Sanyo CHDXR09663, CHDX07263, CHDX09663, CHDXR07263 User Manual 2

0 (0)
Sanyo CHDXR09663, CHDX07263, CHDX09663, CHDXR07263 User Manual 2

SERVICE MANUAL

2-WAY ECO-i MULTI SYSTEM

CHDX07263

CHDXR07263 *

CHDX09663

CHDXR09663 *

Outdoor Units

 

Class

72

96

 

 

 

 

C

ECO-i W-2WAY

CHDX07263

CHDX09663

CHDXR07263 *

CHDXR09663 *

 

 

Refrigerant R410A is used in the outdoor units. * Salt-Air Damage Resistant Specifications.

Indoor Units

 

Class

7

9

12

15

18

19

24

36

48

54

X

4-Way Air Discharge

 

 

XHX1252

 

XHX1852

 

XHX2452

XHX3652

 

 

Semi-Concealed

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

XM

4-Way Air Discharge

 

 

XMHX1252

 

XMHX1852

 

 

 

 

 

 

Mini Semi-Concealed

 

 

 

 

 

 

 

 

 

 

A

1-Way Air Discharge

AHX0752

AHX0952

AHX1252

 

 

 

 

 

 

 

Semi-Concealed

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

U

Concealed Duct Type

UHX0762

UHX0962

UHX1262

UHX1562

UHX1862

 

UHX2462

UHX3662

UHX4862

UHX5462

 

 

 

 

 

 

 

 

 

 

 

 

UM

Slim Concealed

UMHX0762

UMHX0962

UMHX1262

UMHX1562

UMHX1862

 

 

 

 

 

 

Duct Type

 

 

 

 

 

 

 

 

 

 

D

Concealed-Duct High

 

 

 

 

 

 

 

DHX3652

DHX4852

 

Static Pressure

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

T

Ceiling-Mounted

 

 

THX1252

 

THX1852

 

THX2452

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

K

Wall-Mounted Type

KHX0752

KHX0952

KHX1252

 

KHX1862

KHX1962 **

KHX2452

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

F

Floor-Standing Type

FHX0762

FHX0962

FHX1262

FHX1562

FHX1862

 

FHX2462

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

FM

Concealed-Floor

FMHX0762

FMHX0962

FMHX1262

FMHX1562

FMHX1862

 

FMHX2462

 

 

 

Standing Type

 

 

 

 

 

 

 

 

 

** Necessary to install the External Electronic Expansion Valve Kit (Optional:ATK-SVRK56BA).

85464849280000

REFERENCE NO. SM830180-00

IMPORTANT!

Please Read Before Starting

This air conditioning system meets strict safety and operating standards. As the installer or service person, it is an important part of your job to install or service the system so it operates safely and efficiently.

For safe installation and trouble-free operation, you must:

Carefully read this instruction booklet before beginning.

Follow each installation or repair step exactly as shown.

Observe all local, state, and national electrical codes.

Pay close attention to all warning and caution notices given in this manual.

This symbol refers to a hazard or

WARNING unsafe practice which can result in severe personal injury or death.

This symbol refers to a hazard or

unsafe practice which can result CAUTION in personal injury or product or

property damage.

If Necessary, Get Help

These instructions are all you need for most installation sites and maintenance conditions. If you require help for a special problem, contact our sales/service outlet or your certified dealer for additional instructions.

In Case of Improper Installation

The manufacturer shall in no way be responsible for improper installation or maintenance service, including failure to follow the instructions in this document.

SPECIAL PRECAUTIONS

WARNING When Wiring

When Installing…

…In a Room

Properly insulate any tubing run inside a room to prevent “sweating” that can cause dripping and water damage to walls and floors.

…In Moist or Uneven Locations

Use a raised concrete pad or concrete blocks to provide a solid, level foundation for the outdoor unit. This prevents water damage and abnormal vibration.

…In an Area with High Winds

Securely anchor the outdoor unit down with bolts and a metal frame. Provide a suitable air baffle.

…In a Snowy Area (for Heat Pump-type Systems)

Install the outdoor unit on a raised platform that is higher than drifting snow. Provide snow vents.

When Connecting Refrigerant Tubing

Ventilate the room well, in the event that is refrigerant gas leaks during the installation. Be careful not to allow contact of the refrigerant gas with a flame as this will cause the generation of poisonous gas.

Keep all tubing runs as short as possible.

Use the flare method for connecting tubing.

Apply refrigerant lubricant to the matching surfaces of the flare and union tubes before connecting them, then tighten the nut with a torque wrench for a leak-free connection.

Check carefully for leaks before starting the test run.

When Servicing

ELECTRICAL SHOCK CAN CAUSE

SEVERE PERSONAL INJURY OR DEATH.

ONLY A QUALIFIED, EXPERIENCED

ELECTRICIAN SHOULD ATTEMPT TO

WIRE THIS SYSTEM.

Do not supply power to the unit until all wiring and tubing are completed or reconnected and checked.

Highly 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 accidental injury or death.

Ground the unit following local electrical codes.

Connect all wiring tightly. Loose wiring may cause overheating at connection points and a possible fire hazard.

When Transporting

Be careful when picking up and moving the indoor and outdoor units. Get a partner to help, and bend your knees when lifting to reduce strain on your back. Sharp edges or thin aluminum fins on the air conditioner can cut your fingers.

Turn the power OFF at the main power box (mains) before opening the unit to check or repair electrical parts and wiring.

Keep your fingers and clothing away from any moving parts.

Clean up the site after you finish, remembering to check that no metal scraps or bits of wiring have been left inside the unit being serviced.

CAUTION

Ventilate any enclosed areas when installing or testing the refrigeration system. Escaped refrigerant gas, on contact with fire or heat, can produce dangerously toxic gas.

Confirm after installation that no refrigerant gas is leaking. If the gas comes in contact with a burning stove, gas water heater, electric room heater or other heat source, it can cause the generation of poisonous gas.

i

Check of Density Limit

The room in which the air conditioner is to be installed requires a design that in the event of refrigerant gas leaking out, its density will not exceed a set limit.

The refrigerant (R410A), which is used in the airconditioner, is safe, without the toxicity or combustibility of ammonia, and is not restricted by laws imposed to protect the ozone layer. However, since it contains more than air, it poses the risk of suffocation if its density should rise excessively. Suffocation from leakage of refrigerant is almost non-existent. With the recent increase in the number of high density buildings, however, the installation of multi air conditioner systems is on the increase because of the need for effective use off loor space, individual control, energy conservation by curtailing heat and carrying power, etc.

Most importantly, the multi air conditioner system is able to replenish a large amount of refrigerant compared to conventional individual air conditioners. If a single unit of the multi air conditioner system is to be installed in a small room, select a suitable model and installation procedure so that if the refrigerant accidentally leaks out, its density does not reach the limit (and in the event of an emergency, measures can be made before injury can occur).

ASHRAE and the International Mechanical Code of the ICC as well as CSA provide guidance and define safeguards related to the use of refrigerants, all of which define a Refrigerant Concentration Level (RCL) of 25 pounds

per 1,000 cubic feet for R410A refrigerant.

For additional guidance and precautions related to refrigerant safety, please refer to the following documents:

International Mechanical Code 2009 (IMC-2009) (or more recently revised)

ASHRAE 15

ASHRAE 34

ii

CONTENTS

Section 1: CONTROL FUNCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . 1-2

2.

Selecting Outdoor Unit for Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . 1-3

3.

Compressor Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . 1-4

4.

Special Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . 1-9

5.

Other Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . 1-14

6.

Operation of Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . 1-15

7.

Outdoor Unit Electronic Thermostatic Expansion Valves [MOV1, MOV2 & MOV4]

. . . . . 1-17

8.

Outdoor Fan Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . 1-19

9.

Demand Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . 1-20

10.

Indoor Unit Control of the Electronic Control Valve . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . 1-21

11.

Rap Valve Kit Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . 1-23

12.

Indoor Unit Refrigerant Oil Self Recovery Control . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . 1-24

13.

Discharge Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . 1-25

14.

Current Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . 1-26

15.

Pressure Sensor Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . 1-27

16.

Backup Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . 1-28

17.

Service Maintenance Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . 1-30

18.

Other Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . 1-32

Section 2: OUTDOOR UNIT REPAIR PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1

1.

Removing Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. 2-2

2.

Removing Electrical Component Box and Duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3

3.

Discharging Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-5

4.

Backup Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-6

5.

Recovering Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-9

6.

Checking for Leakage After Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-14

7.

Evacuating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-15

8.

Charging Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-16

9.

Pumping Out Refrigerant from Outdoor Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-20

10.

Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-23

11.

High and Low Pressure Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-35

12.

Replacing 4-way Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-36

Section 3: OUTDOOR UNIT MAINTENANCE REMOTE CONTROLLER . . . . . . . . . . . . 3-1

1. Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

2. Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3. Ordinary Display Controls and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

4. Monitoring Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

5. Outdoor Unit Alarm History Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

6. Mode Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Section 4: REMOTE CONTROLLER FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

1. Simple Settings Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

2. Detailed Settings Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

3. Remote Controller Servicing Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

iii

Section 5: TROUBLE DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

1. Contents of Remote Controller Switch Alarm Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 2. Outdoor Unit Control Panel LED Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 3. Remote Controller Servicing Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 4. W-2WAY ECO-i Alarm Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 5. Blinking Inspection Display on the Remote Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27 6. Inspection of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28 7. Test Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29 8. Thermister Characteristics Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30

iv

 

W-2WAY ECO-i SYSTEM

Contents

Control Functions

 

 

1. CONTROL FUNCTIONS

1.

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. 1-2

 

2.

Selecting Outdoor Unit for Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3

 

 

3.

Compressor Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4

 

4.

Special Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-9

1

5.

Other Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-14

 

6.

Operation of Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-15

 

7.

. . .Outdoor Unit Electronic Thermostatic Expansion Valves [MOV1, MOV2 & MOV4]

1-17

 

8.

Outdoor Fan Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-19

 

9.

Demand Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-20

 

10.

Indoor Unit Control of the Electronic Control Valve . . . . . . . . . . . . . . . . . . . . . . . . .

1-21

 

11.

Rap Valve Kit Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-23

 

12.

Indoor Unit Refrigerant Oil Self Recovery Control . . . . . . . . . . . . . . . . . . . . . . . . . .

1-24

 

13. Discharge Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-25

 

14.

Current Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-26

 

15.

Pressure Sensor Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-27

 

16. Backup Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-28

 

17.

Service Maintenance Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-30

 

18.

Other Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-32

 

1 - 1

1. Introduction

W-2WAY ECO-i SYSTEM Control Functions

The W-2WAY ECO-i is a system that allows multiple outdoor units to be connected. The outdoor units all contain inverter compressors, and the system does not utilize the sub units that were used in earlier systems.

The outdoor unit where the unit No. is set to “1” includes the CCU (command controller unit) functions that are used to control the entire system. As a result, the system will not operate if no outdoor unit has been set as unit No. “1.”

Required settings for Test Run

1

 

Outdoor unit No.1

Outdoor unit No. 2

 

 

 

 

 

 

At time of shipment

On-site setting

At time of shipment

On-site setting

 

 

 

System address

1

System 1 ~ 30

1

Not necessary

 

No. of indoor units

1

1 ~ 40 units

1

Not necessary

 

No. of outdoor units

1

1 ~ 3 units

1

Not necessary

 

Unit No.

1

Unit No. 1

1

Unit No. 2

This system can be expanded to connect a maximum of 3 outdoor units. (The max. system capacity shall be within 24 Ton.)

The CCU functions are disabled at all units except the unit that is set as unit No. 1. Therefore no problems will result even if the system address, No. of indoor units, and No. of outdoor units settings are made at the other units. However, making these settings may be convenient for manual backup operation, as it eliminates the necessity of making the settings again if unit No. 1 fails.

1 - 2

2. Selecting an Outdoor Unit for Operation

W-2WAY ECO-i SYSTEM Control Functions

2-1. Outdoor Unit Operating Rules

Because in this system all outdoor units contain an inverter compressor, ordinarily there is no absolute order of priority for compressor operation. Therefore there is no order of priority for the outdoor units.

However, it is possible to operate the outdoor units in sequence, beginning with unit No. 1, by using the outdoor unit maintenance remote controller to change the outdoor unit EEPROM settings.

* For information concerning EEPROM settings, refer to the field application functions.

2-2. Delayed Start of Outdoor Units

1

(1)Delayed start of outdoor units in the same system

If it is necessary to operate the compressors simultaneously at multiple outdoor units, each outdoor unit will start, beginning with unit No. 1, after a delay of a number of seconds equivalent to the outdoor unit address.

The units do not start simultaneously.

This is in order to reduce the load on the power receiving equipment.

Outdoor unit address 1

Outdoor unit address 2

Starts after 1 second Starts after 2 seconds

(2) Delayed start for each system

At the time of factory shipment, delayed start for each system is not set to occur. Therefore when systems are linked and multiple systems are selected for start simultaneously by the central control device, all systems will begin operating simultaneously. For this reason, a function is included to delay the start time for each system address when systems are linked and multiple systems are selected for start by the central control device.

In order to enable this delay time, it must be set in the EEPROM for each system. Those systems where this setting has been made will start after a delay according to their system addresses.

* For information concerning EEPROM settings, refer to the field application functions.

2-3. Outdoor Unit Stop Rules

(1) Simultaneous stop of multiple outdoor units

When all outdoor units, or multiple outdoor units, must stop, the units stop at the same time. However, depending on the communications timing, a difference of approximately 10 seconds may occur.

(2) Stopping individual outdoor units

The last unit to stop operating is the outdoor unit that contains the inverter compressor with the shortest amount of operating time .

In cooling mode, all inverter compressors in the outdoor units are designed to operate simultaneously. Therefore, all the outdoor units will stop at a time when any one unit is stopped. In heating mode, the outdoor unit which has the inverter compressor with the shortest amount of operating time continues to run and rest of the other outdoor units may be stopped.

1 - 3

3. Compressor Control

W-2WAY ECO-i SYSTEM Control Functions

3-1. Compressors Mounted in the Outdoor Units

[CHDX07263, CHDX09663]

 

 

Capacity

 

72

 

96

 

 

 

 

 

 

 

 

Installed

Compressor 1

Rotary

DC Inverter

 

DC Inverter

 

 

 

 

 

 

 

compressor

 

 

 

 

 

 

Compressor 2

Scroll

–––

 

5 hp

 

 

 

1

 

 

 

 

 

 

 

 

 

 

hp = horsepower

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

INV

 

Constant

INV

 

 

speed

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Compressor 1

Compressor 2 Compressor 1

Type 72

Type 96

3-2. Compressor Selection Rules

In cooling mode, all inverter compressors in the outdoor units are designed to operate simultaneously. All the inverter compressors will stop at a time when the outdoor is stopped accordingly. Constant-speed compressors run in order of the shortest amount of operating time. In heating mode, the inverter compressor with the shortest amount of operating time runs at first followed by the compressors in order of the shortest amount of operating time including inverter units.

*Immediately after installation, all compressors have an operating time of zero. In this case, the compressors start in the following sequence: Inverter compressor > Constant-speed compressor 1 > Constant-speed compressor 2.

Examples of accumulated operating time: ODU=Outdoor Unit

Suppose the following tentative system.

 

ODU 1

ODU 2

Comp 1

100 hrs.

70 hrs.

Comp 2

150 hrs.

160 hrs.

Compressor Selection Sequence in Cooling Mode:

All the inverter compressors are firstly selected simultaneously.

 

ODU 1

ODU 2

Comp 1

1st

1st

Comp 2

3rd

4th

Compressor Selection Sequence in Heating Mode:

First, the inverter compressor with the shortest amount of operating time is selected. And then, the remained other compressors are selected and start in the order of shortest amount of operating time.

 

ODU 1

ODU 2

Comp 1

3rd

1st

Comp 2

4th

2nd

1 - 4

3. Compressor Control

W-2WAY ECO-i SYSTEM Control Functions

3-3. Compressor Capacity Control

The compressor operating conditions vary depending on the indoor unit operating conditions and the effects of indoor heat load, outdoor temperature and other factors. Unit No. 1 (CCU) calculates the required capacity according to these operating conditions, and allocates the capacity requirement among the outdoor units, according to the compressor start/stop rules. Fine adjustments to system capacity control are made by the inverter compressors. (Depending on the conditions, all inverter compressors may be operating for fine adjustment.)

3-4. Inverter Compressor Capacity Control

1

(1)The inverter compressor has a center limit value and upper limit value for the operating frequency. These limits are set for each outdoor unit capacity.

(2)The inverter frequency during operation may be lower than the frequency listed above due to overload current protection control.

*If Quiet mode is selected, the inverter may stabilize at a frequency lower than those stated above. For information about Quiet mode, refer to the field application functions.

*If the Power Demand Mode is selected, the inverter may stabilize at a frequency lower than those stated above. Refer to the Field Application Function for the detail.

3-5. Forced Compressor Stop

Once a compressor stops, it will not start for a period of 3 minutes (3-minute forced OFF). However, this does not apply when the compressor was forced to stop as the result of a control operation during the special controls (start control, defrost control, refrigerant oil recovery control, etc.) which are described later.

3-6. Roadmap Control

(1)The below mentioned Roadmap Control are performed according to the pressure sensor on the outdoor unit, and the 2 temperature sensors attached to the indoor unit heat exchanger coil.

* With the roadmap control in heating mode, the pressure detected by the pressure sensor at high pressure side is converted to the saturation temperature. This converted saturation temperature is called the “High Pressure Saturated Temperature”.

(2)This control is performed every 15 seconds.

(3)The evaporation temperature control and the temperature used to determine the area (A, AB, B, C) for the condensation control shown in the figure on the next page, may vary depending on the relationships among factors including the difference between the room temperature setting and the air intake temperature (=air intake temperature difference) and the difference between the air discharge temperature setting and the air discharge temperature (=air discharge temperature difference).

(4)Definitions of evaporation temperature and condensation temperature

Evaporation temperature (Te): Lowest heat exchanger temperature (E1, E3) at any indoor unit

Condensation temperature (Tc): Highest temperature among the outdoor unit pressure sensor temperature and the heat exchanger temperatures (E1) at all indoor units where the heating thermostat is ON.

Ordinarily, this is the outdoor unit pressure sensor temperature. (If multiple outdoor units are connected, this is the highest outdoor unit pressure sensor temperature. )

*E3 temperature in heating mode is not used for the condensation temperature detection, because it may indicate the temperature of superheated gas.

1 - 5

3. Compressor Control

W-2WAY ECO-i SYSTEM Control Functions

3-6-1. Evaporation Temperature (Te) Control: Control of Indoor Units Operating in Cooling Mode

 

 

 

 

 

 

60.8

 

 

 

 

 

 

 

 

°F

 

 

 

 

 

 

 

 

 

 

 

 

Horsepower increase

 

53.6

 

 

 

 

 

 

 

51.9

permitted

Area A

 

 

51.8

 

 

 

 

 

 

 

 

 

 

51.8

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1

 

 

 

Horsepower increase

Area AB

 

 

 

45.5

 

 

 

41.1

permitted

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

41.0

Horsepower increase

 

 

 

 

 

 

41.0

 

 

 

 

Area B

 

 

 

 

 

 

 

 

 

 

prohibited

 

 

 

 

 

 

 

35.6

 

 

 

 

 

 

35.6

 

 

 

 

 

 

 

35.4

Horsepower decrease

Area C

 

 

 

 

 

 

0

15

30

 

 

 

 

 

 

 

 

 

 

 

Maximum requirement level [L]

*Depending on the maximum requirement level of the indoor unit, the judgement temperatures for each area may vary as shown in the figure.

(1)For indoor units that are operating in Cooling Mode, if one unit is selected for a test run mode, the room temperature control by the set temperature cannot be performed. Areas B and C are assumed to be area A for control purposes, instead. By this reason, the compressor continues its operation regardless of the low evaporation temperature (This is used for additional charging of refrigerant, test run checking etc.) Vapor may be discharged if the test run continues for a long time. However, this does not indicate problems.

(2)Even within the same area, the compressor capacity varies depending on the refrigerant temperature.

(3)For 6 minutes after the compressors start, area C is considered to be area B for control purposes.

(4)During special control, control of the compressor capacity according to Te is not performed.

(5)If the thermostat turns OFF while Te is within area C, the next time the compressor starts it may restart from a lower capacity.

(6)When the area changes to area C, area C is considered to be area B for control purposes for the first 6 minutes, even if the horsepower is the minimum value within the range where capacity control is possible (operation with inverter frequency of 25 Hz only). Subsequently if C area continues, the thermostat turns OFF.

1 - 6

3. Compressor Control

W-2WAY ECO-i SYSTEM Control Functions

3-6-2. Condensation Temperature (Tc) Control:

Control of Indoor Units Operating either in Cooling Mode or Heating Mode

PX=125.6°F

Thermostat OFF

Area D

 

 

PX –0.1

 

 

 

 

 

Horsepower decrease

Area C

118.5

 

 

 

 

 

 

 

118.4

Horsepower increase

 

 

 

 

Area B

116.6

prohibited

 

 

 

 

 

 

116.4

 

 

 

 

 

Horsepower increase

Area AB

113.0

permitted

 

 

 

 

 

 

 

112.8

Horsepower increase

Area A

 

 

 

 

 

 

permitted

 

 

 

 

 

 

*Depending on the maximum requirement level of the indoor unit, the judgment temperatures for each area may vary as shown in the figure (example).

 

 

 

 

 

118.4

1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

116.6

 

 

 

 

109.4

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

100.4

 

 

107.6

 

 

 

 

 

 

 

 

98.6

 

 

 

 

 

 

0

15

30

 

Maximum requirement level [L]

(1)For indoor units which are operating in Heating mode, if one unit is selected for a test run, the air intake temperature difference is ignored, however Tc control is performed according to the figure above in order to prevent excessive load. (This is used for test run checks, etc.)

(2)Even within the same area, the compressor capacity varies depending on the refrigerant temperature.

(3)Temperature PX is the coefficient value used to correct for any deviation with the high pressure or condensation temperature. It may vary. (At the time of shipment it is 127°F.)

(4)If the condensation temperature (Tc) enters area D and the thermostat turns OFF, the next time the compressor starts it may restart from a lower capacity.

3-6-3. Protection control

Protection control consists of 2 types of protection: discharge temperature protection and current protection. The limit values from this protection control are incorporated into the output compressor capacity increase/decrease values that were calculated from control based on the temperature at the indoor unit heat exchanger coil (roadmap control).

*In some cases, the control shown below may stop the compressor, issue a warning, or reduce the compressor capacity.

(1)Discharge Temperature Protection

During operation when only a single outdoor unit is installed, the air discharge temperature level is determined (the highest value is used), and the compressor capacity is limited, by using the air discharge temperature of the operating compressor (as shown in the tables below).

Air discharge temperature level: Highest level among the air discharge temperature levels of all compressors

Air discharge temp. level

Discharge temp. °F

Horsepower limit

5

221

Decrease by 2 horsepower

4

219

Decrease by 1 horsepower

3

217

Decrease by 0.5 horsepower

2

212 ~ Less than 217

Prohibit horsepower increase

1

208 ~ Less than 212

Permit horsepower increase (slowly)

0

Less than 208

No control

The values shown in the table above are reduced to the values calculated by roadmap control.

1 - 7

3. Compressor Control

W-2WAY ECO-i SYSTEM Control Functions

(2)Current Protection

Inverter compressor current control is composed of primary current control and secondary current control. Current protection control for the inverter compressor is performed by self-protection in the inverter circuit, and does not increase or decrease the compressor capacity.

 

 

 

Primary current

 

Secondary current

 

 

 

Control

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1

-

 

75.0A or (302°F)

 

 

 

Inverter compressors stop (HIC auto. protection)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Inverter compressors stop (When 100ms is detected,

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

16.0A~

 

16.5A

 

 

 

 

 

 

 

 

current protection works.)

 

 

 

14.5A~

 

 

 

 

 

Hz decrease in the inverter compressor

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

13.5A

 

 

 

 

 

 

 

 

 

 

 

 

13.5A~

 

 

 

 

 

 

 

 

 

 

 

13.0A

 

 

 

 

 

12.5A

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Prohibit Hz increase in the inverter compressor

 

 

 

 

 

 

 

 

 

 

 

12.0A

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Permit Hz increase in the inverter compressor

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

80Hz 90Hz

 

 

 

 

3-6-4. Roadmap Control after Trip

When restarting after the trip stop occurs, the horsepower may increase slowly depending on the trip counter value.

(1)If trip counter =1, the horsepower increases at a speed that is 1/2 of ordinary roadmap control.

(2)If trip counter =2, the horsepower increases at a speed that is 1/3 of ordinary roadmap control.

The trip counter will be cleared if no trip occurs within 10 minutes after operation starts.

1 - 8

4. Special Controls

W-2WAY ECO-i SYSTEM Control Functions

In addition to ordinary heating and cooling operation, this system also includes the following 3 types of special controls for control of the system as a whole.

1.4-way Valve Adjustment Control

2.System refrigerant oil recovery control

3.Defrost control

4-1. 4-way Valve Adjustment Control

When the microcomputer is initialized immediately after power-ON, after warning output, and all outdoor units are

1

kept stopped for a preset period (standard = 60 minutes) , the 4-way Valve Adjustment Control will be performed.

 

This control is intended to changeover the 4-way valve of outdoor unit. When the unit has been stopped for long

 

period, and if refrigerant has accumulated somewhere in the tubing, recovery of the refrigerant is performed. This

 

control can also compensate for tubing thermal loss by radiation during heating start as well as for oil recovery.

 

(1) Cooling control when the outdoor unit heat exchanger is acting as a condenser

 

 

 

 

 

 

 

 

Control time

60 seconds

 

 

 

Outdoor units

All outdoor units operate at the maximum horsepower.

 

 

 

Electronic Thermostat

Valves at all indoor units operate at a fixed pulse according to the indoor unit capacity.

 

 

 

Expansion Valve

 

 

Indoor

 

 

 

 

 

 

RAP valve kit

Valve kits at all indoor units operate in Cooling mode (OFF status).

 

 

units

 

 

Fan

Fan operates at the set fan speed or stops, depending on the indoor unit operation

 

 

 

 

 

 

mode.

 

 

 

 

 

*When the above operation is finished, normal operation starts at the horsepower determined by the indoor units where thermostats are ON.

(2)Heating control when outdoor unit heat exchanger is acting as an evaporator

 

Control time

Minimum 1 min - Maximum 10 min [until max (pressure sensor temp., E1) 95°F ]

 

Outdoor units

All outdoor units operate at the maximum horsepower.

 

Electronic Thermostat

Valves at all indoor units operate at 250 pulses as a default.

 

Expansion Valve

 

 

Indoor

 

 

RAP valve kit

Valve kits at all indoor units operate in heating mode (ON status).

units

Fan

Fan operates at the set fan speed, stops or operates at a very low speed,

 

 

depending on the indoor unit operation mode.

 

 

*When the above operation is finished, normal operation starts at the horsepower determined by the indoor units where thermostats are ON.

4-2. System Refrigerant Oil Recovery Control

4-2-1. System refrigerant oil recovery cycle

This control is performed using the cooling cycle during cooling operation and using the heating cycle during heating operation.

4-2-2. Start of System Refrigerant Oil Recovery Control

When the oil level in an operating compressor is detected as 0 (zero), the compressor stops in 120 seconds. If this compressor repeats this operation 3 times and the oil level does not reach 2, system refrigerant oil recovery control is started.

*When the compressor has stopped because the oil level is 0, a count is added to the alarm counter. The counter for this compressor is not cleared unless the oil level for that compressor reaches 2, or else alarm output occurs.

1 - 9

4. Special Controls

W-2WAY ECO-i SYSTEM Control Functions

4-2-3. Refrigerant Oil Recovery Control between Systems

(1)Simplified flow of system refrigerant oil recovery control

Refrigerant oil recovery control between systems shall be performed as the flow mentioned below.

Normal operation 3-minute stop Refrigerant oil recovery control between systems (Max. 3 minutes) 3- minute stop Normal operation

(2)Cooling cycle

1

 

 

Control time

Maximum 3 minutes (Stops once before and once after control.)

 

 

 

 

 

 

Outdoor units

All outdoor units operate at maximum horsepower.

 

 

 

Electronic Thermostat

Valves at all indoor units operate at a fixed pulse according to the indoor unit capacity.

 

 

 

Expansion Valve

 

 

 

 

 

 

Indoor

 

 

 

RAP valve kit

Valve kits at all indoor units operate in Cooling mode (OFF status.)

 

 

units

 

 

 

 

 

Fan

Fan operates at the set fan speed, or stops depending on the operation mode of the

 

 

 

 

 

 

indoor unit.

 

 

 

 

 

(3) Heating cycle

 

 

 

 

 

 

 

 

 

Control time

Maximum 3 minutes (Stops once before and once after control.)

 

 

 

Outdoor units

All outdoor units operate at maximum horsepower.

 

 

 

Electronic Thermostat

Valves at all indoor units operate at 480 pulse.

 

 

 

Expansion Valve

 

 

 

 

 

 

Indoor

 

 

 

 

RAP valve kit

Valve kits at all indoor units operate in Heating mode (ON status.)

 

 

units

 

 

 

 

 

 

Fan

Fan operates at the set fan speed, stops or operates at a very low speed.

 

 

 

 

 

 

 

 

4-3. Defrost Control

4-3-1. Defrost Methods

This system uses the following 2 defrosting systems.

System employs

Defrost control method

 

 

1 outdoor unit in the refrigerant system

Reverse cycle defrost

 

 

2 outdoor units in the refrigerant system

Outdoor unit cycle defrost

 

 

4-3-2. Constraint conditions

(1)Frost detection does not occur for 5 minutes after operation starts.

(2)Defrost does not begin again for 35 minutes of A/C operation after defrost was once completed.

(3)If all indoor units are stopped while defrost control is in effect, or if the outdoor unit is stopped due to protection control or another reason, then defrost control will not start for a minimum of 10 minutes after restart occurs.

1 - 10

4. Special Controls

W-2WAY ECO-i SYSTEM Control Functions

4-3-3. Frost detection

(A)Frost detection does not occur for 5 minutes after operation starts.

(B)Frost is detected when either condition 1 or 2 below is met.

Condition 1: L2 line or below is detected twice, each time continuously for 4 minutes, when the compressor is operating.

Condition 2: L1 line or below is detected for a total of 60 minutes when the compressor is operating.

 

Heat exchange liquid temperature °F

1

 

 

 

 

 

 

Defrosting operation

 

(The end temperature

 

50

end temperature

 

is different from the

 

 

 

above detection

 

 

 

 

 

 

 

 

 

 

temperature.)

–6.5

 

 

50

External temperature °F

 

 

 

 

 

 

 

30

 

L1

 

26

 

L2

 

17

 

 

 

14

The frost detection area is located under the thick lines

–9

–13

4-3-4. Outdoor units where defrost occurs

Even if the total time has not reached 35 minutes, if there is 1 or more outdoor units that fulfills the defrost detection conditions, all operating outdoor units perform defrost control at the same time.

*Defrost control is also performed at outdoor units where the outdoor unit heat exchanger is not functioning as an evaporator (such as stopped outdoor units).

4-3-5. Reverse Cycle Defrost

If there is 1 outdoor unit and no thermal storage tank in a refrigerant system, a reverse cycle defrost will be carried out.

• Defrost flow

E: Evaporator operation

 

 

 

 

 

 

 

 

 

C: Condenser operation

 

 

 

 

 

 

 

 

 

E C: Switching from evaporator operation to condenser operation

 

 

 

C E: Switching from condenser operation to evaporator operation

 

 

 

 

 

 

 

 

 

 

 

 

Defrost preparation

Defrost in progress

Defrost end

 

Outdoor unit status

E

C

E C

C

 

 

C

E

 

Stopped indoor units

C

E

E

E

 

 

E

C

 

Indoor units where fan is operating

C

E

E

E

Defrost

 

E

C

 

Cooling mode

Thermostat ON

C

E

E

E

end

E

C

 

indoor units

Thermostat OFF

C

E

E

E

judgment

E

C

 

Heating mode

Thermostat ON

C

E

E

E

 

 

E

C

 

indoor units

Thermostat OFF

C

E

E

E

 

 

E

C

 

Compressor

Stopped

Operating

Operating

 

 

Stopped

 

 

 

 

 

 

 

 

 

 

 

Time

1 min

1 min

Max. 10 min

1 min

 

 

 

 

 

 

 

 

 

 

 

1 - 11

4. Special Controls

W-2WAY ECO-i SYSTEM Control Functions

4-3-6. Outdoor unit cycle defrost

Outdoor unit cycle defrost is performed in systems where 2 outdoor units are connected to the refrigerant system.

(1)Description of outdoor unit cycle defrost

With this defrost method, when 1 outdoor unit operates in defrost mode (heat exchanger operating as a condenser), another outdoor unit operates as an evaporator in the same way as in ordinary heating mode.

In this way, the other outdoor unit is heating the unit where defrost is occurring. When 1 outdoor unit completes

defrost, the other outdoor unit performs defrost in the same way.

1 Because the amount of time that the unit operates as an evaporator is very short, there is little danger of frost forming again quickly. Rather, because the heat source is very powerful, it is possible to shorten the defrost operating time.

(2)Defrost sequence

Outdoor unit cycle defrost is always completed in 2 defrost operations.

(A) When there are 2 outdoor units

 

 

 

 

 

 

 

 

 

Switch

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Defrost

 

Evaporator

 

Evaporator

 

 

Defrost

 

 

outdoor unit

 

outdoor unit

 

outdoor unit

 

outdoor unit

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

First operation

 

 

Second operation

• Defrost flow

E: Evaporator operation

 

 

 

 

 

 

 

 

 

C: Condenser operation

 

 

 

 

 

 

 

 

 

S: Shut off

 

 

 

 

 

 

 

 

 

 

 

E C: Switching from evaporator operation to condenser operation

C E: Switching from condenser operation to evaporator operation

 

 

 

Defrost

Defrost in

Switch

 

Defrost in

Defrost

 

 

 

preparation

progress

 

progress

preparation

 

 

 

 

 

 

Outdoor unit(s) where defrost occurs first

E C

C

 

 

C

E

E

 

 

 

E or S

Outdoor compressor(s) where defrost occurs first

OFF

ON

 

 

OFF

ON

 

 

OFF

Outdoor unit(s) where defrost follows later

E

E

Defrost

E

C

C

 

Defrost

C E or S

Outdoor compressor(s) where defrost follows later

ON

ON

OFF

ON

OFF

 

 

 

 

 

end

 

 

 

 

 

end

 

 

Stopped indoor unit(s)

S

S

 

 

S

S

 

 

S

judgment

 

 

judgment

Indoor units where fan is operating

S

S

 

S

S

 

S

 

 

 

 

 

 

Heating mode indoor

 

Thermostat ON

C

C

 

 

 

C

C

 

 

 

C

units

 

Thermostat OFF

C

C

 

 

 

C

C

 

 

 

C

Time

 

1 min

Max. 6 min

1 min

 

Max. 6 min

1 min

1 - 12

4. Special Controls

W-2WAY ECO-i SYSTEM Control Functions

4-3-7. Defrost end judgment conditions

Defrost ends when either of the below defrost end judgment conditions is met.

Condition 1: The temperatures are 50°F or higher at all temperatures sensors installed on the outdoor unit heat exchanger coils.

However, if there is any other outdoor unit where the defrost end condition has not been met, defrost control continues for all outdoor units, and system defrost control is not ended.

Condition 2: The maximum defrost time listed in the table above has elapsed.

1

4-3-8. System defrost end

When all outdoor units where defrost control is in effect have met the defrost end conditions, defrost control is ended for the system.

1 - 13

5. Other Controls

W-2WAY ECO-i SYSTEM Control Functions

5-1. Oil Control

5-1-1. Oil level

 

 

Oil level

Meaning

Conditions of oil

Judgement

 

 

 

 

 

 

 

 

 

 

The compressor contains oil more than

There is no problem.

 

 

 

 

 

 

2

Sufficient

the oil level which is necessary and

 

1

 

 

 

sufficient for normal operation.

 

 

 

 

 

 

 

 

 

The compressor contains sufficient oil

Confirm that oil is returned after

 

 

 

 

 

 

1

Slightly low

but there is a possibility of shortage

performing the oil control operation.

 

 

 

 

against the required oil level.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

The compressor oil is short against

Confirm that oil level is recovered to the

 

0

Extremely low

the required oil level sufficient for normal

required level after performing the oil

 

 

 

 

operation.

recovery control between systems.

 

 

 

 

 

 

At the time immediately after the oil level changes from 2 to 1, there is a specified amount of oil in the compressor. Namely, soon after the oil level is changed to 1, the oil in the compressor is not empty. If the oil level “0” indication continues for more than 5 to 10 minutes, it seems short of oil in the system. Check for any oil leakage as well as the refrigerant tubing.

5-1-2. Oil level detection

Excess oil in the compressor is sent by bypass via a capillary tube to the low-pressure circuit. The temperature detected by a temperature sensor is used to determine whether it is oil (warm) or refrigerant (cold).

5-1-3. Self-separator oil recovery control

* When a low oil level is detected, this control recovers the oil which has accumulated in that oil separator and sends it to the compressor.

(1)Operation when oil level is not 2.

30 seconds after the oil level changes from 2 to 1, the recovery valves turn ON. However, if the oil level becomes 2, this control is stopped.

5-1-4. Unit refrigerant oil recovery control – utilizing balance tubes

*If the low oil level continues, that outdoor unit (oil-receiving outdoor unit) receives a supply of oil from operating outdoor units where the oil level is not low (oil-supply outdoor units).

(1)Control at the oil-supply outdoor unit begins 3 minutes after the oil level at the outdoor unit dose not become 2. Oil supply is performed for a maximum of 5 minutes from each unit.

(2)When oil supply is ended, oil supply from that outdoor unit will not occur again for a period of [(No. of outdoor units minus1) x 5 minutes]. In addition, oil supply is ended if the oil-receiving outdoor unit oil level changes to 2, or if the oil-supply outdoor unit oil level becomes low.

(3)The supply of oil is received from 1 unit at a time, in sequence, according to the order of priority of their inverter compressors.

(4)Operation during unit refrigerant oil recovery

(A) Oil-receiving outdoor unit

The recovery valve turns ON and remains ON.

(B) Oil-supply outdoor unit

The balance valve turns ON and remains ON.

The bypass valve repeatedly turns ON and OFF according to a constant cycle.

5-1-5. Indoor unit refrigerant oil self-recovery control

Refer to the items concerned with indoor unit special control.

1 - 14

6. Operation of Solenoid Valves

W-2WAY ECO-i SYSTEM Control Functions

6-1. Refrigerant Control Valve [RCV]

The main purpose of this valve is to detect the flow of refrigerant (refrigerant volume) on the indoor-unit side when the outdoor unit heat exchanger is functioning as a condenser. When the valve determines that there are signs of a low refrigerant level, refrigerant is supplied from the receiver tank to the system.

(1)The OFF conditions take priority over the ON conditions for this valve.

(2)This valve is OFF when the outdoor unit is stopped.

(3)

This valve is ON when special control is in progress.

Hp

1

 

 

 

 

 

(4) Control during normal operation

(A) Cooling operation

This valve turns ON when symptoms of insufficient refrigerant gas occur at an indoor unit.

This valve turns ON when the outdoor air temperature is 59°F or below. (Under these conditions the high pressure is low and refrigerant flow becomes poor.)

This valve turns OFF when symptoms of refrigerant overcharge are detected at the outdoor unit.

(B) Mixed cooling/heating operation

The RCV turns ON at stopped outdoor units when the heat exchanger at another outdoor unit is functioning as a condenser.

6-2. Refrigerant Balance Valve [RBV] – Gas Purge Valve

The main purpose of this valve is to detect the flow of refrigerant (refrigerant volume) on the indoor-unit side when the outdoor unit heat exchanger is functioning as an evaporator. When the valve determines that there are signs of excess refrigerant, refrigerant is recovered at the receiver tank.

This valve is ON during heating operation and when the outdoor unit heat exchanger is functioning as an evaporator during mixed heating/cooling operation. It also turns ON in order to recover refrigerant at the outdoor unit after heating operation is stopped.

* This valve is never turned ON at the same time with the RCV.

(1)The OFF conditions take priority over the ON conditions for this valve.

(2)This valve turns ON for 30 – 50 seconds after the outdoor unit stops, and then turns OFF.

(3)This valve turns ON once after the outdoor unit starts.

(A) Heating operation

Lp

This valve is ON during heating operation and when it turns ON for the purpose of recovering refrigerant in the outdoor unit at the end of the heating operation. After the valve turns from ON to OFF, it will not turn ON again for 15 minutes.

This valve turns ON when poor refrigerant flow at an indoor unit is detected, and when symptoms of overcharge are detected, if the heat exchanger at the outdoor unit is functioning as an evaporator.

(4)This valve turns OFF when an abnormal drop in discharge gas temperature is detected.

(5)This valve turns OFF when a drop in the detected receiver tank temperature contin-

ues for a set length of time, and when liquid back-flow is judged to be occurring.

1 - 15

6. Operation of Solenoid Valves

W-2WAY ECO-i SYSTEM Control Functions

6-3. Recovery Valve (ORVR)

This valve recovers refrigerant oil from the balance tube to the compressor.

(1)When unit is stopped This valve is always OFF.

(2)When unit is operating

(A)This valve turns ON when separator oil self-recovery control is in progress.

1 (B) This valve is ON when unit refrigerant oil recovery control is in progress (oil-receiving unit).

(C)This valve is ON when control the system in case of insufficient refrigerant gas.

(D)This valve turns ON for 60 seconds after a constant-speed compressor starts.

(E)This valve turns ON for 120 seconds after defrost control ends.

(F)This valve turns ON for 10 seconds after the outdoor unit stops.

(G)This valve remains OFF at all times other than (A) through (F) above.

6-4. Bypass Valve (BPV)

This valve flushes the oil from the balance tubes. In addition, it is used for recovering refrigerant from stopped outdoor units during cooling operation.

(1)When unit is stopped This valve is always OFF.

(2)When unit is operating

This valve is ON at the oil-supply outdoor unit when unit refrigerant oil recovery control is in progress.

* This valve repeatedly turns ON/OFF at regular intervals during unit refrigerant oil recovery control. (It is not constantly ON.)

1 - 16

7.Outdoor Unit Electronic Thermostatic Expansion Valves [MOV1, MOV2 & MOV4]

W-2WAY ECO-i SYSTEM Control Functions

7-1. Types of Electronic Thermostatic Expansion Valves

[CHDX07263, CHDX09663]

 

Capacity

72

96

 

 

Electronic

Heat exchanger

Heat exchanger

 

 

control valve 1

1 valve

1 valve

 

Electronic

Electronic

Heat exchanger

Heat exchanger

 

control valve

control valve 2

2 valve

2 valve

1

 

Electronic

For SC circuit

For SC circuit

 

control valve 4

 

 

 

 

 

7-2. Power Initialization

If no indoor units have started (even once) after the power was turned ON, the outdoor unit electronic control valve operates at 480 pulses.

7-3. Heat Exchangers which are controlled by each Electronic Thermostatic Expansion Valve

The configuration of heat exchangers is as shown in the figure below. MOV3 is excluded.

Heat

exchanger 1

Heat exchanger 2

Front

Operation of Electronic Thermostatic Expansion Valve during normal unit operation

If any one compressor in the outdoor unit is operating, the outdoor heat exchanger coil is used.

In cooling operation, all the inverter compressors are designed to operate, therefore, all the outdoor heat exchangers in the outdoor units will be used.

SH control controls the difference between the liquid temperature and gas temperature to 2°F ~ 10°F.

During heating mode SH operation in the heat exchanger 2 side, in order to prevent a liquid-back or high load operation from occurring a control may be implemented so that refrigerant may not flow intentionally to the heat exchanger.

1 - 17

7.Outdoor Unit Electronic Thermostatic Expansion Valves [MOV1, MOV2 & MOV4]

W-2WAY ECO-i SYSTEM Control Functions

7-4. SC Circuit Electronic Control Valve [MOV4]

(1)SC Control (Cooling Mode only)

During cooling operation, the liquid refrigerant which condenses at the outdoor unit heat exchanger flows into the receiver tank, and SC (sub-cool = supercooling) approaches 0°F. When SC is small and the length of the tubing connecting the indoor and outdoor units is long, the refrigerant flow in the indoor unit will be reduced significantly. To prevent this trouble from occurring, MOV4 operates so as to increase supercooling in the double tube coil near the outlet of the outdoor unit.

1 MOV4 controls refrigerant so that it will not flow back to the compressor in the liquid state with a suction temperature sensor near the accumulator and a low pressure sensor.

Gas refrigerant returns to the accumulator.

Liquid refrigerant (large SC)

Liquid refrigerant (SC = 0°F)

Refrigerant on the outer side evaporates, cooling the liquid refrigerant on the inner side.

Electronic control valve 4 (expansion valve) controls the flow.

(2)Operation when discharge temperature is high

When the discharge temperature increases, the SC circuit electronic thermostatic expansion valve opens to 480 pulses to cool down the compressor. This operation takes priority over operation intended to increase SC. It is performed at top priority in all operating modes. In addition, the valve opening adjustment will be made when the discharge temperature falls.

Liquid refrigerant returns to the accumulator.

Liquid refrigerant

Liquid refrigerant

Does not fully evaporate,

resulting in liquid back-up.

Electronic control valve 4 opens to 480 pulses.

1 - 18

8. Outdoor Fan Control

W-2WAY ECO-i SYSTEM Control Functions

8-1. Fan mode

These outdoor units utilize a DC fan motor that can be controlled in a maximum of 16 steps (16 modes). However, fan modes 15 and 16 can only be used if high static-pressure mode has been set.

* For information concerning EEPROM settings, refer to the field application functions.

8-2. Outdoor Fan Min. Fan Mode and Max. Fan Mode

 

Min. fan mode

Max. fan mode

1

Cooling operation

Outdoor air temp. > 59°F: 1

14

Outdoor air temp. < 59°F: 0

 

 

 

 

Heating operation

1

14

 

*Even if the fan mode is 0 during cooling operation, the fan mode may change to 1 at regular intervals for temperature protection of the inverter hybrid IC.

8-3. Fixed Initial Fan Mode

For the first 30 seconds after operation starts, the mode is fixed at the initial mode which was calculated from the relationship between the outdoor air temperature and the outdoor unit horsepower.

If the outdoor unit horsepower changes dramatically, say for about 2 hp, the initial mode may be recalculated and may be again fixed for 30 seconds.

8-4. Operation after Fixed Initial Fan Mode

After the fixed initial fan mode, the fan mode is increased or decreased according to the operating conditions.

(1)When all indoor units are operating in cooling mode

(A)Fan mode is increased when the high pressure satulation temperature sensed by the pressure sensor is high, and is decreased when the pressure sensor temperature is low.

* The fan mode is always increased when the high pressure satulation temperature sensed by the pressure sensor is 113°F or higher.

(B)The fan mode may be decreased when symptoms of insufficient refrigerant gas are detected at an indoor unit.

(2)When all indoor units are operating in heating mode

(A)If the condensation temperature is low, the fan mode is increased at regular intervals.

(B)If the condensation temperature is high, the fan mode is decreased in order to prevent excessive loads.

(C)The fan mode may be increased when the outdoor liquid temperature drops to 44°F or below.

8-5. Snow Removal Control

(1)When the outdoor air temperature is 50°F or below, the fan operates for 30 seconds every 2 hours in fan mode 8, even when the outdoor unit is stopped or the heat exchanger is not in use. This control is intended to prevent snow from accumulating on stopped fans. (Because the outdoor air temperature cannot be accurately detected when the unit is stopped, a higher outdoor air temperature is used for the control condition, in order to ensure correct operation.)

(2)If the fan mode becomes 0 during cooling operation, the fan mode is changed to 1.

* This control is predictive control. Use a snowfall sensor as necessary according to the installation conditions.

8-6. When the Compressor Magnet Switch Seizing Alarm Occurs

Because there is the possibility that the high pressure has increased, the fan operates in Max. fan mode.

8-7. Other

This unit includes settings for high static-pressure and for Quiet mode.

For information about these settings, refer to the field application functions.

1 - 19

9. Demand Control

W-2WAY ECO-i SYSTEM Control Functions

Serial-parallel I/O must be connected in order to perform demand control. The below input is received by serialparallel I/O, and demand control is performed.

The demand values can be set as needed with this device. For more information, refer to the field application functions.

 

 

 

 

 

 

 

 

Demand setting

Control

Demand meaning

1

 

Contact 1

Contact 2

 

 

 

 

 

 

No control

Operates to maximum capacity.

 

 

 

 

Operates to the upper limit for the rated current.

-

 

 

 

 

Operates to 70% of the upper limit for the rated current.

-

 

 

 

 

Always in stop condition.

-

 

 

: Input present

: Input not present

 

* The rated current indicates the current value that is listed in the catalog or similar material.

1 - 20

10. Indoor Unit Control of the Electronic Control Valve

W-2WAY ECO-i SYSTEM Control Functions

10-1. Normal Control

(1) Cooling operation

 

 

 

Position of electronic control valve

 

 

 

 

 

Outdoor unit operating

Outdoor unit

 

 

 

 

 

 

 

 

 

stopped

 

 

 

 

 

 

 

 

 

Stopped

20

20

 

 

 

 

Fan

20

20

 

1

 

 

Thermostat

20

20

 

 

 

OFF

 

Cooling

 

 

 

 

 

 

Thermostat

Performs SH control in the range of 55 – 480

 

 

 

 

 

 

 

 

ON

pulses.

 

 

 

 

 

 

 

 

 

 

* The SH target value is controlled so that the E3 - E1 becomes between 2°F to 6°F, depending on the operating conditions.

However, a decline in the required level may cause the SH target value to increase. Be aware that in this case, the electronic control valve closes slightly. This can be easily identified incorrectly as insufficient gas.

(2)Heating operation

(A)Except Type D

 

 

 

Position of electronic control valve

 

 

 

 

Outdoor unit operating

Outdoor unit

 

 

 

stopped

 

 

 

 

 

Stopped

Liquid refrigerant is gradually returned to the outdoor unit

85

 

at pulses ranging from 55 to 80.

 

 

 

 

 

 

Fan

Liquid refrigerant is gradually returned to the outdoor unit

85

 

 

at pulses ranging from 55 to 80.

 

 

 

 

 

 

Thermostat

Liquid refrigerant is gradually returned to the outdoor unit

85

 

 

OFF

at pulses ranging from 55 to 80.

Heating

 

 

 

Thermostat

Performs SC distribution control within the range of 55–

 

 

 

 

ON

480 pulses.

 

 

 

*The SC target value is controlled so that the high pressure saturated temp. - E1 becomes between 10°F to 40°F , depending on the operating conditions.

(B) Type D

 

 

Position of electronic control valve

 

 

Outdoor unit operating

 

 

 

Stopped

20

 

Fan

20

 

Thermostat

20

 

OFF

Heating

 

Thermostat

Performs SC distribution control within the range of 55 –

 

 

ON

480 pulses.

Outdoor unit stopped

20

20

20

* The SC target value is controlled so that the high pressure saturated temp. - E1 becomes between 10°F to 40°F, depending on the operating conditions.

However, if installation is combined with except Type D, the high pressure saturated temp. - E1 may be controlled between 10°F to 80°F.

1 - 21

10. Indoor Unit Control of the Electronic Control Valve

W-2WAY ECO-i SYSTEM Control Functions

10-2. Special Control

Control

4-way valve adjustment control

1

Reverse cycle defrost control

Outdoor cycle defrost control

System refrigerant oil recovery control

Operating

Subject indoor units

Position of electronic control valve

mode

 

 

 

 

Cooling

 

All indoor units

Fixed pulse for cooling, according to indoor unit

 

capacity

 

 

 

 

 

 

 

 

 

Heating

 

All indoor units

250

 

 

 

Stopped

Cooling control, according to indoor unit capacity

 

 

 

Fan

Cooling control, according to indoor unit capacity

Heating

Heating

 

Thermostat

Fixed pulse for heating, according to indoor unit

 

ON

capacity

 

 

 

 

 

 

 

 

 

 

Thermostat

Heating control, according to indoor unit capacity

 

 

 

OFF

However, position is 20 pulses for Type D.

 

 

 

 

 

 

 

 

Stopped

60 pulses

 

 

 

Fan

60 pulses

Cooling/

Heating

 

Thermostat

60 pulses

heating

 

ON

 

60 pulses

 

 

 

Thermostat

 

 

 

 

OFF

 

 

 

 

 

 

Cooling

 

All indoor units

Fixed pulse for cooling, according to indoor unit

 

capacity

 

 

 

 

Heating

 

All indoor units

250

1 - 22

11. Rap Valve Kit Control

W-2WAY ECO-i SYSTEM Control Functions

A gas tube valve kit may be connected to the Type D indoor unit. When the gas tube valve kit is connected, operations of gas tube valve kit and indoor unit electronic thermostatic expansion valve are as shown in the table.

 

 

Gas tube valve

Electronic thermostatic

 

 

 

 

expansion valve

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Stopped

OFF

20 pulses

 

 

 

Fan

OFF

20 pulses

 

1

Cooling

Thermostat

ON

20 pulses

 

ON

 

 

 

 

 

 

 

 

 

 

 

Thermostat

ON

Superheat control (65 – 480)

 

 

 

OFF

 

 

 

 

 

 

 

Heating

Thermostat

OFF

20 pulses

 

 

 

 

ON

 

 

OFF

Superheat control (50 – 480)

 

 

 

 

 

 

 

 

Thermostat

 

 

 

 

 

OFF

 

 

 

 

1 - 23

12. Indoor Unit Refrigerant Oil Self Recovery Control

W-2WAY ECO-i SYSTEM Control Functions

This control is carried out regularly in cooling mode only.

(1)During stopped, fan or thermostat OFF condition, indoor unit expansion valve is opened regularly for 1 to 2 minutes regularly (at an interval of once every 2 hours.)

(2)During the thermostat ON, the indoor unit electronic thermostatic expansion valve is opened about 10 pulses from the current status.

1

1 - 24

13. Discharge Temperature

W-2WAY ECO-i SYSTEM Control Functions

<Alarm Information>

(1) Discharge temperature protection alarm

This device sets an upper limit discharge temperature of 222°F for all compressors. When the discharge tem-

perature reaches 222°F, that compressor is stopped and restarted. If the same high discharge condition occurs

4 times, then an alarm occurs.

 

 

 

After a compressor has stopped, that compressor will not operate until the temperature has dropped to or

 

below the start-prohibit temperature.

 

 

1

Discharge temperature protection list

 

 

 

 

 

 

 

 

 

 

Compressor No.

Compressor 1

Compressor 2

 

 

Type

Inverter

Constant-speed

 

 

Stop temp.

222°F

222°F

 

 

Start-prohibit temp.

158°F

158°F

 

 

Alarm display

P03

P17

 

(2)Discharge sensor trouble detection control

An alarm occurs if the discharge temperature remains abnormally high (above 158°F), when the system has been stopped for 60 minutes.

*In this case, possible causes include sensor failure and compressor overheating caused by an insufficient level of refrigerant.

The alarm also occurs if the sensor temperature is at or above the abnormal temperature (176°F) when 20 minutes have passed after the compressor stopped.

*In this case, it is possible that the discharge temperature from a different outdoor unit is being detected, due

to an error in the installation of the discharge thermistor.

Discharge sensor failure list

Compressor No.

Compressor 1

Compressor 2

Type

Inverter

Constant-speed

Alarm display

F04

F05

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