TH22) Gas pipe temperature thermistor(TH23)
40
Rt=15exp { 3480( 1 273+t 0: 10: 20: 25: 30: 40:
Resistance (K")
Thermistor R0=15k' ± 3% Fixed number of B=3480K ± 2% 1 )} 273
15k' 9.6k' 6.3k' 5.4k' 4.3k' 3.0k'
30
20
10
0
-20
-10
0 10 20 30 Temperature (:)
40
50
Linear expansion valve ① Operation summary of the linear expansion valve. • Linear expansion valve open/close through stepping motor after receiving the pulse signal from the indoor controller board. • Valve position can be changed in proportion to the number of pulse signal.
Controller board DC12V Brown
6
Red
5
[4
Blue
4
[4
[3
Orange
3
[3
[2
Yellow
2
[2
[1
White
1
[1
Linear expansion valve 4 M
6
5
2
1 White Red
3 Orange
Blue Brown Yellow
Drive circuit
Connector(CN60)
Note : Since the number of the connector at the controller board side and the relay connector are different, follow the color of the lead wire.
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