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1 specifications
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1. 53 106 212 425 850 1700 3400 6800 1 7 0 ss aE NC 70 e 70 o T K m o Q B 60 lt t I S 4 Lu 50 o v l m m a 40 Q z lt 1 1 m 30 E o o 20 En APPROXIMATE a THRESHOLD HEARING FOR CONTINUOUS NOISE 5 N I 63 125 250 500 1000 2000 4000 8000 IEG Hz OCTAVE BAND CENTER FREQUENCY Z 1 27 I SPECIFICATIONS S TGMP355B Overall data dB Note This operating sound value calculated value is Side measured at an anechoic room The actual value ron ear is bigger than the calculated value because of the Right la surrounding noise and reverberations Noise measuring conditions Semi anechoic room Measuring position 1 5m Octave band levels in front e 50 69Hz
2. Front Noise measuring conditions Semi anechoic room 1m Heating based on JIS Measuring position 1 5m 2 Octave band levels in front e e 0 60Hz 53 106 212 425 850 1700 3400 6800 I 80 NC 70 70 NC 60 60 NC 50 50 1 H NC 40 40 NC 30 30 EN NC 20 20 APPROXIMATE THRESHOLD HEARING FOR CONTINUOUS NOISE x 63 125 250 500 1000 2000 4000 8000 OCTAVE BAND CENTER FREQUENCY 1 26 AISIN Aisin gas heat pump TGMP280B Moe Toysidat 19B This operating sound value calculated value is Front Rear measured at an anechoic room The actual value is bigger than the calculated value because of the surrounding noise and Noise measuring conditions Semi anechoic room Front Heating based on JIS 1m Measuring position 1 5m 2 Octave band levels in front e 50 60Hz
3. 53 pz 212 425 850 1700 3400 6800 80 s E 0 S 70 m 60 i ur m NC 50 E E 50 B e Lu ra a m NC 40 1 40 o E eee a 1 R NC 30 as amp 30 Q NC 20 20 APPROXIMATE A THRESHOLD HEARING FOR CONTINUOUS Tam NOISE 63 125 250 500 1000 2000 4000 8000 IEG Hz OCTAVE BAND CENTER FREQUENCY Z I SPECIFICATIONS 1 6 System flow chart 1 6 1 Refrigerant System Diagram 1 Cooling The refrigerant Freon R407C after exiting the compressor first flows through an oil separator and a four way changeover valve Next the refrigerant is introduced into an outdoor heat exchanger where it is then derived of heat by outside air to change into condensed and liquefied form The refrigerant liquid is further cooled by the supercooler coil After this the refrigerant liquid goes to the indoor unit and is depressurized by the electronic expansion valve within the indoor unit Thus the refrigerant is deprived of indoor heat to become gasified for cooling After that the refrigerant gas returns to the outdoor unit In the outdoor unit the g
4. Setting operation detection Do not turn on in operation aiaee 45 6 7 8 1 umm check display ON Periodic check display on OFF Periodic check display off 2 Periodic check display time ON 6000 hours OFF 10000 hours 3 Setting gas type 4 5 Cold district specifications ON Cold district specifications valid OFF Normal specifications valid 6 Engine oil pan heater Optional setting ON with Oil pan heater OFF Normal mode on 7 Full time silent mode ON Full time silent mode on OFF Normal mode on 9 Optional setting for deodorization ON Deodorization OFF Normal mode Gas 13A 12A A class type 1 2 propane SW74 OFF OFF ON SW73 OFF ON ON 5172 OFF OFF OFF Include 12A 12A 40MJ m N or more 12A less than 40MJ m N Propane Air 63MJ m N AISIN Aisin gas heat pump 2 4 System Input Output Specifications 2 4 1 Indoor Unit Input Output Specifications Electrical Component Connector Name Functions Specs No Indoor temperature sensor 1 Temperature control 2 Cooling heating changeover during automatic Thermister Ros 5 B 3950 k CNH pins 1 and 2 operation 3 Indoor fan speed control during dehumidification Thermister R s 5 kQ B 3950 k CNH pins exchanger 2 3 and 4 sensor Indoor heat 1 Control of hot starting Antifreezing control 3 Display
5. 5 1 5 1 Periodic Maintenance Items and Periods 5 2 5 2 Periodic Maintenance Procedures 5 3 3 24 Changing Engine Oils ati e ite diee ee eie 5 3 522 Replacing the Oil Filter i e de eed ettet er 5 3 5 23 Replacing an Ignition Plug eese ett edere rede rete cM 5 3 5 2 4 Replacing the Air Element sees enne etre as ia 5 4 5 2 5 Replacing the Compressor Belt sse ener 5 4 5 2 6 Adjusting the Valve Clearances annen enen en eeneenvenvenvenvenneenenneenvenenneenveneenvenvenvenvenne 5 5 5 2 7 Adding Coolant and Coolant Reinforcement eene 5 5 5 2 8 Checking the Coolant Hosing eee eene entere 5 5 3 2 9 Checking the Compyessor ice TRI besneden 3 6 5 2 10 Checking the Operational Sounds esee eene 5 6 5 2 11 Prevention of Valve Damage eese enne rene trenne tentent 5 6 3 242 Replacing the Fuel Gas Hose aas dedita de ete d 5 6 6 MAINTENANCE DATA STANDARDS 6 1 6 1 6 2 6 3 6 4 6 5 Engine Related Components deleri ees erede ete et eres en erar to a in Enter boue ee
6. 2 8 2 4 System Input Output Specifications 2 1 2 4 1 Indoor Unit Input Output Specifications eese eene 2 11 2 4 2 Outdoor Unit Input Output Specifications eerte 2 13 2 5 Protection Units 2 15 2 5 1 Protection Units and Sensor Functions esses 2 15 2 5 2 Sensor Mounting Positions essent eene eene ennt treten teens 2 18 2 6 Outdoor Unit Electrical Wiring Diagrams 2 20 2 6 1 Outdoor Unit Electrical Wiring Diagram eene 2 20 2 6 2 Indoor Unit Wiring Diagram t ep tea ee p tee ee reds 2 23 TROUBLE DIAGNOSIS AND REPAIR 3 1 3 1 Circuit Base Board Maintenance Functions 3 2 3 2 Trouble Items and 3 19 3 2 1 Error Codes Contents and Major Likely Causes sese 3 19 CONTENTS AISIN Aisin gas heat pump 3 3 DIAGNOSTIC C 3 27 3 4
7. 167 Goyeolpul sme s 49949 051 5 ON q n soopino XMS JOMOJg JO JOJO LW uonduoseq uonduoseq Ioqu S uonduoseq JoquiAs uonouni Bunyi ojne ue noullA ued e 104 p9JI Jou S Z pexieui PNOO eu L a rE wora SO ak at won 9 07 z OO s CO my Wo MOJI A as ova wand Xutd sloquu s jo uonduoseg uondo 4 28 4 Og wo n 4 d I 1 1 f 1 t I I 1 t I 1 snun Joopui U Ml Q S UII uopeuuoo soul jeuBis h n Joopjno o L ZH 09 09 OWA 002 eseua ejbuis sjueuieJinbeJ JeMOd 2 25 2 CONTROL ndino OGA ZL 1ndino Bune ri zux 0015 L uonejedo j indu uonejedo 440 OqA ZL 1ndino uoneredo LEX pye u L Buissonery 4 jnduruoneredO NO L SMS O peyeu 1052800092 2 01 YUI s ON Hun JOOPINO YMS esn 3 s 01 ON HUN joopino MS ole lpul snye s 49949 pesj Q31 u 031 eoeld s ON nun ZMS smes jeuuou 1ejnduio92049IJA u9919 q31 2 031 oeld SOL ON HUN LMS S UOMAS yons SHOP yun Auo smoys wesberp pus JOJSUEA IFA 103309 ey BuiKueduuo22e 1ejsiu98u Sul ub eyezur eui Jes o M l q lqe eui sn Jeulojs
8. n Qt ZHO9 0S OVA 002 eseud p lunouu Jejeeu 91n99l UIA ZH 09 05 OVA 002 eseud ojbuis SjueuijeJinboeJ JOMOd POS te y y Povver 2 33 TKUP280M5 2 CONTROL uono lj s d L uoisuedx oSluono l 104 JO OWW Buidd lS WS jesseoeu uonoejes ejBue onjen uoisuedx3 osnj 4 Ajaynjosqe s jejeyed J Jeojds pue peso 2 yew m uonoejes yiqiyul e qeus uonejedo snas jeuuou 4 Q31 2 031 p pl lus esf saul Jewod Jeujo ui jejeJed JeuiuJo NOLS VA yew gt ubis 10jeoipur snyeys YOOYD pesj Q31 031 ul Seui ey jou oq yun oguoo aowa y BurkueduJoo9e Jejsiuuleu L UL jonuoo ue 44o ouueu JOJ SUEA IPA seui O p y ew yoolq jeuiuue L aL uonoejes d dund jeeH J WJOJSULJ uL ey Woy Ajayesedas saul jeufis ou NOY H 10 esn HA 40 100w ueq 440 Josues eDueuoxe MUL sun Joopur u Ml q ejo1 OHZS NO Jojyow UIEIJ NO 5 Josues 4lE exelu V lu L seui jeufiis j2euuoo oj pue yun eu H 40 10 98 U09 2neuBeuioJ 29 3 HZS 440 eds ys o s ulI eUBIs Jo uuoo o g pue v o S lqe Jejeou Aieyxny H 2 4 NO sjueuidinbe jeuondo 104 Aierixny YX Jojonpuoo z x WW Q0 z S 0 p uuoO joe U09 eBejo oN 1ndur JO UOI
9. x P 20 7 Z oe C 15 wee lt S li a Sz DM Coolant sensor Discharge temperature sensor L Engine oil pressure switch 2 18 Discharge temperature sensor R Aisin gas heat pump AISIN ff f ff cf aA 2 O E de 9 L r1 ntake temperature sensor 2 0 T NZ Lene H RM ILE E EE 4 ge 7 BE 8 ur jx 1 Hi NT z h En d i L F Ee apos al mounted on the top plate sensor temperature sensor Engine room temperature sensor Outside Low pressure switch Pale Gas pipe temperature sensor Accumulator inlet temperature sensor Heat exchanger temperature sensor wa 2 19 2 6 Outdoor unit electrical wiring diagram 2 6 1 Outdoor unit electrical wiring diagram 4PV 4 way changeover valve AIN net inlet temperature sensor 7 lt Only Cold district spec Option Fuel box i Heat ex BV Hot gas bypass valve 2 1 4PV C P H DH BV Do I 77 G P er c P peen C PFV Quantity adjustment valve HLSW LLSW me rf EFAN Cup E G WH GV2
10. NOLSV LL oyeolpul smiejs 40949 pes 031 4 031 eed 5 0 ON Hun 100pinO JI S JIA pepjelus es seui amod 19440 YIM wed JOJSUEA IEA goed s ON HUN ui seui Ionuoo y ejnoJ jou oq jonuoo ejouie eyy Buikuedwoode J lsiuu u eoeld 501 ON HUN seul IEE o O pexeuj yoolq jeuiuue uonoejes ed 1 Josues eDueuoxe Jemod ey wouy Ajayesedas s uli IeuBis eui esn uonoejes ojbue onjen uorsuedx3 9r Josues Jie exeju Silun Joopul ueemjeg seul eu Is 1o uuoo 0 pue LL H 10 sn uonoejes iIgiuur ejqeue uone1edo sr ING 10J ejen Aaeyixnyz yun ey oj seuIj jeufiis j2euuoo o g pue v H 40 10128 u09 uDis Jeyt4 ve 2 HIN 404 skejer Areyixny o s lqe 10jonpuoo z x WW 00 Z 0 199uuoO Jayeay jonuoo ue 440 ouueu L er Baren uoisuedxe SlIuono 10jouu Buiddars Syoolq 1983009 eBeyo oN ndul Ionuoo louu uonoejes adh duind jeep 9MS YOWUMS 1201 Jeuiuue aul euis A G eyouep g pue v AL DA ZL 1ndino yooy JO 401001 utei 440 DUA iS UO sejyouep dul ay ndino OA ZL 1ndino NO ouueu NO Jojow uleIq NO SMS Joyow uleig
11. s uli jeuBis v H 40 esn eumejeduie uDis 1934 vf h n jonuoo ejouieJ y Burkueduuoooe JejsiuuJeu Sul spun Joopul ueemjeg seui jeubIs Jp uuoo H 401 10 28 u09 oneuDeuionoe 3 030009 1 4 er Josues eDueuoxe M IUL o pue jun Joopino ey o saul jeuDis Jo uuo2o o g Jejeeu Aeyixny uonisod W1 zr Josues Jie V lU L pue v 0 sejqeo Jojonpuoo Z x WW 00 Z 0 JOSUUOD esn uonoejes ejDue n 7 Keje Ae Sx 640010 Euruue eui eUBIS A G ejouep g pue VHL ewuou q31 uonoejes d duind yeay 9MS ING 404 eja1 Aue YX eyis uo sejouep aul eu ole lpul smejs 49949 pes q31 x 440 Jojow 1120 33 We 404 skejas fuel IX SynoJro jun JOOpuI juo swous weuBeip 51 JOJ SUEA NO Jojow uleiq NO SMS YOUMS PW s 43 Jojou JoAno 1983009 eBeyo oN 1ndui jou09 2 Bumes Z SMS U91IMS JEO 4 S4 andino 0 ZL 1ndino 32905 dois L uonejedo j indu uonejedo 440 ureJq wa ndino OqA ZL 1ndino NO oway L pieA u L Duisie es j indui uonejedo NO L SMS 40 Joyoede 132 indino OGA ZL 1ndino 5 ON n n 100pino YMS LIN 40 jeujejul 1467 ndino ddA ZL 1ndino uogejedo eld s 0L
12. 1 Checking the output voltage Check the maintenance board and the outdoor unit circuit board and make sure that an output voltage of 12 VDC is supplied If in spite of the fact that the corresponding LED is on during the check mode of the maintenance board the required output voltage is not supplied the switching circuit on the board is likely to be faulty 2 Checking the gas electromagnetic valve body Disconnect the connector from the gas valve Next check the two electromagnetic valves for continuity between the respective terminals and scan for electromagnetic coil disconnections Reference resistance value 21 O Checking the gas regulator Disconnect the fuel gas hose then start the engine and Gas outlet make sure that when the gas electromagnetic valves operate the fuel gas does not leak from the gas regulator outlet pipe If the fuel gas leaks the gas regulator is malfunctioning If gas injection from the inlet does not result in gas leakage and the gas is taken in smoothly from the outlet the gas regulator is normal Gas inlet Gas operated solenoid valves Checking the ignition plugs Checking each ignition plug for sparking 1 Remove the ignition plug and close the main gas plug 2 After inserting the ignition plug into the high tension cord bring the plug body into contact with the engine body 3 Press the OPERATE switch and check that the engine will crank and that s
13. NO Z SMS HOMO JO 1O O LIN uonduoseq joquiAs uonduoseq joquiAs uonduoseq JoquiAS sioquuAs jo uonduoseg NO 330 NO NO uc sjun 100pui ueemjeg seui IEUB S 1euuoo 330 NO NO 330 ug pue yun ey o seui jeufis j9euuoo o g pue 340 340 340 NO utei V o s lqe 1ojonpuoo z x WW 00 Z 6270 lp uuoO Z 6MS l 6MS Z 6MS 1 6MS yons SYOOlQ jeuruue eui jeubIS A G ejouep g pue v AL gal ZH 09 Baly ZH 0S sun eys uo sejouep aul eu m V H O N ko LO IN bx pr yun Ionuoo ajoway r eee ee eee Dennen 2 O w 9 uonounj Bunjir ojne ue jnoujM jaued e JO p9JIM Jou si AOQE Z POYEW eu L gt White Red FE 1noui jaued e 10 pepi oud jou Ajjenjoe si e oqe White e i 1 z D 1 hp Seer Red White eBueJo Ane NOJI A Red 8 Red White Blue 5 Black 4 OO z 909 cise OC Red Red Brown MO wg 1 x m Blue Yellow Black iron Yellow seul jeuBis y n or 2 09 09 OVA 002 eseud e p yunoul Jejeeu 9149919 uM es 1 ZH 09 0S ECCE MESE OVA 002 ese
14. 104 Buddays WS spun H 40 J0 9e U00 oneuBeuionoe 3 uDis Jey4 yun jonuoo eyy Buikuedwooge Jejsiuueu Sul Joopui u wq q Soul euis o uuo2o oj pue yun ei eey jonuoo ue 440 ouueu L Josues eDueuoxe jeay uL Joopino ey o seuIj jeufis JooUUOD o g pue y osnj jouoo uonisod HINT Josues Jie exeju V luL snyeys jeuuou u9919 q31 uonoejes ejbue 1eAno N7 401 Sx o Sejqeo soyonpuoo z x 20 0072 9270 109uuoO syoolq oyeolpul 6 40949 pes 031 uonoejes adh duind yeay 10jouu ureJp 4o Keje aeixny yx jeulwua aul jeuBis A G g pue v AL JO SUEA 440 100w 1210 33 Buum iS UO sejyouep eui penop ay Jeuuojsuel L NO Jojow uleiq NO LILA 405 S ejo1 Aserixny IX YOUMS qur S1 SynoJr yun soopul Ajuo smoys urejBeip siy 1983009 eBeyo oN 1ndui jonuoo JEUUON 440 16 24 ZL nd no 40 O JOJOW WI 10 1oyoedeg Z WAS DGA ZL 1ndjno NO ouu u L dois kL uonejedo j indu uonejedo 440 Qndjno 3qgA 21 1ndino BuneeH Buisieney indui uonejedQ NO LW 40
15. CN7 9 pin N7 13 14 pin N6 1 2 pin CN6 3 4 pin N6 7 8pin N6 5 6pin oNe9 0prj Accumulator inlet temperature Right discharge temperature Left discharge temperature Gas pipe temperature Intake temperature N6 11 12 pin CN6 13 14 pin CN6 15 16 pin pee 1 7 O up ci el 5 Ru NN Engine room temperature Outside temperature Target temperature in heating and cooling gt Indoor unit individual request frequency Hz gt Indoor unit answer frequency Hz gt Indoor unit request frequency tHz gt Indoor unit expansion valve angle steps controling oi retum o Indoor unit quantity Kw Indoor unit target heat exchanger temperature Indoor unit control heat exchanger temperature Indoor unit intake temperature gt GEE Indoor unit operation status 70 71 72 73 74 75 76 79 91 92 94 95 7 9 only indoor unit expansion valve fully open status 3 3 3 TROUBLE DIAGNOSIS AND REPAIR 2 Operating hours display mode This mode will be set when the outdoor unit in power on This mode will also be set when no maintenance function is operated for at least 10 minutes in any other mode Function of each switch Switch status Switch Function 7 segments display description No setting Display operation hours Display error status error code In case of m
16. A zH09 0S OVA 002 oseud c p lunouu Jejeeu 91N 098 UIA ZH 09 05 OVA 002 eseud ojbuis sjueuijeJinboeJ JOMOd 2 43 Auess u jeinjosqe si jejejed ji p pl lus esn seui amod Jayjo uy Jejjejed Ul s ul o uoo y jou oq seui Jemod l WOI Ajayesedas seui IeuBis v sun U Ml Qq seui jeufiis j2euuoo o pue yun 1oopino eu 0 saul IeUBIS j2euuoo oj g pue v oj sejqeo Joyonpuoo z x WW 0072 S270 PEUUOD syoolq reuruuey aul jeubis A G lou p g pue v AL BuuiM lis uo sejouep eui ul Synor yun doopul juo smoys uiejBeip 511 S910 gun Ionuoo eyoules HL JEWJION 440 39ejuo9 BENOA ON 1ndur lonuoo Jow y SHX O Z GMS ndino OCA ZL 1ndino 4090 yux dois L uonejedo j indu uonejedo 440 jndino 33A ZL 1ndino No oway L EX pijenuj L Duisje es induruogejedo NO L GMS ndino OA ZL 1ndino Sune H CX eoeld s l ON t n 100pjno YMS ndino OQA ZL 1ndino uonejedo LUX eoeld S 01 ON HUN MS O pexieui 103280005 Zo vu oeld s l ON HUN ZMS ollds pue peso 2 uonoejes ed Af eerd 5 01 ON HUN VAS leuw NOLSV i uonoejes ejbue onjen uoisuedx3 9r uoisuedxe
17. SHX dois L uonejedo j indui uonejedo 440 Z LINH 10J s eja1 Auenixny EZ x L H o S4oo q Qndino 3gA 21 1ndino xoeu bux pueauy 4 Buisi9A s indu uonejedO NO Jejjoruoo ueq 94 eui IeuBis A G ejouep g pue VAL ndino OA 21 1ndino NO ux eoeld s ON UN 100pino YoUMs 1801 S4 Buuim eys uo sejouep eui p nop ndino OQA ZL 1ndino Bune TX eoeld s 01 ON Hun joopino Z LIN 40 Joyoede Z HAO 3 yun Joopul Ajuo swous uieJBeip 511 andino 9GA ZL 1ndino uoneJed LYX eld s 4 ON HUN Z LIN Jeusa u 136 s o payew 1ojoeuuog Z vuo eoejd s 91 ON HUN HOAQIQ 104 1030 ZUN uonduoseq 0 uonduoseq uonduoseq JoquiAs sjoquuAs jo uonduoseg yun Ionuoo palesu si Jejeeu m l jeuondo ue yey seuinsse eui payop e u p pesojoue jInoJio Jejeeu eu x oeig 7 SUM SUM 4 o 2221 DE re Es 24000 9492 do tauo eBue1o apus MED 2 eBue1o ued B r 7 9 gl 5 8 YAS EMS ZMS IMS uondo White White Connection lines between indoor units Red MORE oe Blue Whit D O Red Red D gt o Sv 14 2 nk Ak wn e gan 3 2442 Red
18. Aaeyixnyz SX 5 5 jewou 1ejndujoooJoIJA 4 q31 uonoejes d duind jeep 9MS yx S9 0 oyeolpul sniejs 40949 pes 031 440 1040W ureig 330 JOJSUEA NO LW4 405 sAejas z x SMS WI Jeuuojsuel EUON 3dO 1983uo9 eBeyo oN Indu onuoo 2 Sum s NO LW 10 soyoedea L49 cSMS eNe ouueui uw HOMOJ JO 1010 uonduoseq uonduoseq joquiks uonduos q loquu4S Jeued Sunes do er fr ar uon ac MOEI Lew e DUOMO VAG TAG EAG IME 0 JeuuoN vr nt 8719 097 YHE 292 sepeyo 292 7 ANY lini Floor standing type TKF TKFP80M5 140M5 14055 2 CONTROL Red a Yellow AMO A 0 7 D White White White lt Red Red Blue 77777 White 22 White Redt sjoquuAs jo uonduoseg lines between indoor units Connection Signal Power MH a 4T soul jeus yun 15 omosje do jddns Jomod daad eden r 7 Xem ZH 09 09 OVA 002 eseyd ojbuis sSjueuijeJinboeJ JoMOd 2 50 AISIN Aisin gas heat pump TROUBLE DIAGNOSIS AND REPAIR Chapter 3 TROUBLE DIAGNOSIS AND REPAIR 3 1 Circuit Base Board Ma
19. lsi A s j induruonejedO NO L SMS Alesseo9u indino 201 21 1ndino NO oway eux eoejd 5 ON HUN 100pino YMS Ajainjosqe st 6unno jojered ji se 1eoids pu p solo indino 201 ZL 1ndino B ne H ZX oeld s 01 ON n 100pino EMS p pl lus sr s u l ewod euo uy 9rered jeuiuJey NOLSV4 indino OQA 21 1ndino uoneiedo LX eoeld s L ON HUN ZMS ul s uli jojjuoo OU ties jou oq jonuoo y Buikueduioooe L O iojo uuoo Zo yug 4 s 01 ON HUN LMS Seui J9 od O pexeul yoolq jeuruue uonoejes ed 1 uoisuedxe 21000 Buidd lsS ws eu Woy seu jeufis y ejnouy esn einjejeduie L uonoejes onjen uoisuedx3 or Josues eDueuoxe JESH sjun JOOpul ueewjeq Keje uonoejes jqiuui ejqeue uonegedo Sr Josues Jie V luL s uli jeubis joeuuoo oj pue yun Joopjno eu H 40 10328ju09 2reuBeuionoe 3 uis 1 1l d vf sjueuidinbe jeuondo 404 Aejen Ay YX o seuil PUBIS joouuco o g pue v oj sejqeo 1eyeeu fueyxn y jouoo Ue 3j0 ouueu er TINA 103 s eja1 Ai Z 1X Jojonpuoo x ui 0072 SFO OR sn uonoejes d duind jeeH 9MS Jaj o1 u09 ueq 23 smes jeuuou ue949 Q31 J440 100w uleig 440 UOMAS eO 4 Sd eure eui jeubls A G ejouep g pue v aL E s I 2 oyeolpul snjejs 49949 431 E NO Jojow UIEIJ NO SMS 10
20. pejunouu eq oj si poou MOUS JI WW 008 1589 16 JO eoeds e epi oJd eyoN Syun A4 A JO eoeds eoueuejureui e epiAoJd eJou Jo syun INO Buille su ueuM yun euo uey eJOW ullle sul 104 pejunouu eq oj si pooy MOUS E ji WW 008 Se9 Je jo eoeds e opi oJd e3oN yolul ejqeo Hod Bunoeuuoo 1 MOd s edid pinbil 2 uonisod lqe Jemod 0 oc Buneeu ui esou ureJp jsneux3 0910 esoy ulesp ysneyxy id vied edid seb 2 Lave edid pinby 2 pun euo Burp ejsur 104 edid seb 1 yz vezdWo L eoeds UuOne e1su uonduoseq Joqu s ejoy Jououv 0z r 1 14 AISIN Aisin gas heat pump 2 TGMP280 355B eseg Hod Bunoeuuoo edid seb juejeBujes 1 Hod ejesuopuog sou uieJp 1sneux3 p Hod Bunoeuuoo edid jan c UIA pejunouu eq oj si pooy MOUS E JI LULU 008 1829 Je Jo eoeds e epi oJd eyoN sjun Alone JO eoeds eoueuejureui e epiAoJd eJou Jo spun no Burjjeysur ueuM 077 BEET pT GEEL pg 3661 yun euo uey eJOW ullle sul 104 pejunouu eq o si pooy MOUS e ji WW 008 Se9 je jo eoeds e opi oJd 93oN si 005 8601 0 005 gez 00 yun euo Burejsul 104 eoeds uone eisu uonisod je ut ejqeo JeMOd c Hod Bunoeuuoo edid pinbil jueueBujes
21. Joqus uonduoseq joquiAS Jeued Bunyij ojne ss JIA 104 yun Ionuoo aus lE e A a 222 Bu En peu off Ff peu ww w taug ng avo Q eld enig das YAS EMS ZMS IMS ug OO Eh OO 6 r 824 OA w ovo 222 XUld emt memet mmt t 4 t t 1 1 4 1 pee o p 1 woes be sjoquuAs jo uonduoseq 852 52 WO r AN NM 4 s s SER s pa 3e i 1 V u 1 t 4 t I 1 I 1 I 1 1 I I 1 t t 1 1 I I I t 1 4 1 1 4 seud 104 seud Buis 104 m uondo Connection lines between indoor units Signal psow jeufis pun o L ZHO9 0S OVA 002 eseud c pejunow 19 e9u 31199 9 YM ZH 09 08 OVA 002 eseud ejDuis sjueujeumnboeJ JOMOd 2 23 2 CONTROL 440 NO NO uz NO NO 3 wg 340 340 NO Wer L6MS c6MS L 6MS yons ZH 09 ealy ZH 0S Suy snes jeuuou Jejndujoo0JoI A u991S q31 2 031 eoeld sy ON Hun 100pino qoyeolpul snyeys YOOYD pesj 431 u 031 s 01 ON Hun soopino JOISueA IPA eoeld s l ON HUN J WJOJSULJ uL eoe d s 01 ON HUN Jeojds pue peso 2 uonoejes onjen uolsuedxg of un jonuoo ey BuiKueduuoo2
22. swous weuBeip siu O pexeu yoolq jeuruue L gl uonoejes ed dund jeeH 9MS Jojeou INS qH 440 100w uleiq 440 osn Ha d NO Jojow uieig NO SMS smes jeuuou 4 q31 2 031 20 o eolpul snieis 49949 pes 031 4 031 2 Bumes ZSMS JOJSUEA IEA dois uonejedo j indu uonejedo 440 JOWJOJSUBI HL L uissoney j induruogejedO NO L GMS 39ejuo9 BENOA ON 1ndur jo uo9 SHX eoe d sy ON Hun 100pino YMS ndino OCA ZL 1ndino 49949 VX eed 5 0 ON Hun 2OOPINO EMS DGA ZL indino NO oweur EX eerd 5 ON un EMS ndino OA ZL 1ndino HX eerd sov ON nun VAS ndino 20 ZL indino uonejedo LUX Baren uoisuedxe oruoJ29je JO OWW Buiddars WS O peyeu 103280005 Z 9 WUD Josu s eDueuoxe JESH 4 uonoejes d 1 Josues Jie exeju V lu L uonoejes ojbue uoisuedx3 9r 10J ejou Au ny yx Jeoijds pu p solo uonoejes iIqiuur ejgeue uoneJedo Sr LW4 405 s e i Z IX NOLSV i uDis vt LW 10 sopoedeg L49 yun Ionuoo eyoules h n onuoo ejouue y BuiKueduuoooe Jeysiuueu L ue J4Q ouueu L
23. 092 yun jo uoo 36F YO UQ jeuuoN rk rk 031 9 q31 D pur 288 yoeld Huo VHD Zu9 4949284 390 z l h I nig p 95 um oa ee bom J os HUM a x eseud sjoquiAs jo uonduoseg soul jeus yun oseud ZH 09 08 Z seseud OVA ooz eseud c s uoweinbel JoMOd 2 48 AISIN Aisin gas heat pump jesseoeu Apeinjosqe 51 JI S MA pepjelys esf seuij Jemod 1 u O YIM JeijeJed u Saul jozjuoo eu 104 oq seul Jemod ey wo Ajayesedas saul euBIs eui spun Joopul ueemjeg seui euBIs uuo oj pue pun Joopino ey o s uli IeuBis 3oeuuoo 0 g pue y s lqe 1ojonpuoo z x WW 0072 6270 o uuoO Syoolq jeuiuuej eui jeuDis A G eyouep g pue v AL BULIM eys uo sejouep Sul y yun JOOpuI luo smoys uiejBeip 511 169 indino OCA ZL 1ndino 409 yux DGA ZL indino NO oway L EX dois i uoneledO J indu uoneiedo 440 201 ZL 1ndino BuneeH CX ndino OGA ZL 1ndino vonesedg bax f induruogejedO NO L SMS Jeoids pu p solo O 103280005 ZO vu eoeld s l ON pun oopino YMS Jeuiuue NOLS VJ uono lj
24. 167 JO JOJOJJ lt LUNA yun Ionuoo eyoules uonduos q uonduos q uonduos q Joqus yeg ania Ho 0 ko 0 ko PMS EMS MS IMS 400 JeuuoN b ods 4 0371 9 037 m vH zuo 1840949 0 392 EMUI IMUO Pel qa UM 9 D 4 4 8 D r d l Gray n Orange Orange White gt White white CJ gt 8 Orange ow Brown Ot Black Red Yellow 2 White sioquiAs jo uonduoseg Connection lines between indoor units gt Power soul jeus yun Joopyno OL ZHO9 0S OVA 002 eseud e pejunoui Jejeeu uM ZH 09 09 OVA 002 eseud ojbuis SjueuijeJinboeJ JOMOd 2 39 TK EP112 140M5 14055 2 CONTROL ndino dA ZL 1ndino Bune H THX eoeld s l ON Yun 100pino YMS ndino OA ZL 1ndino Lux eoeld s 01 ON Hun soopino MS Jeoids pue peso g O pexyeui 1ojJo uuoo Zo yug eoeld sy ON HUN ZMS leuu NOLSWA uonoejes d L 1 eoeld s 01 ON nun LMS O p yew yoolq jeuruue uonoejes e Due sAjen uoisuedx3 or uorsuedxe l no f 104 10jouu Burddeis ws YOUMS JEjeuulg uonoejes 1qiuui ejqeue uonededo sr weds ys esn eunje1eduje L uDis 1 1l 3 vf yun jonuoo eyouie eyy Bu kuedujoooe Jeysiuuleu Sul H 10
25. ON Hun JOOpINg EMS HOMOJ 10 1020 HN uonduos q uonduos q joquiAs uonduos q joqu As sjoquuAs jo uonduoseg yun Ionuoo Sul uondo i wug ste 4 HOG Oy NOA Ouo i 2 0 0707 j W 92 White wa oDueJo 140 NOII A uwoJg 240 Oa OSH 09H W 3 Q White VVV wa i 0 oo AV z 4 O hite x 2 q S o 5 v o o a o c 8 5 c c 9 UL Red n 1 o o H 0 0 a a VAS EMS ZMS IMS yooyQ EULON x d 68 DEN YaN 9 331 og 1402 VH zuo 1 yo uo 340 IMUO Ou B sit Black 7777 Signal Power soul jeu amp is y n or Black ZHO9 0S OVA 002 eseud e pejunoui Jejeeu 9149919 uM ZH 09 09 OWA 002 eseud ejbuis Sjueugeuinbai JOMOd b er onm 2 28 AISIN Aisin gas heat pump TKTSP71M5 7155 ollds pu p solo o pee 103280005 Z o vu eerd s ON un ZMS euiul9 NO1SV4 uono l s d L 1 eerd SOL ON n n jesseoeu Ajaynjosge si Bunnoi esed y s m p pl luS esf seul Jemod Jeyjo O pe eu yoolq jeuruue L uonoejes UE onjen uoisuedx3 9r Baren uorsuedxe 210110 10j0u1 Burddeis
26. Z 9 WUD eld sy ON Hun 100pino s lli Jeuuuei NOLSW4 uonoejes ed Af eed S OL ON Hun 100pinO Jamod ey wou AjeyeJedes saul jeufis eu NOY lei weds uonoejes UE uorsuedx3 9r eoeld s 1 ON HUN spun joopui seui jeus 12euuoo Tun jonuoo aowa ou Burkueduioooe J ISILUSU uonoejes iIgiuui ejqeue uone1edo Sr eerd 501 ON HUN pue jun Joopjno ey o seul jeu IS 3oeuuoo o g pue O pexueu yoolq jeuruue uDis 1 1l d vr uoisuedxe 210 JO OWW Buiddars V o s lqeo Jojnpuo2 z x WW 0072 7 0 jeuuo sn jonuoo Ue 440 ouueu L er Josues eDueuoxe JESH syoolq jeuruue aul eubis A G ejouep g pue y AL smes jeuuou 4 q31 uonoejes d duind yeay 9MS Josues Jie exeju BuuiM eys uo sejouep yL oyeorpul smers YoeuD por 31 440 100w 1210 440 SynoJr un juo smoys urejBeip 511 JOISUEA NO Jojow uleIq NO SMS N4 101 sAejo1 Aueyixnyz W 40 10128 u09 oneuDeuio29 3 JEWION 3 j9 amp 3u09 Indur jojuoo O Bum s eingejedue NQ ZSMS W4 AIBAOuUu1 U IBuJ lu HOMOJq JO JOJON uonduoseq uonduoseq joquiAs uonduoseq
27. ay pun JOOpuI juo swous uueJBelp siu 9 0 092 ou Uv pP WYO r CF o 70 AN White OO AN Red between indoor units Connection lines TOM Red SMS Hoodoo VAS EMS ZMS LMS HIUD jeuuoN 11 uda 031 vH zoo 1949949 avo ZMU Red ro U Brown Brown White Redi Black OU Black lt Gb Signal Power Red Yellow soul jeuDis yun d c n ZHO9 0S OVA 002 eseud p lunouu Jejeeu 91N 09 8 uyu ZH 09 09 OVA 002 eseyd ojbuis SjueuijeJinboeJ JOMOd Peu Ht SHUMA 2 40 Aisin gas heat pump AISIN TKES suspended oil resisting type TKESP80M5 Ceiling jesseoeu Ajaynjosge si Bunnoi jej ejed ji p pl lus esn seui Jewod uesseoeu Ajaynjosqe si Bunnoi jejeJed ji s l pepjeius esn seui Jemod 1470 YUM ejjeJed ui seui y JOU oq S UII ey woz A eje1edes soul jeuBis v spun s ull IEUBIS j2euuoo oj pue YUN 100pino 34 o Soul eu is JOSUUOD o g pue v 0 s lqe Jojonpuoo z x WW 0072 S 0 19euuo2 syoolq jeuruJe eui eUBIs A G ejouep g pue vgl Buum iS UO sejouep eui eu SynoJro pun JOOpuI
28. pepjelys esn seui Jemod ui ejejed Ul seui jouoo jou oq seui jewod ey Woy A eyeJedes s uli IeuBis eui nos Silun Joopui u wq q saul jeufis j2euuoo oj pue yun 1oopino eu o seui jeuBis j2euuoo o g pue v 0 sejqeo 10jonpuoo z x Ww 0072 9270 PeUUOD Syoolq feuluu ull jeuDis A G ejouep g pue v AL BULA iS UO sejouep lil penop eu SynoJro pun JOOpuI luo smoys WweuBeip 511 S9 O J WJOJSULJ 0015 uogejedo j indu vonesedg 440 1283009 eBeyo oN ndul onuoo eyoules L Buisie es j ijnduruonejedO NO 935 9 QA ZL 1ndino yo uo s ON jun YMS ndino aA Z indino NO ouueu eoe d 5 01 ON Hun Joopino EMS Jeoids pu p solo ndino oq A ZL 1ndino Buneen eld s ON HUN NS NOLS VJ ndino 9AA ZL 1ndino uonesedo oeld 5 01 ON HUN VAS Jii weds o pee 1ojJo 9 uuoo uoisuedxe 01 104 Buiddeys WS yun qonuoo y Burkuedujoooe Jejsiuueu L uonoejes d L Josues eDueuoxe jeeH luL O pexeu yoolq jeuruue L uonoejes ej Due uoisuedx43 Josues Jie exeju V lu L yams Ejeuug uonoojes yq uul lqeu uonejedo IN1 404 Aeje1 Sx osn eunjejedue L
29. 1 Black 2 Black 11 to 13 VDC Brown White 360 Orange White 36 Q Blue VVhite 360 Yellow White 36 Q Wire disconnection detection temperature below 5 C is detected for ten min Discharge temperature sensor wire disconnections E39 Short circuiting temperature above 120 C is detected for one min Discharge temperature sensor short circuiting E36 0 C 182 9 kO 20 C 70 4 kO 50 C 20 2 kO 80 C 7 0 kO 1002 3 7 kO 120 C 2 1 kO OFF 11 13 VDC ON 1 VDCorless Error detection at a high pressure of 2 75 MPa OFF Return to normal at 2 16 MPa 1 MQ or more 1 or less 5 VDC 0 5 V Output voltage CN7 White Black 3 4 2 3 35 Output voltage V The output voltage value is about 1 V for 1 MPa Error detection at a low pressure of 0 05 MPa OFF Return to normal at 0 15 MPa ON OFF 11 13 VDC 11 MO or more ON 1 VDC or less 1 Q or less 3 30 AISIN Aisin gas heat pump Check Item Pasion To BE Normal Voltage Normal Resistance Remarks Measured Indoor unit circuits Liquid flow regulating valve EV1 Electronic expansion valve Oil returning valves 1 and 2 OILB1 OILB2 Heat exchanger liquid temperature sensor 7 temperature sensor GAS ntake temperature CN6 sensor C P SR Accumulator inlet temperature sensor AIN Hot gas bypass valve BV Compressor clutches R and L C P R C P L
30. 142 m uma 2 JOSEAN JJdO JO eA e ouuou 136 O NO Z SMS HOMOJ JO 1010 LS uonduoseq uonduoseq Joquis uonduos q Joquis sjoquuAs jo uonduoseg yun Ionuoo eyoulesJ euo Sur peieisur si YUM Jejeeu oujoeje jeuondo ue Jey yoxs Q 9 Qvo sewnsse e oqe aul p nop e u Y pesojoue ynouio Jeyeeu eu L Hm m of er sr 440 422 Do ow tr MOlleA between indoor units I l Connection lines YAS EMS LMS Blue Whit Red ad 2 00 T 2 Black white yoayg IeULION OF 4 037 9 031 Signal le Power 1 vH ze ee ee hite Red x 199945 Jauo Blue 1 soul jeus yun ZHO9 0S OVA 002 eseud e pejunoui Jejeeu uM ZH 09 05 OVA 002 eseud ojbuis sSjueuijeJinboeJ JOMOd Eme 0 2 32 AISIN Aisin gas heat pump TKUP224M5 1 1 L essooou jeinjosqe si jejejed ji sei p pl lus esn seui amod 1eujo uy Jejjejed ul seui jojjuoo ouu 1 ey JOU oq seui jewod l WOI Ajayesedas seui IeuBis v spun U Ml q
31. Exhaust volume 0 952 Revolution Cooling 1200 to 2150 range Heating 1200 to 2550 Exhaust port position Upper side 50 60HZ Type x Number of units Scroll typex2 min Refrigerator oil enclosure qiy L Sealing amount 4 Outdoor unit heat exchanger 0 0605X2 cooling 2280 to 4085 heating 2280 to 4845 NL10 4 Exclusion capacity Revolution range Compressor Poly V belting R407C Slit fin Exhaust gas heat exchanger Multi pipe heat exchanger Engine radiator Louver fin amount Single phase induction motor e Rated Heat exchanger Front and rear side Fan Motor Refrigeran ziek 12 7 flare connection t pipin mm 28 58 flange connection R 3 4 Fuel gas pipe Exhaust drain pipe Pipe dimensions 125 Equivalent length 100 Actual length Permissible pipe length Permissible difference in m Permissible difference in elevation between indoor units Aisin Coolant S 50 Outdoor unit at top elevation between Sealing amount L indoor outdoor unit 40 Outdoor unit at bottom Freezing temperature C 35 Connectable indoor 1to 12 Type Magnet type spiral pum units capacity P22 to P280 FT gnet type spiral pump Motor 5 Notes 1 The cooling heating capability and electrical characteristics data shown in the above table was measured under the conditions of JIS B 862 2 The operating sound level shown in the above table was me
32. Terminal B oo Terminal B Terminal M 00 2 Checking the transformer 1 Checking the secondary output voltage Check that an output voltage of 12 VAC is applied between the primary terminal of the diode and the frame ground during the operation of both the ventilation fan and the coolant pump and stoppage of the starter 2 Checking the primary input power Check that a voltage of 200 VAC is applied during the operation of both the ventilation fan and the coolant pump The transformer may be malfunctioning if despite the primary input voltage being normal the secondary output voltage is abnormal 3 Checking the transformer unit Check for primary secondary coil disconnections and for internal short circuiting 3 34 AISIN Aisin gas heat pump 3 Checking relays for normal operation See the reference diagram below 1 Relay R 1 turns on at the same time the motor becomes ready for operation the coolant pump and the ventilation fan start operating Therefore make sure at this time that 12 VDC is applied between terminals 1 and 2 Also check the relay coil and verify electrical continuity between terminals 1 and 2 2 Relay R 3 turns on during the start of the starter Make sure that 12 VDC is applied between terminals 1 and 2 during starter start Also check the relay coil and verify electrical continuity between terminals 1 and 2 Starting motor driving circuits Reference diagra
33. low pressu re alarm Classification of Likely Causes Heat exchange inside the evaporator of the indoor unit is obstructed During cooling During 2 Heat heating exchange inside the evaporator of the out door unit is obstructed During 13 Inappropriate cooling amount of and refrigerant heating 4 Refrigerant circuit faults Sub Classification Indoor fan failure Presence of an obstruction Interference No output Fan motor malfunction Fan capacitor fault Deteriorated heat exchange capability Obstructed ventilation pan filter clogging eat exchanger fin clogging Too lovv intake air temperature Short circuiting or others Outdoor fan failure Presence of an obstruction Interference No output Fan motor malfunction Fan capacitor fault Deteriorated heat exchange capability Heat exchanger fin clogging or interference Too low intake air temperature Outside air temperature below 10 C Deteriorated double pipe heat exchanger capabilities Engine coolant channel clogging Thermo valve malfunction Thermo valve mis mounting Shortage of the refrigerant Refilling not enough Refrigerant leakage Refrigerant circuit clogging Ball valve closed Dryer filter clogged Indoor unit electronic expansion valve Capacity regulating valve clogged Check valve clogged Liquid flow regulating valve clogged 5 Low pressur Refrigerant low pressure switch malfunction e switch faults
34. 03D224 280 355PM 1 Aisin Gas Heat Pump Multi Unit Model P224 P280 P355 SERVICE MANUAL Type of Gas Specifications Standard Salt damage proof type Winterized type Salt damage proof Winterized type Note TGMP224B2N TGMP280B2N TGMP355B2N TGMP224B2NE TGMP280B2NE TGMP355B2NE TGMP224B2NH TGMP280B2NH TGMP355B2NH TGMP224B2NEH TGMP280B2NEH TGMP355B2NEH Type of Fuel Gas TGMP224B2P TGMP280B2P TGMP355B2P TGMP224B2PE TGMP280B2PE TGMP355B2PE TGMP224B2PH TGMP280B2PH TGMP355B2PH TGMP224B2PEH TGMP280B2PEH TGMP355B2PEH Products of the salt damage proof winterized specifications are produced only on an order basis AISIN AISIN SEIKI CO LTD AISIN Aisin gas heat pump PREFACE Safety Precautions The safety precautions to be strictly observed in order to avoid possible damage to persons engaged in the maintenance of the multi unit P224 P280 P355 and to other persons are described using the following methods In this manual hazards and damage likely to result from improper maintenance operations are represented using the markings AN WARNING and AN CAUTION Be absolutely certain to observe these warnings and precautions Meaning of Markings AN WARNING This marking is followed by a description of the situation in which failure to observe this warning could result in personal death or serious injury AN CAUTION This marking is followed by a description of th
35. 3 TROUBLE DIAGNOSIS AND REPAIR Trouble Classification or Sub Classification Check and Remedy Likely Causes Insufficient 5 Engine speed heating does not increase during a mode such as error avoidance control 6 Installation status is not appropriate High pressure error avoidance Discharge temperature error avoidance Coolant temperature error avoidance High pressure error detection L Refrigerant high pressure sensor malfunction Engine speed does not increase since the high pressure level has been mis detected as being too high Insufficiency in engine output L Engine starts but it stalls Significant loss of pressure in the piping Piping between indoor and outdoor units is too long Too many bends are present Branched piping is too long Piping size is not appropriate Significant difference in elevation Piping branches The branch pipe is not mounted at the correct angle The branched header is further branched The total connection capacity of the indoor units is too large 3 62 See high pressure error check items See discharge temperature error check items See coolant temperature error check items See 5 Checking the refrigerant high pressure sensor in 3 3 8 See engine stall check items Actual length 100 m max Equivalent length 125 m max Length from the first branch 40 m max Between indoor and outdoor units max Outdoor
36. Changing period At least every 5 years or 10 000 hours Oil level F 0 to 10 0 mm 20 F 18 to 9 mm 90 5 2 2 Replacing the Oil Filter 1 Remove the oil filter using an oil filter wrench Wipe off the dripped oil with a waste cloth 2 Apply engine oil to the surface of the O ring in a new oil filter and be sure to hand mount the filter securely Changing period At least every 5 years or 10 000 hours Tool required Oil filter wrench Oil filter 5 2 3 Replacing an Ignition Plug 1 Hold the cap of the corresponding high tension cord and remove the cap Next remove the ignition plug using a plug wrench 2 Mount a new ignition plug hand fasten it first and then refasten with a plug wrench 3 Confirm the identification number of the high tension cord and Plug mount the cap properly Plug wrench Changing period Atleast every 5 years or 10 000 hours JS Tightening torque 20 to 25 N m Tool required Plug wrench 5 3 5 PERIODIC MAINTENANCE 5 2 4 Replacing the Air Element 1 Release the four snaps of the air cleaner and then remove the old element 2 Mount a new element Mount the element so that the top faces upward 3 Fasten the four snaps of the air cleaner Element Snap Changing period Atleast every 5 years or 10 000 hours 5 2 5 Replacing the Compressor Belt 1 Loosen the bolts nuts and adjust bolts to remove the belt 2 Mount new
37. Check the operational status See 1 Checking the amount of refrigerant in 3 3 10 See 2 Checking the four way changeover valve See 6 Checking the electronic expansion valves in 3 3 8 Check the hot gas bypass valve See high pressure error check items See discharge temperature error check items See coolant temperature error check items See engine stall check items Actual length 100 m max Equivalent length 125 m max Length from the first branch 40 m max Between indoor and outdoor units max Outdoor unit upper 50 m Outdoor unit lower 40 m Difference in elevation between indoor units 15 m max Approx 13096 or less Capability decreases in proportion to the excess amount of capacity 1 Confirming output voltage Measure the output voltage 12 VDC between outdoor unit circuit board output terminals CON11 pin 2 and frame ground If in spite of the fact that the corresponding LED on the maintenance board is on the required output voltage is not supplied the switching circuit on the board is likely to be faulty 2 Checking the electromagnetic clutch Measure the conducting resistance between the connector and frame ground terminal of the electromagnetic clutch and check for coil disconnections Note Disconnect the connector before measuring the conducting resistance 2 Checking the four way changeover valve If the four way changeover
38. During 16 Hot gas cooling bypass valve faults Trouble with the switch itself Incomplete contact or wire disconnections Hot gas bypass valve malfunction Defects in operation Clogging 3 53 AISIN Aisin gas heat pump Check and Remedy Check the indoor fan motor See 2 in 3 3 9 Clean the air filter Clean the heat exchanger fins See 6 Checking the outdoor fan motors in 3 3 5 Clean the heat exchanger fins Confirm the operating conditions See 1 Checking the amount of refrigerant See 2 Checking the dryer filter for clogging See 3 Checking the indoor electronic expansion valve for clogging See 4 Checking the liquid flow regulating valve and capacity regulating valve in 3 3 11 See 4 Checking the check valve for clogging See 5 Checking the refrigerant low pressure switch See 1 Checking the hot gas bypass valves during heating in 3 3 9 3 TROUBLE DIAGNOSIS AND REPAIR 1 Checking the amount of refrigerant 2 3 4 5 lt Operate all indoor units and measure refrigerant pressure levels from the high pressure detection ports provided inside the engine room If measured data oversteps the ranges listed below the heat exchange section of the condenser or the refrigerant circuit is malfunctioning Operating refrigerant pressure values for reference only during operation of Mod
39. SUM Pe soul jeuDis zun ZH 09 0S OWA 002 eseud SjueuijeJinboeJ JoMOd hu eseua OL 2 49 ndino DCA ZL 1ndino y uo VX ndino OqA ZL indino NO oweur EX 0015 i uogejedO J indu uonejedo 440 seul Jewod esn ainjesodwa ndino OGA ZL indino Bune H CX ndino OA ZL 1ndino vonesedg LUX pyeau Buisje es induruogejedOo NO L GMS ey wou Ajayesedas s uli jeuBIs eui H 10 osn sun doopuruss wed H 40 10 98 U09 oneufeuionos 3 o pee Jojo9uU0D Z o vu eoeld sy ON HUN 100pinO YAS uono lj s d L 1 eoe d 5 01 ON Hun Joopino MS seul euis j2euuoo oj pue un Joopino y Jejeou Aielxny uonoejes e Due uoisuedx3 9r _ goed s ON HUN EMS jeuBis JOSUUOD o g pue y s lqeo Jeoijds pue peso 10jonpuoo z x WW 00 Z S 0 109000 exoolg NOLS VJ uonoejes iIgiuur ejqeue uone1edo Sr eoeld 5 01 ON nun LAS uDis Jord vt oaren uorsuedxe oiuo429jo 104 J0 ow B ldd s WS eure euIj 206 6 A G g pue v EL O pexieu poig eurus L Jo3uoo Ue J40 ouueu er Josues eDueuoxe JESH 4L Jeiipi eds er Josues Jie exeju V lu L BULA iS UO sejouep aul eu yun JOOPUI swous weep siu Lr W7 104 5
40. TKTSPOOOMS Ceiling embedded medium static pressure duct type TKUMPOOOMS Floor standing lowboy concealed type TKFUPOOOMS5 Outdoor unit TGMP224 280 355 Note 1 4 3 2 way compact cassette type TKTCPOOOM5 Built in cassette type TKRPOOOM5 Wall mounted type TKKPOOOMS Ceiling suspended type TKEPOOOMS Notes 2 way cassette type TKTVVPOOOM5 Ceiling embedded high static pressure duct type TKUPOOOM5 Floor standing lovvboy exposed type TKFLPOOOM5 Floor standing type TKFPOOOM5 1 The double asterisk symbol denotes a serial code number and differ according to the type of gas used 2 The triple circle mark ooo in model numbers denote a capacity 3 Other than above outside air processing unit vvith a direct expansion coil unit air feed processing unit ceiling suspended oil resisting type floor standing plenum type and floor standing duct type are available 1 2 1 2 1 2 1 1 2 AISIN Aisin gas heat pump Product Specification Model Number and Product Name Product name Gas heat pump air conditioner outdoor unit Model number New Refrigerant Building Use Multi Unit Model P224 TGMP224 New Refrigerant Building Use Multi Unit Model P280 TGMP280 New Refrigerant Building Use Multi Unit Model P355 TGMP355 Description of outdoor unit model number Ex
41. yndjno OA 21 1ndino 49949 VX eoel d s ON Hun JOOPINO YMS ndino 2QA ZL 1ndino NO WOU EX eoe d SOL ON Hun JOOPINO EMS ndino OA ZL 1ndino 6 UIESH CX eoeld s l ON HUN EMS 2QA 21 1ndino uo eJedo LUX eerd s 0 ON HUN VAS peyeu 1039 uuo Zo vu UOlSUEdX 21 104 Buiddays WS uonoejes d 21 Josues eDueuoxe JESH Mur ollds pu p sol uonoejes ejbue onjen 1015 uedx3 9r Josues Jie exeju V lu L Jeuiuue NOLS VJ uono l s iIqiuur ejqeue uor eed Sr GH 405 eje1 Areimxny yx yun qonuoo y Buikuedujoooe JejsiuJeu L uDis 1 1l d vr LILA 404 S ejo1 Aerixny Z x O pexeu yoolq jeuruue L jonuoo ue 440 0 uueu er IW 10 820 Z SE le gun Ionuoo eyoules J e u uonosjes adh dun d 3eeH QMS HOMOJq JO JOJON ZHN uonduoseq uonduoseq uonduoseq joqug t op st pay Held ped BUL yoeld eld HYO PMS EMS ZMS IMS HUD euuoN sen 0 d 8 0 9 d31 vH J zvo Jexoeyg 0 guo tMUO 1MUO NT pay BL pela HN C sjoquuAs jo uonduos ql lun 2 42 AISIN Aisin gas heat pump essooou jeinjosqe si Bunnoi jejeJed ji
42. 1 to 12 units indoor units Note The capabilities of indoor units slightly decrease during the simultaneous operation of these units in excess of a 10096 outdoor unit capacity ratio Capacity available 1 6 AISIN Aisin gas heat pump 1 2 3 Structure drawing Refrigerant pipe Electrical wire Signal wire Power supply or sn Eee Sen S EEN EEE VWV S 3 N S E il Indoor unit Indoor unit Indoor unit ercurrent 1 an breaker Drain pipes Drain pipes VP25 VP25 Remote Remote Remote Outdoor unit controller controller controller Note Indoor unit Th Single 7 phase 200V 7 Single phase 5 m Da Outdoor 200V C unit Three phase TT Exhaust drain 200V Class three Wiring power supply from outdoor unit possible Ground to wire separately Refrigerant gas pipe x wiring separately f TGMP224B 25 uel gas pipe R3 4 TGMP280B 28 58 TGMP355B 31 8 Refrigerant liquid pipe 912 7 Electrical wire Condensation and signal wire drain Exhaust air drain hose inlet Connecting position for piping wiring Rear side of outdoor unit 1 7 I SPECIFICATIONS 1 2 4 Outdoor unit Specification City gas 13A 12A specifications 50 60HZ Model No TGMP224B2N Type x Number of units Scroll typex2 P224 Multi for building Exclusion capacity Lirev 0 0605X2 Cooling rating Revolution range min cooling 2280 to 308
43. 2 Gas mixer 2 places 3 Engine speed sensor 4 Engine oil pressure switch 5 Ignition coil 3 places 6 Coolant temperature sensor 5 Remove the exhaust heat exchanger See Fig 4 Loosen the bolts on the exhaust pipe and exhaust heat exchanger mounting stay and remove the exhaust heat exchanger When removing the exhaust heat exchanger suspend it with strings or other slings Otherwise the exhaust heat exchanger will be unstable 6 Remove the compressor See Fig 4 1 Suspend the compressor with strings or other slings 2 Remove the bracket mounting bolts and remove the compressor together with the bracket from the engine 4 2 622041 33020 G0954 3252 622461 30010 Oil hose clamping position Coolant hose clamping position Engine speed Coolant temperature sensor Coolant drain 3 AISIN Aisin gas heat pump 7 Remove the engine See Fig 4 1 Remove the air suction hose 2 Remove the oil pan from the bottom of the engine 3 Insert a wooden piece about 20 mm thick under the engine 4 Remove the engine brackets 3 pieces and then remove the engine by pulling it to the Compressor front bracket Compressor 8 Check the compression is the specific value or more bracket by the compression gauge The specific pressure 1 4 MPa or more 9 After removing the hose clipper open the radiator cap and fill the radiator with the
44. Code no DOWN When the one s place i is blinking push Set The display is blinking Then push Set to fix the angle set range 60 steps to 2000 steps 7 display is from blinking to flashing 3 9 3 TROUBLE DIAGNOSIS AND REPAIR continuously Ex 1093 steps ePowered three way valve angle oCommand mode Check mode EN c In pressing Set Jido is blinking When is blinking push Code no UP Code Down The hundred s place of the powered three way valve angle is blinking ex 750 steps n pushing Set the blinking place changes from the thousand s place the hundred s place the ten s place to the one s place of the current angle When the one s place is blinking push Set The display is blinking Then push Set to fix the angle set range 12 steps to 820 steps The display changes from blinking to flashing continuously Ex 60 steps eThe capacity adjustment valve angle oCommand mode Check mode E if m In pressing Set is blinking When is blinking push Code no UP Code Down L The thousand s place of the current LI capacity adiustment valve angle is blinking Ex 60 step n pushing Set the blinking place changes from the thousand s place the hundred s place the ten s place to the one s place of the current angle n p
45. Deteriorated heat exchange capability Obstructed ventilation Air filter clogging Heat exchanger fin clogging Too pe intake air temperature Severe environmental conditions Short circuiting or others Inappropriate amount of refrigerant Check and Remedy See 1 Checking the refrigerant high pressure level in 3 3 8 Check the indoor fan motor See 2 Clean the air filter Clean the heat exchanger fins Check if the ball valve circuit faults Overfilling is fully open 2 Refrigerant flow channel clogging Repair the faulty Ball valve closed section 3 4 5 6 Pipeline clogged or damaged Check valve clogged Entry of uncondensed gas into the refrigerant circuit L Ingress of air Indoor unit electronic expansion valve malfunction opening failure Hot gas bypass valve malfunction anon opening failure Sticking Capacity regulating valve malfunction See 3 Checking the check valve angle in 3 3 8 See 6 Checking the electronic expansion valves in 3 3 8 See 1 Checking hot gas bypass valve during heating See 4 Checking the liquid flow regulating valve and capacity regulating valve in 3 3 11 3 Sensor or signal line faults Refrigerant high pressure switch malfunction L Refrigerant high pressure switch circuit fault improper contact or wire disconnections See 4 Checking the refrigerant high pressure switch in
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47. KO Indoor heat exchanger temp 03D224 280 355PM 1 AISI N AISIN SEIKI CO LTD The contents of this publication are subject to change associated with product improvement If you have any questions please contact our Customer Service Department
48. Refrigerant liquid pipe capacity control connecting port 2 Low pressure switch 12 Intake flexible tube 21 Coolant pump 31 Refrigerant gas pipe connecting port 3 Accumulator inlet temperture 13 Intake temperature 22 Double pipe heat 32 Drain filter sensor sensor exchanger 4 Gas pipe temperature sensor 14 Ignition coil 23 High pressure sensor 33 Engine anti vibration rubber rear 5 Capacity regulating valve 15 Reserve tank 24 High pressure switch 34 Gas regulator with gas electromagnetic valve 6 Liquid flow regulating valve 16 Outdoor fan 25 High pressure service 35 Outdoor unit heat port exchanger 7 Heat exchanger liquid 17 Outside air temperature 26 Oil operated solenoid 36 Exhaust fan temperature sensor sensor valve 8 Low pressure service port 18 Fan motor 27 Hot gas bypass valve 37 Fuel gas hose 9 Four way changeover valve 19 Filter drier 28 Terminal block 10 Engine room temperature sensor 29 Filter drier mounted on the top plate I SPECIFICATIONS 1 5 Various Characteristics 1 5 1 Cooling and Heating Capabilities and Gas Consumption for Each Indoor Unit Connection Capacities 1 TGMP224B2 Indoor Unit Connection Capacity Total Capabilities KW Gas Consumption kW New JIS Marking zi 291 29 1 23 8 27 2 19 3 16 4 280 28 0 23 7 27 1 19 3 16 6 270 27 0 23 6 27 0 194 16 8 260 26 0 23 3 26 9 19 0 16 9 250 25 0 23 1 26 8 18 9 17 0 240 24 0 22 7 2
49. a 9 5 kW 1200 to 2450 min Cooling 1200 to 2550 min Heating Aisin Gas Engine Oil 125 m Equivalent length Permissible pipe length mene 100 m Actual length Lubricating oil enclosure 35L Permissible difference in elevation 50 m Outdoor unit upper between indoor outdoor units 40 m Outdoor unit lower Rated output Revolution range Lubricating oil type lt Exhaust port position 4 o Permissible difference in elevation 15m between indoor units Aisin Coolant S Number of indoor units which can 1 to 12 units 155L be combined Capacity P22 to P280 35 C Magnet type spiral pump 0 105 0 150 kW 50 60 Hz Type Enclosure q ty Concentration Freezing temperature Type Motor rated output Notes 1 The cooling heating capability and electrical characteristics data shown in the above table was measured under the conditions of JIS B 8627 2 The operating sound level shown in the above table was measured in an anechoic room subject to the relevant provisions of JIS Under actual conditions the operating sound level shown above is usually exceeded since it is affected by ambient noise and the echoes of the installation room Pu I SPECIFICATIONS 1 3 Outside Drawing of Outdoor Unit 1 TGMP224B eseg yod Bunoeuuoo edid seb Hod 2 asoy ureip 1sneux3 y pod 8unoeuuoo edid jan c 0002 UIN
50. eAvoidance Description oMonitor mode The details of display are as follows eExternal switch status oMonitor mode The details of display is as follows Spare switch 1 Gas electromagn etic valve Origin of three way valve Invdrter error Bignal Spare switch at engine side 3 13 equipment for ventilator 2 H Warming u p complete High pressure switch Low pressure switch Coolant pump Engine coolant avoidance Intake avoidance Lo High predsure prebsure avoidance avoillance avoidance level L Oil pressure Switch 3 TROUBLE DIAGNOSIS AND REPAIR eOperating each part ON oCheck mode The place for each part is as follows 1 Compressor R 2 Compressor L 3 Gas electromagnetic valve 1 4 Gas electromagnetic valve 2 5 Starter 6 Starter transformer 7 Coolant pump 12 Electrical equipment for ventilator 1 13 Electrical equipment for ventilator 2 L 14 Electrical equipment for ventilator 2 H 15 Hot gas bypass valve 17 Oil return valve 1 18 Oil return valve 2 19 Compressor heater 20 Drain filter heater 21 Coolant heater 26 Four way changeover valve 27 Ventilator fan When pressing Set one segment is blinking Then if pressing Code no UP each segment is blinking from small to large number one by one like 12 52752841 If pressing Code no DOWN each segment is blinking from large to small number one by one like 122827 221 Whe
51. exchange Heat exchange fin clogging 2 Improper indoor fan motor rotation Check the indoor fan Abnormal output voltage motor See 3 3 9 Fan capacitor malfunction Fan motor malfunction Sufficient compressor capabilities cannot be obtained Check the operational First measure the refrigerant pressure and status temperature during operation and check the refrigerant cycle 1 Insufficient heat exchange in evaporator Hot water heat collection failure Continued flow of coolant into radiator Thermostat malfunction Check the thermo valve Coolant circuit clogging See 4 in 3 3 5 and 1 in Failure to collect heat from hot air supply 3 3 12 Insufficient ventilation See 6 Checking outdoor Outdoor fan failure fan motors in 3 3 5 Fin clogging Short circuiting Too low intake air temperature 2 Insufficient circulation of refrigerant See 1 Checking the Shortage of refrigerant amount of refrigerant in Underfilling 3 3 10 Refrigerant leakage See 3 Checking the Refrigerant channel clogging indoor electronic expansion Expansion valve sticking valve for clogging in Dryer filter clogging 3 3 10 See 2 Checking the dryer filter for clogging in 3 3 10 motor 3 Indoor unit electronic expansion valve A malfunction See 6 Checking the electronic expansion valves in 3 3 8 Clean the heat exchanger fins 4 Hot gas bypass valve does not close Check the hot gas bypass valve 3 61
52. mS mud r SW5 4 Set to OFF P80 90 P112 P140 P160 P224 P280 SVV6 1 OFF Note Type select switch assembly SW6 is set to the appropriate status default according to the particular capacity of the indoor unit s Do not disturb this setting DIP switch assembly SW9 setting Function Setting Other than TKT 200 cm Auto lifting stroke downward 130 cm 2 8 AISIN Aisin gas heat pump 2 Remote control unit Remove the upper casing from the remote control unit and set the switches Default Selector switches on side of board To the indoor unit Switches Setting Function Upper casing Type selection SW1 T Sub Cool Cooling only 4 Invalid Initialized on power interruption Remote control SWA Sub Sub remote control Main sub remote control Main remote control Heat sensitive section of sensor Jumper wire connection Not connected Display off Timer function jumper Not connected Invalid Not connected Fan speed select jumper J2 1 Connected Intake temperature Not connected Display off 1 Use the table below to set fan speed select jumper J2 Swing jumper J4 2 J2 Jumper Setting Type of Indoor Unit TKT TKTC TKTW TKTS TKR TKE other than P280 TKK TKF TKFL TKFU Connected ON TKU TKUM TKUF TKES TKFP TKFD TKE P280 2 Use the table
53. 0 15 MPa Stop the outdoor unit and perform the following checks 3 Checking the outdoor unit circuit board for improper connector contact Disconnect and reconnect CN7 from the outdoor unit circuit board and check if the pressure displayed on the maintenance board returns to normal Perform repairs if improper contact is detected If the pressure does not return to normal proceed to step 4 below 3 49 3 TROUBLE DIAGNOSIS AND REPAIR 4 Confirming the pressure sensor supply voltage 5 Confirm whether the supply voltage to the pressure sensor is within 5 0 5 V measure the voltage between pins 8 and 4 on connector CN7 If the voltage is within 5 0 5 V proceed to step 5 below In other cases replace the outdoor unit circuit board since it is faulty Confirming the pressure sensor output voltage Measure the voltage developed across the output of the pressure sensor namely between pins 3 and 4 on connector CN7 Required pressure MPa Output voltage 0 5 Compare the measured value and the pressure indicated by a high pressure gauge f the difference is within 0 1 MPa the pressure sensor is normal In this case replace the outdoor unit circuit board since it is faulty f x0 1 MPa is overstepped replace the pressure sensor since it is malfunctioning The output voltage value is about 1 V for 1 MPa 0 0 5 1 2 3 35 Output voltage V 6 Checking the electronic expansion valves
54. 3 3 8 See 5 Checking the refrigerant high pressure sensor in 3 3 8 Check the throttle operation See 3 3 7 High pressure sensor malfunction L High pressure sensor circuit fault improper contact or wire disconnections 4 Engine circuit faults Throttle returning failure Throttle lever malfunction or stepping motor malfunction 3 51 3 TROUBLE DIAGNOSIS AND REPAIR 1 Checking hot gas bypass valve during heating 1 Measure the coil resistance between pins 1 and 8 of connector CN14 on the outdoor unit circuit board Reference resistance value 800 O 2 After confirming on the maintenance board that the hot gas bypass valve is open make sure that the required voltage is applied between pins 1 and 8 of connector CN14 on the outdoor unit circuit board Required voltage 200 VAC If the required output voltage is not obtained the board is likely to be faulty 3 Measure the pipeline temperature at the downstream side of the solenoid valve when seen from the hot gas bypass valve f the hot gas bypass valve is normal a temperature slightly lower than the discharge temperature will be obtained If the bypass valve is stuck temperature will not increase when the valve opens Replace the hot gas bypass valve if stuck 2 Fan motor coil resistance See Chapter 6 MAINTENANCE DATA STANDARDS 3 52 3 4 10 Refrigerant Low Pressure Alarms Trouble E57 88 display Refrigerant
55. 6 MAINTENANCE DATA STANDARDS Indoor Unit Fan Motor Resistance Value 4 3 2 way blowoff cassette type TKT weis moortiodino s went Manz pam vant P90 P112 SSA511A628A 57 5 56 8 29 7 13 7 25 1 2 4 3 2 way blowoff compact cassette type TKTC Unit Q 3 2 way blowoff cassette type TKTW Unit Q SSA511A487J 1 way blowoff cassette type TKTS Cu O wem wowwesdo su Want wanz wans want 5 Built in cassette type TKR Gu Mode Motor modelno Sus Went Man Mans want m2 ser use os os 95 es sswswsr s ar us us ms AISIN Aisin gas heat pump Indoor Unit Fan Motor Resistance Value 6 Ceiling embedded high static pressure duct type TKU Unit Q P140 SSA511A360J 6 23 P224 SSA511A365J 12 6 4 68 P280 7 Ceiling embedded medium static pressure duct type TKUM Unit O fpa0_ ssastiassoai m 3 us ms ms 8 Ceiling suspended type TKE SEDE Q P36 to P54 SSA511A305J 291 8 158 4 37 8 18 9 18 9 Po ssasraw 2420 1518 sso sso so ssasrrasos 29 s1 90 90 so eee ssasrrAsos niz s r so so so 9 Wall mounted type TKK Unit Q 10 Floor standing lowboy exposed Bind TKFL Unit O Pos sonra 230 750 se ves 6 MAINTENANCE DATA STANDARDS Indoor Unit Fan Motor Resistance Value 11 Floor sta
56. 80 90 112 140 160M5 71 14055 Ceiling cassette type 4 way blowoff w Z exons uni 104 1946 oz g ayons Bun NO 33O c 6MS 330 JO b 6MS Ku y uo pejeoo un urew 3y JO Ionuoo sey IMS exoas Bunji oine l ojne 104 luo pepi oud Aen oe s weep Siu UI 1 Peyew Buuiw eu L uonounj BuiBuims ojne ue ynoyyM eued e 10 papiAoid jou Ileni li UUM l l oe SI ureJBelp SIU ul S pexjeui Buuiw u L Auess o u Ajaynjosqe 51 eed J saum pepjelus esf seui Jemod 1eujo eed ui seui ojjuoo eui JOU oq NOIS VJ 440 1040W ureJg 34O O pexeu Hoog jeuruue L 81 NO Jojow uIeIG NO H 40 esn eunjejeduue L JL E UUON 44 H 40 yo Ms je1euuig 9c 2 Dunes NO H 40 10 28juoo oneuBeuionos 3 HZS Jejeeu Aieipxny H 4015 uonejedo j indu uonejedo 440 pensuj Duisie eM j indui uonejedQ NO 12983009 eBeyo oN 1ndui SHX eerd s ON Hun JOOPINO eu s o m l q lqe eur esr 6 S UII Jomod ey Woy Ajayesedas soul jeuBis v 9INOH o pue Silun Joopui uee eq seul yun ey o seul jeu 24615 1o uuoo joeuuoo 0 g SqA 21 1ndino y uo VX eed S 0L ON Hun JOOPINO 3gA ZL 1ndino NO ouweul
57. E G WH Option 3 29 3 TROUBLE DIAGNOSIS AND REPAIR Check Item Section TOBE Normal Voltage Normal Resistance Remarks Measured o o o s c Q o Refrigerant circuits Exhaust temperature sensor E G E Option Outboard 12 V power supply Exhaust drain heater DH Only for Winterized type Coolant temperature sensor WT CN7 13 14 Yellow CN26 1 Red 2 Black CN14 13 Black CN7 7 White 9 Black 12 White Continuity 371100 Q 52600 O 11500 Q 3529 NEN 50 C 17 6 kQ Coolant temperature of 105 C or 80 C 6 1 kO more is detected for 10sec 100 C 3 3 ka Abnormal engine coolant 110 C 25kQ temperature System shutdown Coolant temperature below 0 C is detected for three min when Engine RPM is 700rpn or more during operation Engine coolant temperature sensor wire disconnections System shutdown 200 VAC Coolant pump CN13 5 Black 200 VAC 58 4 kO 10 WP 9 White CN10 9 Brown Motor driven three way valve EWV Discharge temperature sensors R and L C P TR C P TL High pressure switch HL SW High pressure sensor HS Low pressure switch LLSW CN8 10 Black 11 Blue 13 Orange 14 White 15 Yellow 5 Green 6 Red R CN6 7 8 L CN6 5 6 CN8 CN7 CN8 3 Black 4 Black 8 Red 4 Black
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59. Four vvay changeover valve 4PV Capacity regulating valve C P FV ndoor unit temperature sensor THI A ndoor heat exchanger temperature sensor THI R Float svvitch FS CN10 1 White 2 Red 3 Yellovv 4 Brown 5 Orange 7 Blue 1 CN15 9 Red 17 Red 2 CN15 8 Purple 16 Purple CN6 1 2 VVhite 11 12 VVhite CN6 3 4 VVhite CN14 1 8 CN12 2 L CN12 1 CN15 2 11 Black CN10 17 White 18 Red 19 Yellovv 20 Brown 21 Orange 23 Blue On indoor unit circuit board CNH 1 2 FASTON terminal 9 5 On indoor unit circuit board 11 13 VDC Red White 5 6 Red Orange 5 3 Brown Yellow 2 4 Brown Blue 2 1 White Orange 6 3 Yellow Blue 4 1 300 20 200 VAC 10 C 24 0 kO 0 C 15 0 kO 10 C 9 7 kO 20 C 6 4 kO 30 C 4 3 KQ 40 C 3 0 kO 50 C 2 2 KQ 55 C 1 83 kO 60 C 1 56 kO 65 C 1 34 KQ 70 C 1 15 KQ 75 C 0 99 kO mn m m 7 7 m 57 11 13 VDC Red White 5 6 Red Orange 5 3 Brown Yellow 2 4 Brown Blue 2 1 eee 150 Q 10 i Orange 6 3 Yellow Blue 4 1 300 Q 20 Wire disconnection alarm when temperature of less than 39 C is detected continuously for one min Short circuiting alarm when temperature of 90 C or more is detected continuously for one min A
60. GV1 PSH E G B WT TH AIN TL TR GAS S EGR C P L Compressor clutch L i 1 r M TD Gi 1 1 C PR Compressor clutch R lt 4 4 4 i 2 l 4 4 4 I I C PS Intake temperature sensor I 2 E 2 i 2 I L C P TL Discharge temperature sensor L Br i 1 TR Discharge temperature sensor R m LL ME 1 a Ll mnm E R R E G R Engine room temperature sensor I 220 E E m li m TAN M WR YBrOBI WR YBrOBI iYVVOB BKEr G RYBr RR DE A B W RWBk Liquid flow adjustment valve TE axexsaxe an vit 4 DAD 1 EWV Three way electric valve I l 02 33 5 20 TOPADA BOGDOY 5648 DD OD RR Br Br LVVBk A Be ve LBkBk QD OBO I FUEL Fuel gas adjustment valve CN10 CN8 CN15 CN14 CN13 CN7 GAS Gas pipe temperature sensor I HLSW High pressure switch 1 161 Ignition coil 1 2 162 Ignition coil 2 amp IG3 Ignition coil 3 1 Control board 2 LLSW Low pressure switch OLP Engine oil pressure switch OVBI Oil return valve 1 1 OVB2 Oil return valve 2 I CN25 CN1 CN17 CN20 ae pressure sensor baig Il CN16 i IS CN2 GN3 arter 02 1 STM Throttle valve W w YWO R BIR WRYBr OBI BkR BkW Bl Y RW R Y TY Y BI BI BkWW G ROY R N Bk R BkWBr 1 TBI Terminal block 1 for power supply TB2 Terminal block 2 for communication em ua I c s s EE WB Engine revolution sensor WP Coolant pump gm WT Coolant sensor 1 C PH Compressor heater 1 4
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62. NS UM offered ui seuij jouoo eui jou oq ous uonoejes iIqiuur ejgeue uoneJedo Sr Ja eds xS osn eunjejeduje uDis 1 1l d vt yun Jouoo ejouieJ y Burkueduioooe 1ejsiuJeu L Sul seuil Jewod eu woy jeyejedes saul euis ay eynos H 40 10 98 U09 oneuBDeuio12e 3 o3u09 ue 440 0wsay L er Josues eDueuoxe H lUL Silun Joopui u wq q seui 20615 JOsUUOD o Jojeou le jonuoo uonisod PWT er JOosues exeju v IuL pue pun ey o seui jeuDis joeuuoo oj g pue uonoejes 1eAno Lr NT Keje Aerxny Sx V o sejqeo Jojonpuoo z x ww 0072 S270 109000 jeuuou uee19 041 uonoejes d duind jeep 9MS ING 404 Auexn y yx snieis 49949 pes 031 330 100w ueq d3O syoolq eui eUBIS A G g pue VAL JOJSUEA NO Jojow uleiq NO SMS LW 104 sejas aenixny g Z EX YOUMS HUN 51 HUN JOOPUI swous WeuBeip siy JEWJON 44 39e7U09 BENOA ON Indu 9 NO 9 5 NI Uoys 18014 53 Y Buum eys uo sejouep Sul z L N s lo indino OqA ZL ndino y
63. Remove the exhaust pipe 10 Loosen the 14 bolts and remove the cylinder head Remove the high tension cords and remove the Loosen the three nuts and remove the cylinder Loosen the three nuts then remove the rocker shaft assembly and remove the stem cap See Remove the exhaust heat exchanger stay from the Remove the air suction hose and the oil hosing 622043 33020 G0954 3252 622461 30010 Coolant hose clamping position Exhaust manifold Exhaust pipe R LNE cO melWuU 7 lt N Coolant isq va temperature ED o if eat exchanter E v di cadi Zeus R52 37 GEN Een Ignition coil K zip Al ilt H T Mia eb r rdi g e Coolant drain Fig 3 3 Reassembly procedure 1 Mount accessories in on a new cylinder head See Fig 4 1 Intake manifold Replace the gasket 2 Exhaust manifold Replace the gasket 3 Ignition coils The 2 coil has bolts at its reverse side as well 4 Water inlet and water outlet Replace the gasket 5 Hosing 6 Stud bolts 2 from the surface of the cylinder block using a ae scraper and a gasket remover Notes Fig 4 Do not allow dirt to enter the oiling port the coolant holes or the boltholes Use a gasket remover only for metallic sections If the bolts are tightened with the boltholes filled with oil or coolant the resulting overflow may deteriorate
64. Support for autonomous engine start Igniter 1 Controls the ignition timing of the three cylinder engine ignition coils 17 Stepping motor for 1 Control of engine revolutions engine control 1 Note For details see Stepping Motor Control ON 1 VDC or less CN8 pins 17 brown OFF 11 to 13 VDC and 18 yellow CN23 pin 1 12 VDC 4 A R CN12 pin 2 L CN12 pin 1 11 to 19 VDC Motor plus terminal to ground CN11 Structure 4 phase PM Excitation 1 2 phase Single step angle 0 15 8 Coolant pump 1 Circulation of engine coolant 200 VAC CN13 pins 5 black and 9 white nen 19 Ventilation fan 1 Internal ventilation of engine room 200 VAC CN14 pins 3 vvhite and 10 black 1 On during heating and low pressure circuits persists for 10 sec in succession The valve is switched when an operation mode different from the previous mode is selected or when power is turned on 20 Four way changeover valve Note This valve is activated either 60 sec after turning on the both compressors or if a differential pressure of 0 2 MP between the high pressure 1 Supply and shutoff of fuel gas to outdoor unit 21 Gas electro magnetic valve 1 22 Gas electro magnetic valve 2 23 Heat exchanger fan motor 1 24 Heat High exchanger fan motor L Oil returning valve 1 Oil returning valve 2 Liquid flow 1 Four level control H M L UL when the thermovalve is open during
65. Trouble Diagnosis and sisirain 3 30 3 4 1 Ifthe System Does Not Operate annen enneenenneenveneenvenvenveenenneenvenvenvenvenvenvenneenenvenn 3 30 3 4 2 If the Starter Does Not Operate asa an nasus aun a nre ener nennt 3 32 3 4 3 If the Engine Does Not Start essere emeret eren 3 34 3 434 Ap ihe Engine Stallen beet dudo eie e de e 3 39 3 4 5 Coolant Temperature Alarms sese 3 41 314 6 Oil Pressure Alarms eite terdege iE teet Rn ete ae y n 3 44 3 4 7 Engine Speed Too High Alarm sese eee eene nnne 3 45 3 4 8 High Pressure Alarms During Cooling nnen essen eene 3 46 3 4 9 High Pressure Alarms During Heating sse 3 49 3 4 10 Refrigerant Low Pressure Alarms sese 3 51 3 4 11 Refrigerant Discharge Temperature Alarms 3 53 3 4 12 Communications Trouble and Indoor Unit Circuit Trouble sss 3 55 3 4 13 If Sufficient Cooling Cannot Be sse 3 57 3 4 14 If Sufficient Heating Cannot Be Obtained sse 3 59 MAINTENANCE OF MAJOR FUNCTIONAL COMPONENTS 4 1 44 Engine Body Replacem ht eeu eee ete teet LT SA s gente eoe eene ood 4 2 42 Cylinder Head Replacement 4 4 4 5 Compressor RePlaCeOM 2r D 4 7 PERIODIC MAINTENANCE
66. Z LINH 10 Joyoede rae SynoJr yun JOOPUI smoys urejBeip siy o 201 ZL ndino Bur JEuJON 330 S O Ir i O r Li Qndjno 9gA 21 1ndino uonesed Dunes eimeiedue NO cC SMS Z LING 40 AIPAOULISU jeuroju 1367 gomojg so OON Z ual uonduoseq uonduoseq joquis uonduoseq JoquiAS gun Ionuoo Ke feo 330 pelg Jpeg EPRD NO OJ9A Ducis Aq 1 VSO poy ped O SMS 2 0 ENUO ENUO PAS CMS 245 MS NUD pela Speg ml peu HIUD jeuuoN NE NE 230 1940949 279 O White Red Red uondo s k Molle QUI Ul 5 pou sjoquiAs Jo uonduos ql paesu si Jejeeu m l jeuondo ue Jey sewnsse aAoge aul p nop e ul pesojoue Jejeeu eu L o E one S 25 St 85 Lo cz oo SoS ee eee Power n de eeen Signal soul IeuBis yun ZHO9 0S OVA 002 seyd pejunow Jejeeu h l UIA ZH 09 09 OVA 002 eseud ejpuis sSjueuijeJinboeJ JoMOd 2 31 High static pressure duct type TKU TKUP45 56 71 90 112 140M5 14085 2 CONTROL 1983009 eBeyo oN 1ndui jou09 ejouies 0015 L uonejedo j indu 440 ndino 201 ZL 1ndino 49949 VX pue u
67. belt 3 Adjust belt tension using the adjusting bolts and fasten the nut 4 Retighten the bolts 5 Rotate the engine pulley through several full turns by hand and then check for appropriate belt tension Adjust bolt Adjust bolt Reference belt tension 550 to 600 N Compressor belt changing period At least every 5 years or 10 000 hours Tool required Oil filter wrench Offset wrenches 12 mm 14 mm Belt tension gauge 5 4 AISIN Aisin gas heat pump 5 2 6 Adjusting the Valve Clearances 1 2 3 Make sure that when the crank pulley is rotated by about 20 degrees horizontally the IN rocker arm of the 1 cylinder does not move If the rocker arm moves rotate the crank pulley through one full turn for matching to the top dead center Remove the head cover Match the crank to the top dead center mark as shown in the view 4 Loosen the adjust nuts on the 1 and 3 intake cylinders and the 1 and 2 exhaust cylinders as shown and adjust each cylinder 5 6 Rotate the crank pulley through 360 degrees Loosen the adjust nuts on the 2 intake cylinder and the 3 exhaust cylinder as shown and adjust both cylinders Reference clearance 0 35 0 05 mm hot status Notes 1 Do not use thickness gauges of 0 2 mm or more To adjust clearances of 0 2 mm or more be sure to use two appropriate gauges in overlapped form 2 Do not use corrod
68. both Code no UP and Code no DOWN Jido is linking E Kie display is fixed Setting range ON OFF The display changes from blinking to flashing continuously Ex Oil return is ON AISIN Aisin gas heat pump eDisplay of indoor unit capacity oMonitor mode ex Indoor unit capacity J280 28 0 kw ENSE x Indoor unit capacity J28 2 8 kw aB 3 TROUBLE DIAGNOSIS AND REPAIR lndoor unit operation condition oCommand mode Operation condition of selected indoor unit address is blinking Ex When the selected indoor unit is stopped When pressing Set the x 5 s place is blinking When the hundred s place is blinking if Code no UP is pressed li F J C H If Code no DOWN is pressed H 5C J F When Set is pressed the value is blinking 2 2 H H kb VVhen the value is blinking if Code no UP is pressed the value changes from small to large number like18 19 30 cr If Code no DOWN is pressed the value changes from large to small number like cr 30 19 18 f press Set all data is blinking Then pressing set the value is fixed The display of data changes from blinking to flashing continuously Ex heating mode set temp 30 Display of Indoor unit operation condition data is following Ex Cooling set temp 19 setting C19 Heating set temp 30 setting H30 Dehumidify
69. boz 1292 1 Signal White 190 1ex eup Jauo soul jeus yun ZHO9 0S OVA 002 oseud c p lunouu Jejeeu 91no l uM ZH 09 09 OWA 002 eseud ejBuis SjueuijeJinboeJ JoMOd BI ERRAT ee 2 34 Aisin gas heat pump AISIN TKUM auO pue eiu w 2440 eu ebueuo1ejur suoneoyioeds eunsseJd onejs uBiu 104 essooeu jeinjosqe si Bunnoi jejeJed ji p pl lus esn seui Jemod 19470 ui Ul seui O4JUOD jou oq seui jewod ey Woy A eyeJedes s uli IeuBis eui spun Joopui uee eq saul jeufis j2euuoo oj pue yun eu o saul jeubis j2euuoo o g pue y 0 sejqeo Jojonpuoo z x WW 0072 9270 1004400 syoolq IButuu eui jeus A G eyouep g pue v HL BULA iS UO sejouep eu EMS ZMS O io josguuoo Zo yugo 0015 L uogejedo j indu uonejedo 7440 osn 4 L Buisje es ijnduruonejedO NO l SMS Jeojds pu p so smes jeuuou 4 qan 2 031 oeld 5 ON yun JOOPINO YAS leuw NOLSV oyeolpul snieis 49949 p s 031 x qa eoe d 501 ON Hun 100pino MS Jol wed JOJSUEA BA eoeld s l ON n n NS 9 3uoo y Bui ueduuoo2e 9 uL 4 s 01
70. dert et edet bete ueteres 1 8 1 3 Outside Drawing of Outdoor Unit eee rete ss 1 14 1 4 Outdoor Unit Internal Structure nnvenvonnvensvenseenseonsensennsennvenneenseenseenseenseenseonseenvenseonseonsenneenveenvenneense 1 16 1 5 Various Character 1 18 1 5 1 Cooling and Heating Capabilities and Gas Consumption for Each Indoor Unit Connection Capacities eese tette ettet eene eene net eren eere tree tenerent 1 18 1 5 2 Allowable Cooling and Heating Temperature Ranges see 1 21 1 5 3 Changes According to Piping Length seen eee 1 22 13 4 FuelComs nphion screenen emet ette e teo dide 1 23 1 5 5 Outdoor Unit Operating Sound Characteristics esse 1 26 16 System AOT E M 1 29 1 6 1 Refrigerant Circulation Diagrams and Description eee 1 29 1 6 2 Coolant Fuel Air Circulation Diagrams and 1 31 CONTROL a Raiser iini ben ies kee Prope es 2 1 21 System Control Function ccsciesosisscssescssescssoncsscseesoasessanssocsissceecvostescs ceosessecessesdesccecsonseaccdsencoiescedsonsees 2 3 2 2 Remote Control Unit Functions vvenvoonvonseonvennvenneenseenseensvenseonseonseonvnnnennsenneenseerseenseenseenseenseenseonvennennee 2 7 2 3 DIP Switches for Function
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72. eoeld s ON nun Youms 1sneuxo HOMOIG 104 100 EME J WJOJSULI eerd 5 01 ON HUN uo1ws Ajddns se JJOAO q JO 10101 SIN uonoejes ed L eunsseJd ones jsneuxe uols 109 uonduoseq joquAg uonoejes ejBue onjen uorsuedx3 eunsseud ones Ajddns are 5 joeles uonoejes yIgiuur ejgeue uonejedo Josues eDueuoxe JESH uDis 1834 Josues Jie exeju jo1uo9 UB J4Q ouueu L andjno uonesedo Aejas Areyixny uonduoseq uonduoseq 1210 440 SMS PMS EMS ZMS LMS LI V enuo znvo ko ORIG Pet ex NYO dn 1 d31 J zuo 1 yo uO aug LMG NOII A ILS S 0 ABD pP je INH sjoquiAs jo uonduos ql Hc sour reubIs 1707 poy Yolonuoo UOISJOAIp Sn HS znHx nlg CIS seul jeubIS 2 uondo eng 215 00 041402 JO epis H T as sseid onejs MOT sed neis YIH o o E o o o 2 o 2 Connection sad san MOT iddns any sold oneis YIH J Signal Power soul jeus zun oL d G 2 s ie La is ZH 09 09 OVA 002 eseud ejbuis sSjueuijeJinboeJ JoMOd 2 46 AISIN Aisin gas heat pump Asess o u Ajeinjosqe si Sunnol JeijeJed J seJl p pl lus esf seui amod 19470 ejjesed u
73. heat exchanger temperature sensor and related harness are short circuited Check and if necessary correct the assigned outdoor unit addresses Check and if necessary correct the assigned outdoor unit address numbers 1 Check the power supply wiring 2 Check setting of power supply 1 Reconnect the connector Confirm the pipe temperature and pressure of the refrigerant system Confirm the amount of refrigerant discharge temperature refrigerant high pressure value and refrigerant low pressure value Check the air filter for clogging in heating mode Confirm the operation of the hot gas bypass valve oil returning bypass valve and four way valve Confirm temperature display using the maintenance board Check the discharge temperature sensor harness for short circuiting Check the discharge temperature sensor connectors 3 TROUBLE DIAGNOSIS AND REPAIR Alarm Code Maintenance Display of Board Remote Control Unit Diagnosis and Repair Major Likely Causes Diagnosis Remedy 1 Outside air temperature sensor 1 Check the temperature display Contents Outside air temperature sensor wire disconnections Outside air temperature sensor short circuiting Compressor discharge temperature sensor wire disconnections Refrigerant high pressure switch wire disconnections Refrigerant high pressure alarm Engine room temperature sensor wire disconnections Engine room temper
74. high 2 15 2 CONTROL Protection Unit Unit ChekDispay ChekDispay Detector een Error Item Remote Maintenance Red LED Connector Control Unit Board Blinking Accumulator inlet temperature sensor Engine room temperature sensor Exaust temperature sensor option Outside air temperature sensor Outdoor heat exchanger liquid temperature sensor Gas pipe temperature sensor Outdoor unit addressing switch Communication cable Outdoor unit board Indoor unit addressing switch Remote control unit wire Communication cable Indoor heat exchanger sensor On the outdoor unit board CN6 3 4 On the outdoor unit board CN6 13 14 On the outdoor unit board CN7 13 14 On the outdoor unit board CN6 15 16 On the outdoor unit board CN6 1 2 On the outdoor unit board CN6 9 10 On the outdoor unit board Swi 2 On the outdoor unit board CN26 1 2 Inside the outdoor unit board On the indoor unit board Swi 2 On the indoor unit board CnB On the indoor unit board CnK On the indoor unit board CNH 3 4 Accumulator inlet temperature sensor wire disconnections Accumulator inlet ee saksa S sensor short E saksa S Engine room temperature sensor wire disconnections Em Rs room temperature sensor short Em Rs bw S Exhaust sensor wire ET HMM Exhaust air error air error Outside air temperature sensor wire dis
75. hours AN WARNING Be absolutely certain to perform the following operations before starting periodic maintenance operations Turn off the 200 V ground leakage circuit breaker located inside the control box of the outdoor unit Before turning off the breaker stop remote controlled operation and wait for at least about one minute Close the main plug on the fuel line Frequency of maintenance Item To Be Performed No of years 5 10 o Replacing an ignition plug Replacing the air element Checking and replacing the compressor belt Checking the coolant level and adding coolant and coolant reinforcement 7 1 Checking for engine oil leakage Checking for coolant leakage Checking for exhaust gas leakage Checking the compressor 16 Checking 7 m Notes 1 After test operation or checking at five years on a calendar basis or 10 000 hours of actual operation whichever comes the first perform maintenance and check operations subject to the above table 2 The H mark and L mark in the table denote replacement and check adjustment respectively Items marked need to be performed with the system running 3 The mark indicates that carburetor cleaning is required 4 Forthe items that require only all year checking replace parts when abnormality is detected in the checking operations 5 Refill the reservoir with the specified amount of coolant strengthening agent Use Aisi
76. is engaged 3 Improper indoor unit heat exchange Trouble with the clutch itself 205 clutch ncomplete contact No output Control section 2 Indoor temperature sensor malfunction See 1 Checking the disconnections 3 3 12 disconnect contact or wire temperature sensor in Sensor fault Adequate air conditioning cannot be obtained since the indoor temperature is mis judged to be lower than its actual value Heat exchanger temperature sensor See 1 Checking the Incomplete contact or wire temperature sensor in disconnections 3 3 12 Sensor fault Since the heat exchanger temperature is mis judged to be lower than its actual value the antifreezing control function operates during cooling 1 Automatic activation of refrigerant circuit Confirm circuit protector protector status No error is displayed until the refrigerant circuit protector has repeated its automatic activation and automatic resetting several times During this automatic resetting cycle therefore the clutch is repeatedly engaged and disengaged 2 Extreme decrease in indoor heat exchanger See 3 Checking the indoor temperature electronic expansion valve for Expansion valve clogging clogging in 3 3 10 Dryer filter clogging See 2 Checking the dryer Other clogged blocked status filter for clogging in 3 3 10 The antifreezing control function of the indoor heat exchanger operates 1 Insuffic
77. of the water associated with the stop of the pump may result in an error The situation under which these events may occur is shown below Checking the drain pump 1 Confirming the operating sounds of the pump Confirm the operation of the pump by judging from its operating sounds and from the flow of the water through the pipe 2 Confirming the output voltage If the drain pump is not functioning check for an output voltage of 200 VAC at the output terminals of the indoor unit circuit board 8 Checking the drain pump motor Measure coil resistances between lead wired terminals and scan for disconnections and short circuiting Type of Indoor Unit Reference Resistance Values TKTP 4 way cassette type 2120 TKTWP 2 way cassette type TKRP Built in cassette type 136 O TKTSP 1 way cassette type TKUMP Medium static pressure duct type 3 58 5 Checking the float switch Confirm the electrical conducting status of the float switch FS AISIN Aisin gas heat pump Note Error code E9 will be displayed if the switch wiring is disconnected or if the switch itself is not connected 3 4 13 If Sufficient Cooling Cannot Be Obtained Trouble Classification of Sub Classification Check and Remedy Likely Causes Insufficient 1 Electromagnetic 1 Electromagnetic clutch malfunction See 1 Checking the cooling clutch of the compressor is not engaged 2 Electromagnetic clutch of the compressor
78. only for cold district spec e Control box DH Exhaust air drain heater only for cold district spec QU DB E GE Exhaust air temperature sensor option C P or E SUB PCB FG E G WH Engine oil pan heater option I DH T Cl C2 Condenser for ventilator 1 2 L Fuer 1 Ds 041 Sirge S 111 CS Electrolysis Condenser Dr phase R 11 01 23 Diode 1 2 3 1 2 Three DB Diode bridge 47 1 oz Phase 11 A t ELB Electrical leakage breaker FG Qi DI 1 s FG Frame ground F i E FUI 2 3 Fuse 1 2 3 4 8 IGN Digital Igniter controller Engine FU3 6 D2 TRI S lt I R1 2 Relay 1 2 EN I R3 Starter relay 1 cs CS jos i SUB PCB Sub circuit base board 1 TRI Transformer for Starter IT FG I TR2 Transformer for circuit board 1 5 5 Le FMI Electric equipment for ventilator 1 I 2 3 FM2 Electric equipment for ventilator 2 sm Poe eee T o THO Outside temperature sensor t s GVI Gas electromagnetic valve 1 tp I m e GV2 Gas electromagnetic valve 2 EL fs BL R3 TB1 Note1 The setting in the diagram indicates b 1 ais rl l ls distance stopping state Note 2 No color connector is natural m U i Sr Grounding AC200V 1 To indoor unit To Long Si 2 20 21 2 CONTROL 2 22 AISIN Aisin gas heat pump Indoor Unit Wiring Diagram 2 4 3 TKT TKTP28 36 45 56 71
79. r HOMOJq JO JOJON LAHI uonduoseq uonduoseq Joqui s uonduoseq JoquAg eld pes BUL yoelg pay yoejg eld Moa YAS EMS NS IMS jeuuoN 1526 z 5 d31 vH J 290 auo EMIO LMUD Ao sjoquuAs jo uonduos ql sa P gi uun soopino 2 41 2 CONTROL TKESP140M5 140S5 iesseoeu l lniosqe 51 Bunnoi jejeyed JI SOUIM pepjelys esf s uli Jjewod uesseoeu jeinjosqe si Bunnoi jejejed J p pl lus esn seui amod ui JejjeJed ui seui jonuoo U JOU oq seul ey Woy A oye1edes soul IeuBis eui inox spun ueemjeg seuIj jeuDis 19euuoo oj pue yun Joopino eui O saul jeuBis Jp uuo2 o g pue v s lqe 1ojonpuoo z x WW Q0 z 870 p uuoO Syoo q Tuua aul jeuDis A G ejouep g pue y HL IM l s uo sejouep Bul yL Synourm yun JOOpuI juo smoys ureJBerp siu esnj Ha d 440 40 ouu uleiq 440 smes jeuuou s yndulo20 21 y 4 1371 9 031 NO Jojow ueg NO SMS o eolpul snieis 49949 pes q31 N31 JEuJON 33 JOJSUEA IEA 2 NO ZSMS J uuJOJSUEJ HL dois L uonejedo j indu uonejedo 440 ioe uoo BENOA ON 1ndur Ionuoo OWH SHX pijenuj L Duisje es induruogejedo NO L GMS
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81. set temp 18 setting J18 Ventilation Setting F Stop Setting Cooling test operation Setting Cor Heating test operation Setting Her Range of set temperature 18 to 30 In cooling test operation the set temperature is the present target temperature which is set presently 3 20 3 2 Trouble Items and Diagnosis 3 2 1 Error Codes Contents and Major Likely Causes Alarm Code Maintenance Display of Board Remote Control Unit Contents Communication error betvveen the indoor unit and the remote control unit ndoor unit address number overlapping Pairing error Diagnosis and Repair AISIN Aisin gas heat pump Major Likely Causes Diagnosis Remedy 1 Power off of some specific indoor units during multiple indoor unit control from one remote control unit Incomplete contact or wire disconnections of the remote control unit signal line white Noise in the remote control cable Indoor unit circuit board fault CPU uncontrollable Indoor unit address number overlapping The outdoor unit is powered off or the CPU on the circuit board of the outdoor unit is uncontrollable The network signal line of the outdoor unit is not connected properly or is disconnected The machine number of the outdoor unit is not set properly an outdoor unit having the same machine number as that of the indoor unit is not present The circuit board of the outdoor unit is abnormal The o
82. seuIj jonuoo ey jou oq seuil ndino OqA ZL 1ndino y uo yux 33A ZL 1ndino NO oway L EX 0015 i uogejedQ J indul uonegedo 440 ndino OGA ZL 1ndino CX ndino 201 ZL 1ndino vonesedg bax f induruonejedO NO L GMS Jeoijds pu p solo peysew Joyoauu0D ZO vu eld s ON Hun 1oopino YAS euiu49 NOLSV i uonoejes d L Af eoe d SOL ON Hun Joopino MS Floor standing duct plenum type TKFD TKFP TKFPP140M5 Jamod ey wo Ajayesedas s uli euBls v yelp pede ys sun u wg q seu leUbis Jo uuoo yun joguoo ey Buikuedwoooe 1ejsiuueu pue ey o s uli jeufirs 32euuoo o g pue O payiew oord jeu aL V o s lqeo Jojonpuoo z x WW 002 SZ 0 UD ESFI F 101002 ue 3jo ouueu er org fenus eui jeubis A G ejouep g pue v AL smes jeuuou 40 q31 2 031 uonoejes d duind jeeH 9MS eys uo penop SUL jojeorpur smes yo u peu 0511 M Q31 440 1040W ueg 43O Synoarm yun JOOpUI luo smoys uiejBerp 511 JO SUEA IPA NO uleiq NO uL 440 j9 amp 3uo9 eBeyjo oN 1101 jojuoo ejoue Sux 2 NO uonduoseq JoquiAS uonduoseq uon
83. small number to large number Only pressing 00 gt 01 98 99 00 01 Code Ne Change code number from large number to small number Only pressing 00 gt 98 98 gt 01 00 99 98 gt Code no In checking each indoor unit data select the unit you want to display In pushing the switch the address of indoor unit is changing Only pressing Selecting an Use in case more than the code no 80 indoor unit The minimum of indoor unit address gt The maximum address The minimum address Only pressing Mode Change the mode gt Operation hours display Selecting Oniy pressing Clear Clear the set data In setting operation the current operation status is displayed and yp g in other indications the previous status before set is selected Onlv pressinq Set Fix the set data Ex In case of setting indoor unit operation in pushing the switch yp g finally the data is sent to the indoor unit Code no list in Check mode Throttle valve angle step Fuel gas adjustment valve angle step Liquid quantity adjustment valve angle step 60 to 2000 Calculated powered three way valve angle step Quantity adjustment valve angle step Individual part operation ON On Indoor unit expansion valve angle step 3 7 3 TROUBLE DIAGNOSIS AND REPAIR Instruction Description Instruction Description ePrevious error 1 10 oM
84. status See 1 Checking the amount of refrigerant in 3 3 10 Check the indoor unit electronic expansion valve See 3 in 3 3 10 See 2 Checking the dryer filter for clogging in 3 3 10 See 4 Checking the check valve for clogging in 3 3 10 See 1 Checking the four way changeover valve See 4 Checking the liquid flow regulating valve and the capacity regulating valve Clean the indoor air filter Clean the indoor heat exchanger fins Clean the outdoor heat exchanger fins See 2 Confirming the operating environmental conditions in 3 3 8 Confirm the operational status of the compressor 3 Deteriorated compression efficiency If in spite of the compressor rotating at full speed adequate air conditioning cannot be obtained at low condensing pressure and high evaporation pressure the compressor is likely to have deteriorated in compression efficiency Confirm the operational status of the compressor Overheating of the compressor body 4 Hot gas bypass valve malfunction Insufficient compression efficiency Compressor malfunction See 2 Checking the hot gas bypass valves See 3 Checking the discharge temperature sensor Malfunction open idi bypass valve malfunction Interference due to obstructions 5 Discharge temperature sensor malfunction Discharge temperature sensor Trouble with the sensor itself 3 55 3 TROUBLE DIAGNO
85. the radiator if the coolant level is too low 6 Repeat step 5 above until the coolant level in the radiator has stopped decreasing 7 Start the engine and check for oil leakage coolant leakage and other abnormalities 8 Stop the engine and after waiting for at least 10 minutes pull out the oil level gauge of the oil sub tank and check the oil level Specified amount FULL level 0 to 20 mm 4 3 4 MAINTENANCE OF MAJOR FUNCTIONAL COMPONENTS 4 2 Cylinder Head Replacement 1 Components tools and materials required 1 1 Small quantity Components Cylinder head set Aisin Coolant S Aisin Gas Engine Cil L 10000 Materials Others Gasket remover Waste cloth Hose clipper Scraper Iron pawl Belt tension gauge Torque wrench Plug wrench 2 Disassembly procedure 1 Drain the coolant See Figs 1 and 2 1 Clamp the coolant hose in two places 2 Loosen the coolant drain plug and drain the coolant 3 Remove the coolant hosing 2 pieces from the engine 2 Remove the harness See Figs 1 and 2 1 Gas mixer 2 places 2 Ignition coil 3 places 3 Coolant temperature sensor 3 ignition plugs 4 5 Fig 3 Note Be careful at this time so as not to drop the stem cap into the engine 6 Remove the push rods Note After removing the rods arrange them in order of removal 7 exhaust manifold 8 9
86. uo 0015 L uogejedo j Indu uonejodo 440 indino 201 21 1ndino NO oway L L uissoney indu n uonejedO NO 95 Jojoui ureJq Wa LW Jo Joyoedeg Zlo 201 ZL 1ndino Sune H oeld s ON Hun 1oopino YAS LI 40 136 Qndjno 501 ZL 1ndino uoneiedg eld s QL ON lun yomoyg 40 OW Z LW yun onuoo uonduoseq uonduoseq uonduoseq joqw s Comte xoelg xoelg PAS EMS ZMS LMS xoeuo JeuuoN AR WE 031 9 331 4 290 0 390 OW Black o Black i Red sel Yellow Whitey o Red r sjoquiAs jo uonduoseg o 2 c im S o 5 o o a o c 8 5 c c 9 Power seul jeu amp is y n o L ZHO9 0S OWA 002 eseud e pejunoui Jejeeu 9149919 uM ZH 09 08 OVA 002 eseud ejBuis s Ju uu uinb i JOMOd 2 29 TKRP22 28 36 45 56 71 90M5 Built in type TKR 2 CONTROL peysew 40jeuuo dois uoneJedo Indu uoneu do suoneoyioeds eunsseud onejs 104 Jeoijds pua paso pue EE pjenu Bulsioney 4 jndui ERES E L SMS uess o u Ajejniosqe si jojjejed 21 NOLSV sn e s jeuuou ue9J
87. 2 y nno ejqeo amod Jououv 0zo r 1 15 I SPECIFICATIONS 1 5 Outdoor Unit Internal Structure 1 2 3 4 5 6 7 8 9 10 Exhaust port Radiator cap Reserve tank filling port Intake air silencer Air cleaner Oil filter Engine oil pressure switch Outdoor unit heat exchanger Radiator Gas mixer 11 12 13 14 15 16 17 18 19 20 3 l E Z A N Nay K WY LI yy jig fy 4 1 11 d Ws L Coolant temperature sensor 21 Engine 22 Discharge temperature sensor L 23 Compressor L 24 Compressor belt L 25 Oil subtank 26 Engine anti vibration rubber L Oil pan Engine anti vibration rubber R Electric three way valve WO Sch dee os 2 1 NE Les read Nem Control circuit board Exhaust heat exchanger Power supply unit Discharge temperature sensor R Compressor R Compressor belt R AISIN Aisin gas heat pump 1 11 13 2 RD NN 4 MC H 5 6 Ne EET e 3 A 221 if Sal VO CCD A A A i LA IN T 1 K 2 EAAS 36 22 31 33 34 1 Discharge flexible tube for 11 Discharge flexible tube 20 Accumulator 30
88. 27 50 10 Outside air CN6 15 16 White 20 C 39 58 kO Unconnected wire detection temperature 10 C 23 95 ka temperature below 39 C is sensor o detected continuously for one min THO 7 77 Outside air temperature sensor Engine room CN6 13 14 Red yn wire disconnections E38 ENS cae i 20 C 6 43 kQ Engine room temperature sensor sensor 30 C 4 21 KQ wire disconnections E52 E GR 40 C 3 04 kO Short circuiting detection temperature above 90 C is detected continuously for one min Outside air temperature sensor short circuiting E38 Engine room temperature sensor short circuiting E52 Throttle valve CN11 9 to 14 Pulse waveform at STM 30 to 30 VDC Engine oil CN8 Brown Yellow ON 1 VDC or less 1 Q or less The oil pressure is abnormal for three pressure switch OFF 11 13 VDC 1 MO or more Sec or more OLP Gas electro CN7 White White 10 16 VDC magnetic valve 1 19 20 14 VAC full wave GV1 rectification Gas electro CN7 Black Black magnetic valve 2 17 18 GV2 Starter Motor plus terminal 11 19 VDC STR Ground Starter pinion coil Starter relay output 11 13 VDC terminal or starter pinion terminal Ground Main unit Digital igniter controller IGN Fuel gas CN11 3 Yellow 30 to 30 VDC regulating valve 1 White FUEL 5 Orange 4 Red 7 Blue 6 Red Coolant heater CN13 1 6 Blue 200 AVC 1600 120
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90. 4 104 sAejas Z IX Jejjonuoo ue4 2d 1983009 1ndui jou09 JEUUON 44 ndino OA ZL 1ndino y uo 2 Dunes NO YOU MS 1201 Sd LIN 10 sopoede 130 OGA ZL 1ndino No oway L 4015 uogejedo j indu uonejedo 4JO ndino 9qA ZL 1ndino BuneeH p leAul 4 Duisie eM indui uoneiedg NO LW 10 jeujeju 167 104 uonduoseq uonduoseq uonduoseq joqug RAAR 4084 z LI T sloquu s jo uonduoseg lines between Connection indoor units 2 45 TKUS TKUSP90 140M5 140S5 ing uni Air feed process ay neg HUL erg we 4 031 8 031 Black u Black O White lt vH JzuS Signal Power 193995 auo Gray soul jeuBis yun oL ZH 09 09 OVA 002 eseud ejBuis SjueuieJinboeJ JOMOd 2 CONTROL TKSA ing un Ir process a de TKSAP28 45 56M5 Outs uos j1sneux3 3s yous Ajddns any SS s y ms Joejes ey Bunei do Aq lu uudinb jeuse x9 ey Jo suoreoyioeds eunsseJd onejs je nonjed eur o Buipyoooe peeds euonejoi JOJOW Jjowo q eui JS jesseoeu Ajaynjosge si Bunnoi eiresed ji sel p pl lus esn seui UM ui se
91. 5 kW Capability Heating rating min heating 2280 to 3895 Specified refrigerator oil NL10 Power transfer method Poly V belting Compressor Normal 53 Silent Mode 51 3 6GY 8 0 0 9 DIC546 1 2 Single phase 200 Three phase 200 20 3 9 4 7 2 3 2 7 8 Exhaust gas heat exchanger Multi pipe heat exchanger Heat exchanger EE m8 Rated air um r i im nor ar Motor Rated Water cooled vertical type Liquid 2 4 cycle 3 cylinder OHV Refrigeran 57 are connection mm t pipin 0 952 Db 25 4 flange connection 7 5 Fuel gas pipe Ravolotian Cooling 1200 to 1650 Pipe dimensions range Heating 1200 to 2050 Aisin GHP Oil L10000 Capacity L ia 125 Equivalent length Capacity L Permissible pipe length Upper side 100 Actual length 35 Aisin Coolant S Permissible difference in 50 Outdoor unit at top elevation between L 14 indoor outdoor unit 40 Outdoor unit at bottom 65 3 Permissible difference in 15 elevation between indoor units Connectable indoor 110 12 Magnet type spiral pump units P22 to P224 1 The cooling heating capability and electrical characteristics data shown in the above table was measured under the conditions of JIS B 8627 2 The operating sound level shown in the above table was measured in an anechoic room subject to the relevant provisions of JIS Under actual conditions the operating sound level shown above is usually exceeded since it is affected by amb
92. 50 60 70 80 90 100 110 120 Equivalent length m 1 22 AISIN Aisin gas heat pump 1 5 4 Fuel consumption TGMP224B 14 16 1819 20 22 24 26 28 60 30 50 20 17 5 40 10 30 26 5 20 1 23 I SPECIFICATIONS TGMP B 60 50 40 gt Coding capacity kw 70 0 60 0 50 0 40 0 33 5 30 0 20 0 30 28 0 20 16 12 8 Cooling operation 18 19 20 temperature Outdoor A 22 24 26 Indoor intake temperature WB 4 468 12 16 20 24 1 24 3 Fuel consumpti n kw AISIN Aisin gas heat pump TGMP B Cooling operation 70 60 z EE 50 k g gt 40 E e o o o amp 35 5 2 8 o 2 30 SW 20 14 16 181920 22 24 26 28 Indoor intake 25 temperature WB Heating operation x c K g E E 2 o f o o gt Og EE Si L EW 8 I 16 12 8 4 0 468 12 16 20 24 Outdoor intake wet bulb temperature WB 1 25 I SPECIFICATIONS 1 5 5 Outdoor unit operating sound characteristics 1 TGMP224B 1 Overall data dB dB 0dB 0 0002ybar OCTAVE BAND SOUND PRESSURE LEVEL Front Rear left Note This operating sound value calculated value is measured at an anechoic room The actual value is bigger than the calculated value because of the surrounding noise and reverberations
93. 6 7 18 8 17 2 AISIN Aisin gas heat pump 2 TGMP280B2 Indoor Unit Connection Capacity Total Capabilities KW Gas Consumption kW New JIS I SPECIFICATIONS 3 TGMP355B2 Indoor Unit Connection Capacity Total Capabilities KW Gas Consumption kW 1 20 AISIN Aisin gas heat pump 1 5 2 Allowable Cooling and Heating Temperature Ranges 1 Cooling Indoor intake air wet bulb temperature WB C 2 Heating Indoor intake Allowable heating DB C i temperature range Outdoor intake air wet bulb temperature WB C Note The temperature setting ranges of the remote control unit are listed in the table below These temperature ranges slightly differ from the allowable operating temperature ranges of the system Maximum Minimum Cooling 30 18 1 21 I SPECIFICATIONS 1 5 3 Changes According to Piping Length 1 Cooling capacity Outdoor 50 0 88 0 86 0 84 0 82 0 800 78 0 76 0 74 0 72 unit r upper 40 0 92 30 0 94 Difference in 20 ue i 98 10 1 0 0 10 Outdoor _99 unit lower 30 40 10 20 30 40 50 60 70 80 90 100 110 120 Equivalent length m 2 Heating capacity 0 94 0 93 50 96 0 95 ae 40 upper 0 97 20 0 9 0 99 Difference in 10 elevation m TO 0 10 20 Outdoor 30 unit lower 40 10 20 30 40
94. 9 q31 eoel d sy ON Hun 100pino YMS ji oj pepleiys esn s ti Jemod eujo uw q lbi ed oyeolpul snieis 40949 pes q31 oeld 5 04 ON vun oopino MS Jeieed ui Saul jo guoo ey 104 oq qu JOSUEA eved L ON HUN ZMS seul jow y BuiAuedwos0e SUE eoejd SOL ON jun Jomod eu Woy l yeed s seuy leubis y lnoti ES yooq jeuruuJe TERES ER Josues eDueuoxe ET Syun Jooput UBEMjaq Soun jeufis j euuoo oj pue esn eunje1edui uonoejes ejDBue onjen uorsuedx3 Josues Jie oye uy V UL yun etg o s ll jeus 3290009 9 a pue v H 40 esn uonoeles 1Iqiuuiejgqeue uonejedo ING 10J Aaeyixnyz YX ol Sejqeo 10jonpuo9 x WLW 006 920 PORDI H 104 uBis 1 1l 3 LIS 405 S ejoi ny ZX 5 Saq 3 Jeyeeu uelxn 1033009 ue JJO OWleU uolsuedxe 01 104 1030uu Burddeis WS k cue 1983009 1ndur Ionuoo 9J0WS uonoejes adh duind jeep U91MS je0 J 24 synouo n n Joopul juo smoys urejBeip sul ndino OQA zL 1ndino yo u 340 100w ueg 440 Wa ee d ees ndino OGA ZL 1ndino NO ouueu NO 40 ouu uIeIg NO LIN 40 J0joede 1302 indino OA ZL 1ndino uye EWJON 440 40 eAe ouueu 1367 indino 401 21 1ndino uonesed O Dunes NO HOAQIQ JO 1 HN uonduoseq u
95. Alarm code E36 91 2 3 dwnd jeau seb uisi NISIV System block chart Remote Controller Description 1 Centerized control Center remote 2 Operation mode 3 Fan airflow rate 4 Auto swing 5 Use set room temperature 6 Timer mode 7 Intake temperature 8 Filter sign 9 Ready for heating 10 Error code 11 Unit number 12 Operation and check LED 13 Indoor heat exchanger temperature Trial operation in cooling 14 Periodic inspection Communication Input signal 1 Remote controller sensor 2 Address switch O uoneJed Start Stop 2 Operation mode 3 Fan airflow rate 4 Auto swing 5 Indoor temperature setting Use set time 6 Timer mode 7 Filter reset signal 8 Check 9 Filter automatic up down Only with L type remote controller Description of communication between Remote controllers Indoor unit Indoor control section Heat exchanger fan motor Vane motor Drain motor HA terminal Outdoor control terminal Electronic expansion valve Description of communication between indoor and Power supply AC 200 V Communication Input signal Indoor temperature sensor Indoor heat exchanger temperature sensor Float switch Limit switch In position of the vane HA terminal Outdoor control terminal Dip switch for change of control Indoor address switch Outdoor address switch remote controller Indoor Remote controller 1 Start Stop 2
96. E38 61 1 Gas pipe gas temperature sensor Judgment of antifreezing operation conditions during heating Detection of gas pipe temperature sensor wire disconnections Alarm code E55 64 0 Detection of gas pipe temperature sensor k short circuiting Alarm code E55 64 1 Coolant temperature sensor Engine warm up completion judgment Detection of coolant overheating avoidance operation Detection of coolant temperature alarm Alarm code E80 80 0 Detection of wire disconnections Alarm code E87 70 0 Detection of short circuiting Alarm code E80 80 1 Detection of engine coolant shortage Alarm code E80 80 2 Control of outdoor heat exchanger fan speed Starter coil terminals Detection of starter malfunction Alarm code E83 60 2 Pickup coil Detection of engine speed Fan motor Drain pump Vane motor 200 VAC Indoor unit See 2 3 DIP Switches for Function Selection to set the jumper wires and DIP switches on the indoor unit board SVV1 SVV2 sw3 sw4 A A Indoor address No External control terminal CN TLI CN ZLI J2 Ja Fan speed control with heating thermovalve off Louver 4 position setting HA terminal Indoor Outdo circuit board ieee address No High ceiling control for TKT Indoor control section Information that has been entered from the remote c
97. ISIN Aisin gas heat pump 6 Checking the outdoor fan motors If the outdoor fans are not functioning properly check them as directed below Note The number of fans to be operated is controlled during low temperature cooling and high temperature heating 1 Check that an output voltage of 200 VAC is properly developed at the output of the CN13 connector on the outdoor unit circuit board 2 Measure the fan motor coil resistances at the connector terminals relay connector Coil resistance values between fan motor terminals 22 4 kW 28 0 kW ite o FM White Black 24 6 10 Black Yellow 60 9 10 White Black 24 6 10 FM2 Orange Red 35 2 10 Red Black 25 7 10 a 5 kW Black Yellow 17 3 10 White Black 17 4 10 H White Black 17 4 10 Orange Red 6 4 10 Red Black 11 0x 10 Note If the coil resistances are infinite thermal fuses are likely to be functioning 8 Checking the fan capacitor Connect an insulation voltage tester across the fan capacitor within the outdoor unit control box and check the transient characteristics of the resistance value Zan owe v am 10 O Or more Time Depends on the capacity of the capacitor Fan capacitor 7 Checking the coolant temperature sensor Check the connector for backlash and improper electrical contact Also measure the resistance values between the coolant temperature sensor terminal and body and t
98. Normal ON Thermister Ro 15 KQ B 3450 k Thermister Ro 15 kQ B 3450 k Thermister 15 3450 Thermister Ro 15 kQ B 4095 k Thermister Ro 15 kQ B 3450 k Thermister Ro 15 KQ B 3450 k Thermister R100 3 3 kQ 3970 k 5 0 5 VDC Contact point switch 12 VDC Normal ON AISIN Aisin gas heat pump CN8 pins 3 black and 4 black CN6 pins 1 white and 2 white CN6 pins 9 white and 10 white CN6 pins 15 white and 16 white R CN6 pins 7 and 8 L CN6 pins 5 and 6 CN6 pins 11 white and 12 white CN6 pins 3 white and 4 white CN7 pins 9 black and 12 white CNT pins 8 red and 4 black CN8 pins 1 black and 2 black 2 CONTROL Name Functions Electrical Component Connector No Specs 11 Engine revolutions signal crank angle sensor 1 Detection of engine revolutions Engine oil pressure switch 1 Oil pressure abnormality judgment 2 Detection of engine oil pressure switch wire disconnections Starter malfunction detection signal Compressor 1 Starter malfunction detection 2 Starter trouble and wire disconnection detection 1 Turns on in accordance with a request frequency instruction from the indoor unit but only when the inhibition timer is off clutches L R 2 Control of refrigerant flow rate quantitative control of units to be operated Starting motor 1
99. ON n VAS O pe xeu yoolq euu o uonoejes ed 1 Josues eDueuoxe JESH 4 1 esn uonoejes e Due uoisuedx3 or Josues Jie V lu L iz Fio H 10 os uonoejes iqtuui ejqeue uonejedo Sr ING 404 eje Aselixny yx H 40 J0 9e U00 oneuBeuionoe uDis 1 1l d or LILA 405 S ejo1 Z IX Jejeou Kel x 5 103302 UB J4o ouueu uoisuedxe oiuoroeje 104 Burddeis WS 12983009 eBeyo oN Indu jo3009 louu uonoejes d duind 3esH YONI MS 1e0 4 Sd OqA ZL 1ndino xoeu 440 100w ure4q 440 andino 2gA ZL 1ndino NO 04 NO 10 0W Jq NO Jojoui ureJq Wa JO 130 o ndino OA ZL 1ndino JEWJON 440 Qndjno 9qA 21 1ndino uonejed JO z JO lui 2 Sum s NO LW 40 aajeaowway IEUuJ lu Ld6v JOMOJg 104 JOJOJI LWA uonduoseq uonduoseq uonduoseq Joqui s 4084 o c O White WhiteO White 5 m o Red UMS palesu si Jejeeu m l jeuondo ue Jey seuinsse aAoge payjop e ul pesojoue n l Jejeeu eu cione 1 uondo eA s ass i White White White White sjoquuAs jo uonduoseg 2 35 Medium static pressu
100. Operation mode Dehumidification cooling ventilating heating Fan air flow rate Direction of air flow User set temperature Filter sign Ready for heating Centralized control Indoor unit address number 10 Error code 11 Room temperature 12 Periodic inspection display 0 0 00 Remote controller Indoor 1 Start Stop 2 Operation mode Dehumidification cooling ventilating heating 3 Fan air flow rate 4 Direction of air flow 5 User set temperature 6 Filter reset 7 Remote controller sensor temperature Using remote controller with sensor Outdoor Indoor 1 Start Stop Signal 2 Operation mode Dehumidification cooling ventilating heating Fan air flow rate Direction of air flow User set temperature Filter reset Defrosting signal Address no Error code 10 Starting Compressor 11 Trial operation 12 Answer frequency 13 Periodic inspection display Al ndoor outdoor 1 Start Stop Signal 2 Operation mode Dehumidification cooling ventilating heating Fan air flovv rate Direction of air flovv User set temperature Filter sign Filter reset Address no Error code 10 Compressor ON OFF 11 Indoor temperature 12 Indoor heat exchanger temperature 13 Request frequency 004 00 Maintenance equipment Outdoor control section Sensor Communication High pressure switch Low pressure switc
101. S AND REPAIR 3 4 2 If the Starter Does Not Operate Trouble dn Sub Classification Check and Remedy Likely Causes E83 74 The starter 1 Starter pinion does not operate See 1 Checking display does not Pinion driving coil malfunction the 2 Engine starting operate No output failure 2 Starting motor and pinion do not operate Starting motor malfunction No output The starter driving circuit is likely to be malfunctioning if neither the pinion coil nor the starting motor develops an output voltage 3 Starter driving circuit malfunction See 2 Checking Transformer the transformer Relay malfunction See 3 Checking relays for normal operation 1 Checking the starter 1 Checking the output voltage to the starter Output voltage to the starting motor Check that an output voltage of 12 VDC is applied between the terminal B and body of the starting motor during the operation of the ventilation fan Terminal S Terminal B Output voltage to the pinion driving coil Check that when the starting motor lamp on the maintenance board is on an output voltage of 12 VDC is applied between the terminal S and body of the starting motor Terminal M 2 Checking the starter Measuring Sections Reference Resistance Value at 20 C Terminal S Body ground 0 24 Q Terminal B Body ground 00 Terminal M Body ground 0 019 Terminal S Terminal M 0 24 O Terminal S
102. SIS AND REPAIR 1 Checking the four way changeover valve 2 3 Four way changeover valve malfunction may cause the slide valve to get stuck in its middle position and if this state persists the hot gas will leak into the intake port and increase the intake temperature with the result that the discharge temperature will also increase 1 Check for unusual operating sounds clear hissing sounds from the four way changeover valve during operation 2 Check for significant temperature differences between the inlet and outlet of the four way changeover valve for the low pressure refrigerant gas Checking the hot gas bypass valves 1 Measure coil resistance between pins 1 and 8 of the CN14 connector on the outdoor unit circuit board Reference resistance value 800 Q 2 After confirming on the maintenance board that the hot gas bypass valves are closed measure the voltage between pins 1 and 8 of the CN14 connector on the outdoor unit circuit board If 200 VAC is constantly supplied the board may be faulty 3 Measure the pipeline temperatures at the downstream side of the solenoid valves with respect to the hot gas bypass valves When the bypass valves are open temperatures slightly lower than the discharge temperature must be detected Obstructions may be interfering with the hot gas bypass valves if the valves are open without 200 VAC being applied Checking the discharge te
103. SlIuono 104 JO OWW Buiddes WS yun Joquoo eyy Bui ueduuoooe JejsiuJeu uonoejes iqiuur ejgeue 4 Sr Josues eDueuoxe JESH M IUL O pexeu yoolq uDis Je34 vt Josues Jie aye U V Iu L osn 103u02 UB JJo ouueu er LIN3 40 s ejeu Mexny z x snes jeuuou u991S q31 uonoejes d duind 3esH 9MS IN4 40 Joyseded 149 oyeolpul snle s 40949 pes 031 440 10joui uleiq 440 JOJ SUEA NO Jojow uit NO SMS 1 1 136 YOMOIA 19 10101 m uonduos q uonduoseq joquiks uonduoseq joqu g tr gr sr or er sjoquuAs jo uonduoseg lines between Connection indoor units 2 44 ooa j 2 CONTROL Floor standing lowboy concealed type FKFU TKFUP28 45 56 71M5 Floor standing lowboy TKFL TKFLP28 45 56 71M5 bMS EMS MS IMS HUD JeuuoN nk vk 0319 030 GS ae iE vH zuO auo 1 4 4 1 1 4 m u ab Signal m m Power EE DERRER soul jeuDis yun ZH 09 09 OVA 002 eseud ejBuis SjueuijeJinboeJ JoMOd Aisin gas heat pump AISIN Alessooau Ajeinjosqe si Bunnoi jajjesed ji p pl lus esf seui Jemod Jayjo uy ejeJed ul seui jo g
104. U IS Jord sun jeuondo Joy Aejas yx H 40 40 8 u02 oneu amp euionos 3 o uoo UP 1 0 0UL U L LW4 104 sAejas xny Z x Jayeay Ael uonoejes d duind jeep UMS yur S1 440 40 0wW ureJg 440 sn e s jeuuou ue9J9 q31 NO 1040W uIeIg NO 10 0w Jeqno IW 10 1oyoedeg 19 GoyeorpuI smeis 40949 p i q31 EUUON 43 15 O Sum s NO IS 40 1367 JO uonduoseq uonduoseq uonduos q Joqus Wall mounted type TKK TKKP28 36 45 71M5 sjoquiAs jo uonduos ql jun jouoo aus mmm dod TOT AMEN ur or sr 330 uondo p 2121 225 2222216 ne em 330 MOJA 3 5 Ys NO w er ouo 1 ku 0 3 g nia SUI D 4Uld wup 92 YAS EMS ZMS IMS yo uo IPULION AX NE u 031 9 037 palesu si Jejeeu m l Ieuondo ue Jeu sewnsse aAoge payjop e ul pesojoue n3119 Jejeeu eu L lines between Connection indoor units KMS r AN De AW c f orro re ao o vH zv zug ile go 1849949 Java o 2 m im z n Signal soul jeus yun Lu p
105. ZO vu leuw NOLSV LL osn d yun ouoo ejoujeJ y Buikueduioooe 1 siuu u smes jeuuou 4 q31 9 031 O pexeui yoolq jeuiuue smeis 49949 pes q31 4 041 esn l njejed uae JOJSUEA IEA IK IE E H 10 os 5 J WJOJSULJ HL H 40 10 98 U09 oneufeuionoe uonoejes d 1 Jejeeu Aieipxn uonoejes e Due uorsuedx3 9r 1983009 eBeyo oN Indu Ionuoo louu uonoejes 1qiuui ejgeue uoneedo Sr indino 20 ZL 1ndino yooy uDis Jord vt andino OGA 21 1ndino NO ouueu Jo uoo Ue J40 ouueu er indino OGA 21 1ndino Bune uonoejes d duind jeeH 9MS iz F JO Li Qndjno 0 ZL 1ndino uonesed 440 40 ouu ureJg 440 uonduoseq NO Jojow 12 NO SMS Black M White White White Black Black JEWION ddO 2 Sum s NO c SMS dois L uonejedo j indu uonejedo 440 Buisje eM indu NO L GMS eoel d s ON HUN JOOPINO YAS eoe d SOL ON Hun 100pino palesu si Jejeeu m l jeuondo ue Jey seuinsse aAoge p nop e u pesojoue jino 19 Jejeeu eu MS eoeld s ON HUN CMS eerd s 01 ON HUN LMS Josues eDueuoxe JESH 4 1 TEX qm uon
106. aJow y tp r 89d ERE ELEN yeg IMS YO UQ Hoed e pal peu HL peu k yan 9 031 yoelg E ayaa 2026 HUD Ce ku M vu zo5 Hu D toxoeug ava SHUM BL Jeoids pu p solo ndino OCA ZL 1ndino 4090 VX uonosejes d L Jeuiuue NOLSV4 ndino 201 ZL 1ndino NO ouweul EX uonoejes e Due uorsuedx3 Jay eds ndino OA ZL 1ndino CX uonoejes iIgiuur ejgeue UOReISdO y n jonuoo aowa y Buueduuoooe Jersey ndino dA ZL 1ndino uonejedo LUX uis Jo d O pexeu yoolq O 103280005 Z 9 WUD jonuoo UB J4O OWJey osn eunjejedue L sms jeuuou 4 q31 2 031 uonoejes ed dund jeep H 49 SN4 esnj d 440 100w uleiq 440 H 104 10128 u09 oneu amp euionos 3 o eolpul snieis 49949 pes q31 4 031 NO Jojow ueq NO Jejeeu JOJSUEA IEA JEuJON 33 1983u09 eBeyo oN Indu onuoo eJOWeH JewJojsue HL 2 NO uonduoseq uonduoseq joquiAs 0015 L uogejedo j indui vonesedg 7440 e White White Black White White White Ownit x 4 Red Brown 9 Black Brown quo Seuinsse AoqEe el peieisur si
107. air silencer Water temperature sensor AISIN Aisin gas heat pump CONTROL Chapter 2 CONTROL 2 1 System Control Function List 2 1 1 Outdoor unit 2 2 2 Indoor unit 2 2 Remote Control Unit Functions 23 DIP Switches for Function Selection 2 4 System Input Output Specifications 2 4 1 Indoor Unit Input Output Specifications 2 4 2 Sensor Mounting Positions 2 5 Protection Units 2 5 1 Protection units and Sensor functions 2 5 2 Outdoor unit Input Output Specifications 2 6 Outdoor Unit Electrical Wiring Diagrams 2 6 1 Outdoor Unit Electrical Wiring Diagram 2 6 2 Indoor Unit Wiring Diagram 2 1 2 CONTROL LO NOTE 2 2 v 6 2 2 1 System Control Function List Judgment of antifreezing operation conditions Detection of indoor unit heat exchanger sensor wire disconnections Alarm code E6 96 Detection of indoor unit heat exchanger sensor short circulting Alarm code E56 94 Heat exchanger temperature sensor Room temperature sensor Detection of room temperature Detection of room temperature sensor wire disconnections Alarm code E7 97 Ambient temperature judgment for system operation inhibition cooling inhibition conditions Less than 12 C Apparent engine speed control Detection of outside air temperature sensor wire disconnections Alarm code E38 61 0 Detection of outside air temperature sensor short circuiting Alarm code
108. al 1 Start stop signal 1 Start stop signal 8 Check 2 Operation mode Cooling heating 2 Operation mode Cooling heating 8 Filter auto lifing for blowoff or dehumidification blowoff or dehumidification B L type remote control unit 5 yp 5 3 Fan speed 3 Fan speed oc 3 4 Direction of air flow 4 Direction of air flow 6 5 User set temperature 5 User set temperature 2 6 Filter reset signal 6 Filter sign S 7 Defrosting signal 7 Filter reset signal s AM Z arm code arm code 10 Compressor ON 10 Compressor ON OFF Remote gt G 11 Operation test signal 11 Indoor temperature control unit S 8 12 Answerback frequency Hz 12 Indoor heat exchanger temperature 5 13 Periodic check display 13 Request frequency Hz Remote monitoring addressing switch Sw 7 SW5 SW6 GEERTE 2 3 4 5 6 7 8 9 10 1 Periodic check display ON Yes OFF No 2 Periodic check display time ON 6000 hrs OFF 10000 hrs a Joas type selection VVinterized type setting ON Winterized type OFF Normal type Optional setting for coolant heater Use the switches only when remote monitoring system is used 221 901 Be dex 43 773 654 Addressing switch Setting Address 1 Factory setting 49 Manual addressing 00 to 47 Address 1 Automatic addressing 49 Outdoor control section Based on the information received from each sensor and the indoor
109. ample LPG specification salt damage proof type TGMP280B2NE EEn Outdoor unit Type Capacity kW Model change Minor change Gas type Special additional No additional No specification in alphabetical in numerical order order Refrigerant N 13A 12A P Propane gas type A S Single P R407C M Building use multi type Capacity N Store use multi type 224 22 4 kW 280 28 0 kW 355 35 5 kW E Salt damage proof type H Winterized type Blank for standard specifications C Low calorie gas type A Description of serial number Assign a serial number beginning with 00100101 Description of indoor unit model number Capacity kW Type of outdoor Serial No for unit connected design Example S Jsseries 4 way cassette type FU 4 way compact cassette type 2 way cassette type 1 way cassette type Built in cassette type High static pressure duct type Medium static pressure duct type Ceiling suspended type Wall mounted type Floor standing lowboy exposed Floor standing lowboy concealed 280 28kW M Jm series Outside air processing 140 14 kW Design serial No for unit with a direct 90 9 kW remote control units expansion coil unit 71 7 1 kW Air feed processing 45 45 kW unit ES Ceiling suspended oil Omitted for remote resisting type FP Floor standing plenum type FD Floor standing duct type F Floor standi
110. as heat pump Top dead center mark 1 Remove the head cover 2 Match the crank pulley to the top dead center mark as shown in the right view 3 Make sure that when the crank pulley is rotated by about 20 degrees horizontally the IN intake rocker arm of the 1 cylinder does not move If the rocker arm Rear moves rotate the crank pulley through one full turn for matching to the top dead center 4 Loosen the adjust nuts on the 1 and 3 intake cylinders and the 1 and 2 exhaust cylinders as shown and adjust each cylinder 5 6 Rotate the crank pulley through 360 degrees Front J Loosen the adjust nuts on the 2 intake cylinder and the 3 exhaust cylinder as shown and adjust both cylinders Reference 0 35 0 05 mm Hot status Value 0 25 0 05 mm Cold status Cu IN lt Front EX Improving incomplete compression due to an obstruction on the valve seat If carbon gets caught on the surface of the valve seat clear this abnormal state by cleaning with a valve cleaner as follows 1 Remove the ignition plugs and the air hose of the mixer 2 3 Open the head cover and rotate the crankshaft to where the clearances corresponding to the 1 and 3 IN cylinders can be adjusted Disconnect the igniter connectors from the control 4 Open the throttle valve of the mixer by an angle of 493 steps fully open using the maintenance function of the mainte
111. as returns to the compressor passing through the four way valve and the accumulator c a gt a II 111 H N Ns 1 Outdoor heat exchanger z Outdoor unit Indoor unit Cooling SN1 High pressure sensor SVV1 High pressure switch SVV2 High pressure switch Jeulens Four way EV1 Hot gas bypass valve changeover EV2 Oil gas bypass valve 1 Filer dryer c Strainer ANN Capillary VVV Bl Check valve EM Temperature sensor P1 High pressure port EEV1 Quantity adjustment valve EEV2 Liquid adjustment valve soresedes IO 4 777 UV 77 VV LV VVV I I I I I I valve EV3 Oil gas bypass valve 2 1 I 1 1 I f I I I I I I 1 1 I LLC 1 AN SDS Ball valve lt Compressor Changeable Compressor Accumulator Mejlldeg JeBueyoxe yeay soopul I SPECIFICATIONS 2 Heating The refrigerant Freon R407C after exiting the compressor first flows through an oil separator and a four way changeover valve Next the refrigerant is introduced into an indoor heat exchan ger indoor unit where it then releases internal heat to the room and is condensed and liquefied After this the refrigerant is depressurized by the electronic expansion valve within the outdoor u nit and by a capillary tube After flowing through the capillary tube the refrigerant is introduced i nto an outdoor heat exchanger where it th
112. asured in an anechoic room subject to the relevant provisions of JIS Under actual conditions the operating sound level shown above is usually exceeded since it is affected by ambient noise and the echoes of the installation room 1 10 Propane gas specifications Model No TGMP280B2P Capability Operating Sound Exterior color DIC Electricity characteristics Fuel Engine coolant P280 Multi for building kW Heating rating 33 5 Normal 57 Silent Mode 55 l 3 6GY 8 0 0 9 DIC546 1 2 Single phase 200 Three phase 200 A 20 Power source Starting current Running current A Power consumption Power ratio Revolution Cooling 1200 to 2150 range Heating 1200 to 2550 Aisin GHP Oil L10000 Exhaust port position Upper side Magnet type spiral pump 105 150 L Concentration Freezing temperature C w 1 under the conditions of JIS B 8627 AISIN Aisin gas heat pump 50 60HZ Type x Number of units Scroll typex2 0 0605X2 cooling 2280 to 4085 heating 2280 to 4845 mw 1 Outdoor unit heat exchanger Slit fin Exhaust gas heat exchanger Multi pipe heat exchanger Louver fin Exclusion capacity Revolution range Compressor Engine radiator Air suction port Front and rear side Exhaust heat absorption deas Heat exchanger Type x Number of units Propeller fan x2 amount 2000 induction motor Rate
113. ature sensor short circuiting Exhaust air temperature sensor disconnections Compressor intake temperature sensor wire disconnections Compressor intake temperature sensor short circuiting Accumulator inlet temperature sensor wire disconnections Accumulator inlet temperature sensor short circuiting 2 fault wire disconnections or improper connector connections Outside air temperature sensor fault or short circuiting Discharge temperature sensor fault wire disconnections or improper connector connections High pressure switch malfunction Harness wire disconnections or improper connector connections Improper heat release from condensing unit Refrigerant circuit malfunction such as a blocked or overfilled status Engine room temperature sensor fault or improper connector connections Engine room temperature sensor fault or short circuiting Discharge temperature sensor fault or improper connector connections Compressor intake temperature sensor fault Compressor intake temperature sensor harness wire disconnections Improper connector connections Compressor intake temperature sensor harness short circuiting Accumulator inlet temperature sensor fault wire disconnections or improper connector connections Accumulator inlet temperature sensor fault or short circuiting 3 24 2 Check the outside air temperature sensor and connector connections Check the temperature dis
114. below to set swing display jumper J4 Not connected OFF J4 Jumper Setting Type of Indoor Unit Not connected OFF TKR TKU TKUM TKUF TKES TKFL TKFU TKFP TKFD Connected ON TKT TKTC TKTW TKTS TKE TKK TKF 3 The check reset filter sign reset and auto lifting control functions can be controlled only with the main remote control unit 4 The indoor unit TKUF is used only for cooling Set SW1 to Cool Note To operate the system in cooling test mode first press the OPERATE switch and select cooling mode Next press the SET switch while holding down the TEMP V switch Thirty minute forced cooling will be initiated Press the STOP switch to abort the cooling operation 2 9 2 CONTROL Function switches on the outdoor unit control circuit board Remote monitoring addressing switch SW5 SW6 0 10 2 SAM Use the switches only when remote monitoring ssa system is used Address svvitch SW2 etting Addres actory setting 9 Manual addressing 00 to 47 Automatic addressing 49 9 91 Address 1 NISIY 2 WREE ao tirs y YBTOPTOJOS 2 10
115. clean the air filter Periodic check display When this display appears perform periodic check of the outdoor unit REMOTE display Indicates that the air conditioning System is being controlled from the remote control unit This display appears even when the System is not in use CENTER display Indicates that the air conditioning system is being controlled from an optional center remote control unit Timer operation display Shows details of timer operation This display appears even when the air conditioning system is not in use SET TEMP display Shows the user set temperature Fan speed display Shows the user set fan speed Filter auto lifting control switch Moves the filter intake grill vertically Cover CHECK switch Use the switch to service the system TIMER switch Use the switch to specify details of timer operation Operation mode display Shows the selected operation mode Heating ready status display Weak air blowoff or stop status is displayed when the thermovalve is turned off or when defrosting or heating is started up Operation check indicator lamp Operating Green on Alarm Red blinking OPERATE STOP switch Starts and stops the air conditioning System Press the switch once to select OPERATE Press again to select STOP Intake air temperature display Shows the intake air temperature This display may differ from the value indicated o
116. connections Outside air 2077 sensor short 2077 Outdoor heat exchanger liquid temperature sensor vvire disconnections Outdoor heat 5 7 liquid temperature sensor short 5 7 Gas pipe temperature sensor vvire disconnections Gas pipe 7 sensor short 7 Gas electromagnetic valve output error Outdoor unit address number overlapping EM 3t0 Outdoor unit address number setting error v Indoor outdoor communications error communications error Power supply connection error Less phase error Communication impossible Local send data not readable No indoor unit connected indoor unit connected Communications error between remote control unit and indoor unit Remote controller intake temperature ECT 00 07 disconnection Pairing errr error Communications error between indoor unit and outdoor unit EEPROM error Indoor heat exchanger sensor wire disconnections Indoor heat exchanger sensor short circuiting 2 16 AISIN Aisin gas heat pump Protection Unit Unit ChekDispay ChekDispay tstecl r Error Item Remote Maintenance Red LED Connector Control Unit Board Blinking Indoor intake On the indoor Indoor intake sensor wire disconnections sensor unit board E7 97 Continuous CNH 1 2 Float switch On the indoor Indoor unit drain error unit board E9 95 Cnl 2 17 2 CONTROL 2 4 2 Sensor Mounting Positions SN J 22 D J
117. control section output signals are sent to various system components Transfar the information detected by each sensor to the indoor control section Silent mode setting ON Silent mode OFF Normal mode Optional setting for deodorization I 1 Detection of overspeed error 200 VAC 200 VAC m Alarm code E82 82 0 1 o 4 V Detection of engine starting speed error 1 x Alarm code E83 74 1 A qo l AC DC Y MES 1 converter Heat exchanger E 2 io fan motor Oil pressure switch 1 12 VDC 42 VDC Oil pressure alarm 1 V 200 VAC Alarm code E81 81 0 12 VDC signal Throttle valve Wire disconnection alarm l Alarm code E86 71 0 1 12 VDC Starter lt 1 12VDC Four way 1 changeover valve I I Detection of wire disconnections Stepping motor 12 VDC Alarm code E53 53 0 Detection of short circuiting p L R Alarm code E53 53 2 200 VAC 200 VAC Detection of abnormal temperature increase Alarm code E89 87 0 Outdoor unit heat exchanger liquid sensor Answerback frequency calculation Detection of outdoor unit heat exchanger liquid sensor wire disconnections Alarm code E89 65 0 Detection of outdoor unit heat exchanger liquid sensor short circuiting Error code E89 65 2 Coolant pump Igniter Hot gas bypass valve Oil bypass valve 200 Ventilation fan Gas operated solenoid valve Liquid flow regulation valv
118. coolant Condensation of coolant 65 Volumetric concentration 10 After operating the coolant pump with the Check mode 34 water filling mode check the amount of coolant in the radiator cap and if the water level is lower fill it with the coolant 11 Until not checking the decline of the water level like in 10 repeat the performance in the 10 12 Operate the engine and check the oil leakage water leakage and other errors Reassembly procedure 1 Connect the gas mixer the exhaust manifold the compressor pulley and the blowby hose to a new engine Replace the gaskets of the gas mixer and exhaust manifold Compressor pulley tightening torque 39 N m 2 Mount the engine in the reverse order to that of removal Replace the gasket of the exhaust pipe with a new one Note When placing the engine on the ground lay out waste cloths and slowly rest the engine on them taking care not to damage the bottom of the oil pan Compressor belt tension 550 N to 600 N 3 After removing all hose clippers open the radiator cap and add coolant until the radiator has become full Coolant concentration 65 Volumetric concentration 4 Add the specified amount 35 liters of new engine oil from the oiling port of the oil sub tank 5 After driving the coolant pump in Check Mode 34 Refilling Mode of the maintenance board open the radiator cap and check the coolant level in the radiator Refill
119. cooling 2 Single level control H when the thermo valve is open during heating 3 Stop when defrosting in heating mode is necessary or the thermovalve is closed The amount of oil return within the required range is obtained from OCR calculation results 1 Controls the liquid flow valve to stabilize the compressor intake temperature and discharge temperature regulating valve 2 Defrosting operation during heating 2 14 1 Operates in oil returning valve control mode 200 VAC CN15 pins 2 black and 11 black 10 to 16 VDC CN7 pins 19 white Full wave rectification and 20 white OP 14 VAG CN7 pins 17 black and 18 black 200 VAC 100 W CN13 pins 2 and 7 200 VAC 7 W a Structure 4 phase PM CN10 1 to 7 Excitation 2 phase AISIN Aisin gas heat pump 2 4 Protection Units 2 4 1 Protection Units and Sensor Functions Protection Unit Unit Check Display Check Display Detector MEE CUM Error Item Remote Maintenance Red LED Connector Control Unit Board Blinking Starter malfunction detection signal Engine speed signal Pickup coil Coolant temperature sensor Oil pressure switch Refrigerant high pressure switch High pressure sensor Refrigerant low pressure switch Compressor discharge temperature sensor R L Compressor intake temperature sensor On the outdoor unit board CN23 1 On the outdoor unit board CN5 On the outdoo
120. ctions in particular 1 Capacitor connections 2 Diode connection terminals and body grounding connection terminals 3 Terminals for cord connection to the starter and others 3 4 7 Engine Speed Too High Alarm Classification of Likely Sub Classification Check and Remedy Causes E82 82 display Throttle 1 Throttle lever malfunction Check the operation of returning L Mixer throttle failure the throttle failures 2 Stepping motor malfunction Trouble with the stepping motor itself 3 47 3 TROUBLE DIAGNOSIS AND REPAIR 3 4 8 High Pressure Alarms During Cooling Classification of Likely Causes 1 Heat exchange inside the condenser of the out door unit is obstructed Trouble E40 During 76 86 cooling Refrigerant high press ure alarm 2 Refrigerant circuit faults 3 Sensor or signal line faults 4 Engine circuit faults Sub Classification Outdoor fan failure Presence of an obstruction Interference No output Fan motor malfunction Fan capacitor fault Deteriorated heat exchange capability L Heat exchanger fin clogging or interference Too high intake air temperature Severe environmental conditions or installation status Short circuiting or others Inappropriate amount of refrigerant Overfilling Refrigerant flow channel clogging Check valve sticking Pipeline clogging or breakage Ball valve malfunction or not fully open Entry of uncondensed gas into the refrige
121. ctor disconnections 1 Four way changeover valve stalled in the middle 2 Hot gas bypass valve malfunction 1 Fault in motor driven three way valve hole IC Confirm temperature display using the maintenance board 2 Check the outdoor heat exchanger liquid temperature sensor for wire disconnections and improper connections 1 Confirm temperature display using the maintenance board 2 Check the outdoor heat exchanger liquid temperature sensor and harness short circuiting 1 Confirm pressure display using the maintenance board 2 Check the high pressure sensor and harness short circuiting 1 Confirm pressure display using the maintenance board 2 Check for wire disconnections of the high pressure sensor and harness and for improper connections of the connector 1 Check the temperatures of the four way changeover valve and periphery 2 Check the operation of the hot gas bypass valve 1 Check the output of the motor driven three way valve hole IC 2 Check for wire disconnections and improper contact of the harness 3 Check the outdoor unit circuit board 25 EEPROM error 1 EEPROM error Check the outdoor unit circuit board ndoor unit not connected ee uid Mode mismatch Mode mismatch 1 The setting of the outdoor unit address at the indoor unit side is not correct 2 Despite the indoor outdoor unit independent power specifications the indoor unit is powered off 3 27 Conf
122. d 220X2 output 12 7 flare connection pipe 028 58 flange connection Motor Refrigeran 5 m t piping Exhaust drain pipe mm Pipe dimensions Permissible pipe length Permissible difference in elevation between indoor outdoor unit Permissible difference in elevation between indoor units Connectable indoor units 9 125 Equivalent length 50 40 Outdoor unit at bottom 15 P22 to P280 R 3 4 100 Actual length m Fuel gas pipe Outdoor unit at top 0 The cooling heating capability and electrical characteristics data shovvn in the above table vvas measured 2 The operating sound level shovvn in the above table vvas measured in an anechoic room subiect to the relevant provisions of JIS Under actual conditions the operating sound level shown above is usually exceeded since it is affected by ambient noise and the echoes of the installation room I SPECIFICATIONS 13A 12A specifications Type x Number of units Scroll type x 2 TNT Exclusion capacity 60 5 cm rev x 2 New Refrigerant Model P355 9 2280 to 4655 min Cooling Type Building Use Multi Unit 2 Revolution range 2280 to 4845 min Heating Q Cooling rating 35 5 kW 5 Specified refrigerator oil NL10 o Heating rating Refrigerator oil enclosure q ty Exterior color Munsell 2 Engine radiator dimensiol Heat exchanger 5 0 5 9 2 9 3 4 A Cooling I 5 3 6 1 3 1 3 5 A Heating Exhaust heat collection met
123. d malfunction Improper ignition timing Improper compression Upward valve plunging Valve malfunction due to an obstruction Throttle malfunction Stepping motor malfunction Improper output Engine speed reading error or incomplete contact of the distributor connector Incomplete contact of the 12 VDC terminal connector connections Malfunction due to ignition circuit induced noise 1 Checking and adjusting ignition timing 1 Connect the timing light pickup clip to the high tension cord of one cylinder 2 Radiate timing light to the ignition advancer scale at the top of the rear crank pulley and confirm ignition timing Engine Speed Angle of Advance Note The above is common to 13A and propane gases 3 41 Timing light Check the air cleaner Check the gas operated solenoid valve See 3 Checking the ignition plugs in 3 3 3 See 4 Checking the high tension cords in 3 3 3 See 1 Checking and adjusting ignition timing See 6 Checking for appropriate compression in 3 3 3 Clean the valve See 8 Improving incomplete compression due to an obstruction on the valve seat in 3 3 3 See 2 Checking the throttle actuator See 3 Checking the starter driving circuit for incomplete contact See 4 Checking the ignition circuit for noise 3 TROUBLE DIAGNOSIS AND REPAIR 2 Checking the throttle actuator 1 When the OPERATE switch is turned o
124. disconnections and short circuiting Primary connector Reference resistance value 2 8 O 10 20 C 3 Checking the cam angle sensor Confirm the resistance value between both terminals of the cam angle sensor Resistance value 1100 150 20 C Checking for appropriate compression Measure the compression pressure of each cylinder using a compression pressure gauge to achieve the required engine output The procedure is as follows 1 Remove the ignition plug 2 Insert and firmly screw down section 5 of adapter 4 into the plug hole 3 Fully rotate section 3 in the direction of the arrow as far as 3 can go The rubber piece of section 5 will be firmly pressed against the plug hole and fixed 4 Mount a pressure gauge at a sufficient distance from all movable sections 5 Crank the engine by pressing the OPERATE switch and measure the compression pressure of the cylinder After selecting the check mode with the maintenance board functions and then turning on the transformer power the above check can be performed by turning on the starter and letting it operate independently for 5 seconds Part code 01 6 Reset the needle to zero by pressing section 1 and perform similar measurements for other cylinders as well lt Compression pressure gauge gt lt i Qeoe GSS Reference value 1 4 MPa or more 3 38 7 Valve clearance check and adjustment 8 AISIN Aisin g
125. do Dd o Red aL Yellow Red Josues Jie exeju 1 ING 10J ejen yx LI 405 sAejos Aueixny EZX uorsuedxe 2140110 104 Buiddars WS UoyMs 1e0 4 Sd Jojoui ureJq LINH JO Joyoede 140 LIN 10 167 HOMOI JO JOJO LWA uonduoseq joquiAs sjoquuAs jo uonduos ql lines between Connection indoor units Power heee Signal soul jeuBis zun 1 r zH09 0S OVA 002 eseud e pejunoui Jejeeu 914989 uM ZH 09 05 OVA 002 eseud ojbuis SjueuijeJinboeJ JSAOd 2 36 AISIN Aisin gas heat pump TKUMP112 140M5 siojo uuoo 3uO pue eiuw Z4UD ou eBueuo1ejur suoneoyioeds eunsseJd onejs uiu 104 ressegeu Ajaynjosge 51 Bunnoi jejejed pepjelys esf seui Jewod 1 u O YIM u seui jozjuoo ey JOU oq seul Jemod ey wol Ajayesedas saul jeubIS eui spun ueemjeg seu jeuDis 19euuoo oj pue jun ey o seuIj jeufirs joeuuoo o g pue v o s lqe oyonpuoo z x WW 00 Z 8 0 1094000 Syoo q Jeuiuue eui eu Is A G eyouep g pue v HL BULA iS UO sejouep ull eu SynoJro YUN JOOpuI juo smoys uieJBerp SIU L S9 0 yun Ionuoo
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127. e step J o o Powered three way valve angle step oa ee J o Quantity adjustment valve angle step o 1 5 9 df 260 l 23 1 Output of powered equipment for Ventilator 1 5 gt Lo gt 24 1 Outputofpowered equipmentforVentlator2 o Dro f gt 27 Outputstatus e 28 Avoidance Status 29 External Switchstatus jj 31 Individual parts operation ON 32 Individual parts operation OFF FT 34 Vvater filing mode Ono T fJ gt 39 Outdoor unit capaciy KW 40 Engine operation time hours hoursf0 gt 41 Previous periodic check time hours hoursff0 o 51 17 42 Right compressor operation time hours hours 10 9 51 17 43 Left compressor operation time hours hoursff0 gt gt 50 Stareronoffcount times timesnoo o 1 gt 51 Engine on off count times tmes 100 gt gt 52 Right compressor on off count times times 100 9 f gt 53 Left compressor count times tmes 100 05821 gt 56 Periodic inspection reset On setting o 57 Automatic address erase On setting 58 Main micro computer version Highpressure mea le 63 High pressure equivalent temperature e 66 Engine Cooling water temperature 68 Engine exhaust air temperature
128. e Motor driven three way valve Fuel gas regulation valve Capacity regulation valve Ey LI ON With heater OFF Without heater ON Deodorization OFF Normal mode See 2 3 DIP Switches for Function Selection 200 VAC to set the function Switches and jumper wires on the remote control unit board Sub Remote control unit master sub addressing Reset signal Main Refrigerant high pressure sensor Control of refrigerant high pressure control of outdoor fan speed Refrigerant high pressure sensor alarm Alarm code E89 73 0 1 Refrigerant high pressure switch Detection of refrigerant Y SN high pressure alarm Alarm code E40 86 0 N Detection of wire disconnections Y Alarm code E40 76 0 Detection of refrigerant low pressure alarm Alarm code E57 88 0 Detection of wire disconnections Alarm code E57 88 2 No refrigerant Alarm code E57 88 5 Accumulator inlet temperature sensor Detection of wire disconnections Alarm code E54 63 0 Detection of short circuiting VAC V Alarm code E54 63 1 Y Discharge temperature sensor Detection of discharge temperature 12 VDC increase avoidance operation Detection of discharge temperature alarm Alarm code E36 91 0 Detection of wire disconnections Alarm code E39 78 0 1 Detection of short circuiting
129. e judgment Inhibition of operation Below 12 C during cooling 2 Control of oil returning valve 3 Wire disconnection short circuiting detection for outside air temperature sensor 4 Control of outdoor fan quantity 1 Compressor discharge temperature alarm judgment 2 Compressor discharge temperature alarm avoidance control 3 Wire disconnection short circuiting detection for compressor discharge temperature sensor 1 Wire disconnection short circuiting detection for compressor intake temperature sensor 2 Oil returning error detection 3 Compressor intake temperature alarm avoidance control 1 Wire disconnection short circuiting detection for accumulator inlet temperature sensor 2 Oil returning error detection 2 1 Engine coolant alarm judgment 2 Engine warm up completion judgment 3 Engine coolant alarm avoidance control 4 4 Engine coolant no load operation preventive control 5 Wire disconnection short circuiting detection for engine coolant temperature sensor 6 Outdoor fan speed control 1 Refrigerant high pressure control for maintaining high pressure in heating mode 2 Refrigerant high pressure error avoidance control 3 Outdoor fan speed control 4 Answer frequency calculation correction of supercooling 1 Low pressure abnormality stop judgment 2 Detection of refrigerant low pressure switch wire disconnections 2 13 Contact point switch 12 VDC
130. e situation in which failure to observe this precaution could lead to personal injury and or product damage Before starting maintenance operations m VVARNING Turn off the leakage current circuit breaker located inside the control box of the outdoor unit Failure to observe this warning may result in electrical shock 2 Close the fuel gas cock Fuel gas leakage may induce gas poisoning and or gas explosion During maintenance AN WARNING 1 Wear the clothes that fit the nature of the work 2 Beware so as not to touch hot sections or rotating bodies Touching could result in burns or injury 3 Do not apply a valve cleaner to hot sections when cleaning valves Failure to observe this warning may result in fire About brazing operations AN CAUTION For brazing conduct nitrogen gas blowoff using the method specified in the relevant service manual Failure to observe this precaution could lead to pipeline clogging due to the occurrence of oxide scales Page SEEC FIC 055 L 1 1 1 1 Product External Views os ooos 1 2 1 2 Product SpeciflEdHON M 1 3 1 2 1 Model Number and Product Name seen nns 1 3 1 2 2 Combination of Indoor Unit and Outdoor Unit eee 1 4 1 233 Structure Drawing i uoo p oe a As n 1 7 1 2 4 Outdoor Unit Specificationis 4
131. ease from evaporator unit Refrigerant circuit malfunction such as a blocked or overfilled status Major Likely Causes Diagnosis Remedy Confirm temperature display an actual temperature value and the resistance value Confirm gas pipe temperature sensor and connector connections Check for clogging of the heat exchanger near the evaporator and for abnormal operation of the fan Check the refrigerant system check for refrigerant leakage clogging etc using refrigerant system diagrams A B D and Q Check the refrigerant low pressure switch Confirm harness continuity and connector connections Refrigerant leakage Malfunction of pressure sensor or low pressure switch 1 Check the deodorization agent Refrigerant low pressure switch wire disconnections Low pressure switch malfunction Harness disconnections or connector disconnections No refrigerant Refrigerant leakage from the flare connection and others 2 Pressure sensor malfunction Exhaust 1 Deodorization agent clogging temperature alarm Engine coolant too hot Engine coolant temperature sensor wire disconnections Coolant circulation error Heat release insufficient Sensor malfunction 1 Check if the coolant level in the reservoir tank is between F and L Also check the thermostats Short circuiting due to contact of and the thermovalves the coolant sensor harness with Confirm the temperature the body di
132. ectrical Equipment 6 4 Coolant Related Components 6 5 Thermister Characteristics Note Specifications without Model number of the outdoor unit are common to all models 6 1 6 MAINTENANCE DATA STANDARDS 6 1 Engine Related Components Standard Value Remarks P224 P 1200 1600 KAT 1200 2150 Cooling 1200 1800 Engine speed P280 P E 1200 2550 P355 P 1200 2450 1200 2550 After stopping the engine being warmed up Valve perform meas clearance urements within 30 minutes Compression system Engine speed of at least 300 min Compression cranking Adjustment Ignition Pee eae iiy impossible timing Ignition timing 16 x 3 1200 min High tension Cylinder 1 cord Ignition resistance Cylinder 2 m vae Cylinder 3 Ignition plug Idling fuel adjustment 3 to 10 1800 min Oz value Fuel gas Fuel system AISIN Aisin gas heat pump Engine oil pump Lubricant system Including oil for Engine oil Aisin GHP Oil L10000 10 L can he oil filter i Sealing amount Initial setting 550 to 600 Compressor Belt tension belt After mounting 450 to 500 Manually rotate the engine pulley several times before measuring initial compressor belt tension Use torque Cylinder wrench without head bolt fail Compressor pulley bolt Engine pulley bolt Tightening torque Valve rocker shaft nut head cover After hand tightening at 2 5 N m Water dra
133. ed or bent thickness gauges 3 When the engine is not cold enough perform adjustments for a valve clearance that permits a 0 33 mm gauge to be inserted and does not permit a 0 38 mm gauge to be inserted Rear Top dead center mark 5 2 7 Adding Coolant and Coolant reinforcement Agent 1 Refill the reservoir with the specified amount of coolant strengthening agent If the specified amount of refilling is likely to cause the FULL level to be exceeded drain out the coolant from the reservoir beforehand Frequency of addition At least ever ears or 10 000 hours Specified amount 280 to 330 cm 2 Add coolant until the FULL coolant level in the reservoir has been reached AN CAUTION Be absolutely certain to use the specified Aisin coolant reinforcement To add coolant always use Aisin Coolant S A Add coolant at a concentration from 50vol to 60vol96 5 2 8 Checking the Coolant Hosing z hose Ippl Check the coolant hosing 6 pieces for cracking deterioration loose hose clipping coolant leakage and other unusual states 5 5 5 PERIODIC MAINTENANCE 5 2 9 Checking the Compressor 1 Check that the compressor does not generate unusual sounds during operation 2 Make sure that when the electromagnetic clutch is disengaged the shaft of the compressor does not rotate synchronously Electromagnetic clutch 3 After stopping the engine rotate the shaft by hand and check that it ro
134. el P280 High Pressure Outside Air Temp Checking the dryer filter for clogging Fully or partially clogged dryer filter in front of the expansion valve reduces the refrigerant pressure Measure the pipeline temperatures in front of and at the rear of the dryer filter and if measured values significantly differ by 5 C or more replace the filter since it is clogged Checking the indoor electronic expansion valve for clogging 1 Turn off the power circuit breaker temporarily and then turn it back on The indoor electronic expansion valve will repeat full opening and full closing actions Confirm the operating sounds at this time 2 Disconnect the CnA connector from the indoor unit circuit board and measure coil resistance values between the pin terminals of the driving motor Pin Connection To Be Measured Reference Resistance Value 10 Orange Red Black Gray 4 5 Checking the check valve for clogging Clogged check valve reduces the refrigerant pressure Measure the pipeline temperatures in front of and at the rear of the check valve and if measured values significantly differ by 5 C or more replace the valve since it is clogged Checking the refrigerant low pressure switch Confirm electrical continuity between pins 1 and 2 of connector CN8 on the outdoor unit circuit board If no continuity is detected or if applying a shock to the switch body interrupts continuity the contacts of the switch are not normal re
135. en absorbs heat and is gasified Then after the refrig erant joins with the refrigerant that absorb heat from the outside air and goes through four way c hangeover valve the refrigerant absorb heat from engine exhaust heat in double pipe heat exchan ger and gasified The refrigerant returns to the compressor through an accumulator a gt a HE 111 H N Outdoor heat exchanger 2 Outdoor unit Indoor unit Cooling SN1 High pressure sensor SW1 High pressure switch SW2 High pressure switch EV1 Hot gas bypass valve Jeulens Jeulens Four way c changeover EV2 Oil gas bypass valve 1 valve i Filer dryer Strainer Capillary 2757 m Et Check valve Temperature sensor 1 High pressure port EEV1 Quantity adjustment valve EEV2 Liquid adjustment valve Jojesedes JeBueuoxo 1e u Joopul JeBueyoxe yeay soopul 2777 77 VV LV LVv I I I I I I EV3 Oil gas bypass valve 2 I 1 1 I I I I I I I I 1 L I Ball valve 1L gt SPS Ball valve Compressor Changeable Compressor X Accumulator I SPECIFICATIONS 1 6 2 Coolant Fuel Air System oil supply Diagram and description Coolant In heating or low temperature cooling modes the coolant that has been sent from the coolant pump and heated through the exhaust heat exchanger and the engine flows into the double pipe heat excha
136. ent Connector Name Functions Specs NO External 1 Operation monitoring output Can be driven at 12 VDC CNT pins control On when remote control unit is on 75 mA with the OMRON 1 and 2 terminals 2 Heating mode monitoring output LY2F relay CNT pins On during heating except for defrosting 1 and 3 3 Compressor monitoring output CNT pins On when compressor is on 1and4 4 Alarm monitoring output CNT pins On in case of alarm 1and 5 5 OPERATE STOP instruction CNT pins ON 1 and 6 OFF Operating Stopped Operation starts and stops with the rising and falling edges respectively of the signal Note When pin 1 of DIP SW5 is on the OPERATE STOP signal level is reversed at the rising edge of the signal shown above Heat Fan speed can be changed by tap changeover 200 VAC FASTON cae fan 1 Specification of fan speed from remote control unit tab 2 Control of hot starting 5 and 8 Heat 3 Dehumidification FASTON exchanger fan Note tab High TKU is of the two speed type High and Very high 5 and 7 select lines are connected outside the circuit board Heat TKF and TKFD are of the single speed type FASTON exchanger fan 1 4 Heating thermovalve off intermittent operation tab Very high without J 3 5 and 6 Vane motor The vane motor controls the louver 200 VAC FASTON 1 Specification of air flow direction from remote control tab unit 3 and 5 2 Control of hot starting The stopping po
137. erall length m of 9 52 mm diameter liquid pipeline L3 Overall length m of 6 35 mm diameter liquid pipeline Notes When adding refrigerator oil refer to the section of the MAINTENANCE DATA STANDARDS that describes the compressor circuit 8 After charging the compressor with refrigerant check the operation of the compressor by measuring the refrigerant high pressure low pressure and temperature 4 8 AISIN Aisin gas heat pump PERIODIC MAINTENANCE Chapter 5 PERIODIC MAINTENANCE 5 1 5 2 Periodic Maintenance Items and Periods Periodic Maintenance Procedures 5 2 1 Changing Engine Oils 5 2 2 Replacing the Oil Filter 5 2 3 Replacing an Ignition Plug 5 2 4 Replacing the Air Element 5 2 5 Replacing the Compressor Belt 5 2 6 Adjusting the Valve Clearances 5 2 7 Adding Coolant and Coolant Strengthening Agent 5 2 8 Checking the Coolant Hosing 5 2 9 Checking the Compressor 5 2 10 Checking the Operational Sounds 5 2 11 Prevention of Valve Damage 5 2 12 Replacing the Fuel Gas Hose 5 1 5 PERIODIC MAINTENANCE 5 1 Periodic Maintenance Items and Periods Periodic maintenance and part replacement are required for continued normal operation of the gas heat pump air conditioning system The recommended periodic maintenance and part replacement items for 2 000 hours of operation on an annual basis are listed in the table below For more hours of annual operation conduct these items at least every 10 000
138. essing 00 gt 99 gt 98 049 00 99 98 gt Code no In check each indoor unit data select the unit you want to display In pushing the switch the address of indoor unit is changing Only pressing Selecting 3 Use in case more than the code 80 indoor unit The minimum of indoor unit address The maximum address The minimum address Only pressing Mode Change the mode gt Operation hours display Selecting Onlv pressinq Clear Clear the set data In setting operation the current operation status is displayed and yp g in other indications the previous status before set is selected Onlv pressinq Set Fix the set data Ex In case of setting indoor unit operation in pushing the switch yp g finally the data is sent to the indoor unit Code numbers List of Command mode Set Range Requested engine RPM min Min to max Calculated engine RPM min Liquid quantity adjustment valve angle step 60 to 2000 Calculated powered three way valve angle step 12 to 820 1 Quantity adjustment valve angle step 60 to 2000 Output of powered equipment for Ventilator 1 96 0 to 100 Hi Lo 0 to 100 3 6 AISIN Aisin gas heat pump Check mode Renew the memorized data and indicate each unit operation Function of each switch Switch status Switch function 7 segments LED display description Change code numbers from
139. eujeumboe JOMOd Q en P Lf pou l poy po SIM nua Ceiling cassette compact type 4 way blowoff TKTCP28 36 45 56M5 2 24 AISIN Aisin gas heat pump TKTW Ceiling cassette compact type 2 way blowoff TKTWP22 28 36 45 56M5 NO 330 NO NO uz 430 NO NO 330 ug 330 430 330 NO uci Z 6MS rems zems rems ons eol ZH 09 Loy ZH 0S Bun Dunyi ojne ju6 exeju ay Jos o Aol q lq eui esr jesseoeu Ajaynjosge si Bunos Jeieed ji s s p pl lus esf s u Jemod Jeyjo UMA JojeJed ul seu jojuoo eui JOU oq seul Jemod ey wouy Ajayesedas saul IeuBis eui spun UBEMyeq s ull jeufis 1094 00 pue pun 100pjno ey o s uli jeuDis 32euuoo o g pue V 0 s lqe jojonpuoo z x WW 0072 9270 lp uuoO Syoo q jeuruue oul eUBIS A G eyouep g pue VAL DUA iS UO sejouep dul eu SynoJro jun Joopul juo swous weuBeip siu yun Jouoo Jowo meets eee ee pol uonounj BuiBuims ojne ue noyy m jeued e 104 jou jenjoe si e oqe aban POW PND eu o To oder YAS EMS EMS UMS JOJSUEA IEA eoe d 5 0 ON Hun 100pinO Y SIOJOW 10 62 Jeuuojsuel L HL eoeld s L ON nun Jeoijds pu p sol uonoejes adh L 41 eoeld sv ON HUN leuw 5 uonoejes ejDue onjen uorsuedx3 9r gun
140. fferences between A B and No load operation without added C D connections per the coolant coolant system diagram Cooling 7 to 10 C Heating 10 to 15 C Check for clogging of the radiator and for abnormal operation of the coolant pump and outdoor unit fan No engine coolant Check the coolant temperature sensor Check the harness connector Engine oil pressure alarm Oil pressure too low or oil level too low or others Check the oil level the oil level must be between F and L on the oil level gauge Check the oil pressure switch and harness 57 il Stepping motor malfunction or Confirm the stepping motor coil others resistance value Check connector and harness connections 3 25 3 TROUBLE DIAGNOSIS AND REPAIR Alarm Code Maintenance Display of Board Remote Control Unit Code 55 Starter alarm Contents Engine starting speed alarm 4 Engine speed control alarm Gas electro magnetic valve output alarm Engine start alarm Engine stop Indoor unit mismatch m Qo Engine oil pressure switch disconnections N o Engine coolant temperature sensor vvire disconnections Engine speed hunting alarm co A Engine microcomputer communications Diagnosis and Repair Fusing of the starter driving relay inside the control box Outdoor unit circuit board malfunction Starting motor malfunction Connector disconnec
141. for indoor unit 1 Checking if the electronic expansion valves open 2 3 After about 30 minutes of cooling the electronic expansion valves in indoor units about 10 C higher than the respective heat exchanger temperatures may not open even during the operation of all indoor units Even when an indoor unit has its electronic expansion valve operating properly the heat exchanger temperature differs by about 5 to 7 C depending on the type and capacity of indoor unit and on the indoor temperature Proceed to step 2 below if the electronic expansion valves are not open Confirming the output voltages of the indoor unit circuit board Measure the voltages developed at the control pins of electronic expansion valve connector CnA white 6 pin 5 conductor Also measure how long the voltages are applied a Between orange and gray c Between yellow and gray b Between red and gray d Between black and gray For a to d above after power on a voltage of approx 5 VDC is applied for about 15 sec After power on a voltage of 5 VDC must be developed for about 8 sec and then after the voltage has temporarily decreased it must increase to about 5 VDC for about another 8 sec During measurement using a digital multimeter voltages from about 3 to 6 VDC must be developed in sequence f the above is confirmed the indoor unit circuit board is normal If the electronic expansion valve does not operate does n
142. gerator oil from the inlet and outlet ports See Fig 2 Refri tor oil Amount of oil to be added for 621030 11020 and 621030 11030 3 Inlet 50 cm Outlet 150 cm Refrigerator oil can be easily added by performing this while manually rotating the clutch plate Place the inlet and outlet ports on the compressor and tighten bolts to the required torque in the required order diagonally Bolt tightening torque 19 6 to 24 5 N m Note When remounting the ports take care so as not to damage the O rings Mount the new bracket to compressor into the position Mount the belt and adjust belt tension After this rotate the compressor through several full turns by hand and check for appropriate belt tension Belt tension 550 to 600 N New belt 450 to 500 N After mounting 4 7 L fixed AISIN Aisin gas heat pump L aw tow 4 MAINTENANCE OF MAJOR FUNCTIONAL COMPONENTS 6 After making sure of no refrigerator oil leakage execute at least one hour of vacuum pumping When replacing the variable capacity compressor vacuum the amount adjustment valve with the maintenance board functions like check mode after 1000 Steps or more 7 Recharge the compressor with refrigerant and refrigerator oil up to the required level Factory preset amount of charging 13 kg Recharge kg L4 x 0 12 L2 x 0 06 Lax 0 03 Where L4 Overall length m of 12 7mm diameter liquid pipeline L2 Ov
143. ging Fuel circuit Leakage from gas regulator Mixer malfunction 3 Exhaust circuit clogging Drain water freezing Drain hose freezing Exhaust heat exchanger or muffler clogging 1 Plug malfunction JE Deposits or moisture Plug gap out of specs High tension cord malfunction Igniter malfunction 2 Ignition failure Es or connector disconnections No output 3 Ignition timing error Check and Remedy See 1 Checking the gas electromagnetic valves Check and if necessary replace the air cleaner See 2 Checking the gas regulator Check and if necessary replace the mixer See 9 Mixer fuel valve check and 2 Checking the throttle actuator in 3 3 4 Install a drain heater See 3 Checking the ignition plugs See 4 Checking the high tension cords See 5 Checking the igniter See 1 Checking and adjusting ignition timing in 3 3 4 Improper compression is likely if the crankshaft can be readily rotated by hand without resistance 3 Compressor circuit faults 1 Upward valve plunging Valve clearance error 2 Valve caught in the mechanism 3 36 See 6 Checking for appropriate compression See 7 Valve clearance check and adjustment See 8 Improving incomplete compression due to an obstruction on the valve seat AISIN Aisin gas heat pump 1 Checking the gas electromagnetic valves 2 3 4
144. h Engine oil pressure switch Water temperature sensor Outdoors air temperature sensor Discharge temperature sensor 1 4 Engine room temperature sensor 8 Accumulator inlet temperature sensor 1 2 9 Engine RPM sensor 10 High pressure sensor 11 Heat exchanger liquid temperature sensor 12 Intake temperature sensor 13 Accumulator inlet temperature sensor 14 Discharge air temperature sensor Option Operation time display NOOR WD Error monitor red Dip switch for changing control Outdoor address switch Switch for maintenance Address switch for long distance monitor PO Nos Compressor clutch R L Throttle valve Gas electromagnetic valve 1 2 Liquid flowing capacity adjustment valve Electrical three way valve Fuel gas adjustment valve Capacity adjustment valve Output DC12V 1 Electric motor for ventilator 2 2 Coolant pump 3 Four way changeover valve 4 Ventilation fan 5 Hot gas bypass valve 6 Oil return valve 1 to 4 7 Discharge drain heater only for cold district specification 8 Compressor heater only for cold district specification 9 Coolant heater Option Output AC200V AC DC changeover equipment Output 200 Transformer Diode Signal DC12V AISIN Aisin gas heat pump 2 2 Remote Control Unit Functions The following view shows the remote control unit with its cover opend Filter sign When this display appears
145. he coolant temperature bypass pipe surface temperature and examine for significant deviations from reference characteristics Characteristics of the coolant temperature sensor Temperature Resistance 3 45 3 TROUBLE DIAGNOSIS AND REPAIR 8 Checking the radiator cap 1 Make sure that the seal packing is free from cracking deformation and other defects 2 Make sure that the operating pressure at the radiator cap is within 0 05 0 01 MPa Seal packings Cap tester Radiator cap tester Adapter 3 4 6 Oil Pressure Alarms Trouble Classification of Sub Classification Check and Remedy Likely Causes E81 81 1 Decrease in If the oil pressure decreases during display oil pressure operation Oil pressure 1 Shortage of oil See 1 Checking oil alarm Oil leakage consumption Unusual oil consumption 2 Oil line clogging See 2 Checking the oil Oil strainer clogging pressure 2 Sensor signal Oil pressure switch malfunction See 3 Checking the oil circuit faults Sensor fault pressure switch Improper contact 3 Noise others Ignition system See 4 Checking the ignition Improper contact circuit for noise in 3 3 4 Starter driving system See 4 Checking the starter Improper contact driving circuit for improper electrical contact 1 Checking oil consumption Estimate engine oil consumption from the decrement in oil level and the previous maintenance result data Co
146. hen pressing Code no UP or Code no DOWN ON and OFF is sada altemately s Setting range ON or Off The display change from flashing to ex Water supply on Supplying water for 5 minutes at maximum eEngine oil supply mode oCheck mode De OFF is displayed on the data display Pressing Set Oil is blinking on the data display Pressin b 2 seconds or more the data is fixed Oil on is displayed on the data w Keep this mode by power off It is invalid to turn on the switch eEngine operation time 40 ePrevious periodic inspection time 41 eCompressor R operation time 42 eCompressor L operation time 43 oCheck mode LI The present operation time is inllidatef LI Ex Engine operation time is 1350 hours 10 When pressing Set each digit is blinking from thousand s place hundred s place ten s place one place If pressing ne no UP the number changes from small to T f 3 s 39 p D down the number changes from small to LI ser number like 9 0 9 0 VVhen the one s place is blinking and Set is pressed all indicators for data are blinking Then if pressing Set the data is fixed Setting range 0 10 6553 10 hours The indicator changes from blinking to flashing continuously Ex 65530 hours 10 3 TROUBLE DIAGNOSIS AND REPAIR eEngine on off count 50 eStarter on off count 51 eCompress
147. hod Refrigerant heating 0 961 15 kW Cooling 1 10 1 19 kW Heating Type x Number of units Propeller fan x 2 96 97 96 9896 Cooling 95 98 94 98 Heating 29 9 kW Cooli ting Single phase induction ooling rating motor 6P Consumption 29 6 kW Heating rating Motor 6P Rated output 0 22 kW Water cooled vertical type ES 412 7 mm 4 cycle 3 cylinder OHV Refrigerant Liquid pip Flare connected piping Exhaust volume 952 cm Gas pipe 931 8 mm Flange mounted Rated output 9 5 kW Fuel gas pipe R3 4 1200 to 2450 min Cooling I Revolution range 1200 to 2550 min Exhaust drain pipe 615 mm Heating E Aisin Gas Engine Oil uS 125 m Equivalent length Lubricating oil type Permissible pipe length eese 7 100 m Actual length Lubricating oil enclosure as Permissible difference in elevation 50 m Outdoor unit upper qty between indoor outdoor units 40 m Outdoor unit lower Exhaust port position Top Permissible difference in elevation 4 between indoor units C Electrical characteristics Power ratio Rated air amount 210 m min Pipe dimensions a 3 Number of indoor units which can 1 to 12 units be combined Capacity P22 to P280 2 5 0 60 Ha Notes 1 The cooling heating capability and electrical characteristics data shown in the above table was measured under the conditions of JIS B 8627 2 The operating sound level shown in the above table was measured in an anechoic room subject to the relevant pro
148. ient noise and the echoes of the installation room 1 8 Propane gas specifications Model No TGMP224B2P gt Cooling rating Heating rating 26 5 Operating Sound Normal 53 Silent Mode 51 imensions Outer 3 6GY 8 0 0 9 Exterior color DIC DIC546 1 2 V Single phase 200 Three phase 200 A 20 95 96 93 96 Water cooled vertical type 4 cycle 3 cylinder OHV Cooling 1200 to 1600 d Power source Starting current Running current A Power consumption o 2 2 o o S ge o 2 o k m o o Power ratio Revolution range Heating 1200 to 2050 3 Concentration 96 65 w 105 150 Engine coolant 1 under the conditions of JIS B 8627 AISIN Aisin gas heat pump 50 60HZ Type x Number of units Scroll typex2 Exclusion capacity 0 0605X2 Revolution range min cooling 2280 to 3040 heating 2280 to 3895 Compressor Specified refrigerator oil Refigerator oi enclosure qiy Power transfer method Poly V belting Refriger Slit fin Multi pipe heat exchanger Louver fin Outdoor unit heat exchanger Exhaust gas heat exchanger Heat exchanger Engine radiator Air suction port Front and rear side Exhaust heat absorption Heating refrigerant in double pipe Type x Number of units Propeller fan x2 Rated air Single phase induction molor Motor Rated Refrigera
149. ient ventilation Clean the indoor unit air filter Indoor unit air filter clogging Heat exchange fin clogging Improper indoor fan motor rotation Check the indoor fan motor Abnormal output voltage See 3 3 9 Fan capacitor malfunction Fan motor malfunction 3 59 3 TROUBLE DIAGNOSIS AND REPAIR Trouble Classification of Sub Classification Check and Remedy Likely Causes 4 Compressor rotates but cold air is not supplied Insufficient 5 Engine speed cooling does not increase during a mode such as error avoidance control Installation status is not appropriate 1 2 Shortage of refrigerant Underfilling Refrigerant leakage Refrigerant circuit fault Four way changeover valve body malfunction Others Indoor unit electronic expansion valve malfunction Hot gas bypass valve does not close High pressure error avoidance Discharge temperature error avoidance Coolant temperature error avoidance Insufficiency in engine output L Engine starts but it stalls Significant loss of pressure in the piping Piping between indoor and outdoor units is too long Too many bends are present Branched piping is too long Piping size is not appropriate Significant difference in elevation Piping branches he branch pipe is not mounted at the correct angle The branched header is further branched The total connection capacity of the indoor units is too large 1 Checking the electromagnetic clutch
150. ikely Causes Diagnosis Remedy Check for improper outdoor and indoor unit signal line connections Check the wiring route Shield the indoor and outdoor unit signal lines Measure the supply voltage at the power terminal block of the indoor and outdoor unit Confirm power W the power fuses the power transformer the power circuit board and the outdoor unit circuit board Check the outdoor unit circuit board Confirm the connection of the indoor heat exchanger temperature sensor and sensor connector Confirm temperature display and compare an actual temperature value and the resistance value Check the indoor unit circuit board Confirm the connection of the indoor intake temperature sensor and sensor connector Confirm temperature display and compare an actual temperature value and the resistance value Check the indoor unit circuit board Check the pipe installation angle and start up dimensions Check the float switch float Switch harness and connectors continuity normal Check the drain piping For details refer to 3 1 2 Details of Address Setting Errors 1 2 Check the remote control unit sensor Alarm Code Maintenance Display of Board Remote Control Unit Code 55 43 o cO cO il 77 s T Contents Too many indoor units connected Indoor heat exchanger temperature sensor short circuiting Outdoor unit address overlapping Outdo
151. in bolt 6 MAINTENANCE DATA STANDARDS 6 2 Refrigerant Related Components Compressor oil NL10 Outdoor unit bod 4L Refrigerator oil 4t Refrigerant gas Recharge kg Li x 0 12 L2 x 0 06 Ls x 0 03 L Overall length m of 12 7 mm diameter liquid pipeline L2 Overall length m of 9 52 mm diameter liquid pipeline Ls Overall length m of 6 35 mm diameter liquid pipeline n 120 Equivalent length Refrigerant Piping length 100 Actual length piping length and permissible Between indoor and Outdoor unit lower m difference in outdoor units Outdoor unit higher elevation Between indoor units For details see the Installation Manual Poz P280 Refrigerant pipe dm i Liquid pipe mm 912 7 912 7 Gas pipe mm 25 4 28 58 31 8 Refrigerant OD Nominal Flare nut tightening pipe mm diameter in torque Flare nut torque Liquid pipe 9 52 34 to 39 values 12 70 49054 A m 12 70 49 to 54 Gas pipe 15 88 59 to 64 19 05 76 to 81 During replacement of the discharge tubing the expansion valve the filter dryer or other consumable parts in vvhich the refrigerator oil 100 cc does not accumulate During release of vvaste refrigerant gas Quantities of During replacement of compressor VVhen refrigerant pipe 0ce refrigerator oil to filter dryer included interior is not to be cleaned be added during When refrigerant pipe the repair of interior is to be cleaned 1000 cc refrigerant relate d sections D
152. ino 201 ZL 1ndino BuneeH ZX oeld s 01 ON lun 100pino EMS p pl lus esn seuj eod Jao uy jejezed indino 201 ZL 1ndino uonejedo LHX eerd s L ON lun ZMS SSU onc POLSMODE Jeoijds pu p solo O pexeu 1opeuuo Z YUI 4 s 01 oN1un LMS SSUIIJSMOG leuw NOLS VJ uonoejes ed L Z enen uorsuedxe ojuoasre 109 Jo owW Buddays WS ey Woy Ajeye1edes lu on O pexieui yoolq jeuiuue L uonoejes ejBue uorsuedx3 or vun jonuoo y Burkueduuoooe Jeysiuueu L Sul U91 s ejeuilg uonoejes uonejedo cr Josues eDueuoxe 189 4 1 Seul 20 7 ms s b esn L uBIS 1 1l 3 or JOSU S JIP eyeju V IUL v H 10 J015e1009 oneuBeuionoe 3 jonuoo ue 33o ouueu er 11201 SX Jojonpuoo x WW 0072 SLO 195099 jonuoo uonisod HINT zr 10 0W ureJp 10J YX A E A a pue 77 Jejeou Aieixny uonoejes ejDue 1eAno Wt LW4 405 S ejo1 Al z4X Baum En AUD sejouep eesi penop ay esn uonoejes ed dund jeep 9MS YOUMS LUIT 21 SINO lur JOPI AUD SOUS Ule Balb SUL smjejs jeuuou 1ejndujo0J9IJN ue816 q31 440 Jojow 1120 440 JO OW NT uoyeoypuI snyeys 49949 PONH 091 NO 0100 0120 NO SMS LVS 10 ioyoedeo 132 JO SUEA EULON 440 LIN 401 eAje ouueu eue Ld6y JeuuojJsuel 2 eumejedue ZSMS HOAO Q 1OJ JoJOJA LIN uonduoseq uonduoseq joquiAs uonduoseq joqus sloquu s jo uonduo
153. intenance Functions 3 2 Trouble Items and Diagnosis 3 1 1 Error Codes Contents and Major Likely Causes 3 3 Diagnostic Items 3 4 Trouble Diagnosis and Check 3 4 1 Ifthe System Does Not Operate 3 4 2 If the Starter Does Not Operate 3 4 3 If the Engine Does Not Start 3 4 4 Ifthe Engine Stalls 3 4 5 Coolant Temperature Alarms 3 4 6 Oil Pressure Alarms 3 4 7 Engine Speed Too High Alarm 3 4 8 High Pressure Alarms During Cooling 3 4 0 High Pressure Alarms During Heating 3 4 10 Refrigerant Low Pressure Alarms 3 4 11 Refrigerant Discharge Temperature Alarms 3 4 12 Communications Trouble and Indoor Unit Circuit Trouble 3 4 13 If Sufficient Cooling Cannot Be Obtained 3 4 14 If Sufficient Heating Cannot Be Obtained 3 1 3 TROUBLE DIAGNOSIS AND REPAIR 3 1 Circuit base board maintenance functions Six 7 Segment LED on the outdoor unit control board indicate operation hours and operation situation etc In addition this maintenance function block is able to give mandates for the individual operation of indoor units 1 Summary of maintenance functions of the control board Mode functions and display Monitoring Input output data signal indicator Green light Check Memory data updating and independent activation of various Red light components In switching the other mode during Command mode mode LED is lighting color corresponding each mode and blinking yellow five times alternately ex In monitoring mode mode LED is blinki
154. ion of Model P280 High Pressure Outside Ar Temp Heating 3 48 2 11 to 2 40 o o 2 Confirming the operating environmental conditions AISIN Aisin gas heat pump Check for unusual increases in the intake air temperature of the outdoor air heat exchanger due to short circuiting or other effects of external or peripheral system components 3 Clogged check valve in the refrigerant room causes the flow of the refrigerant to stop inside the condenser thus leading to increases in refrigerant pressure due to the shortage of the heat Maximum Permissible Operating Temperature Intake air temperature of the outdoor air heat exchanger Checking the check valve angle release area Measure the pipeline temperatures in front of and at the rear of the check valve and if there is a significant temperature difference of 5 deg or more replace the check valve since it is clogged 4 Checking the refrigerant high pressure svvitch 1 Checking the refrigerant high pressure switch for continuity 2 5 Check for continuity between connector terminals under a stopped status If continuity is not detected or if it is interrupted by applying shocks to the switch body replace the switch since its contact points are malfunctioning Checking the refrigerant high pressure switch for normal operation While performing continuity checks from the connector terminals and based on the press
155. ipment for Ventilator 1 96 Output of powered equipment for Ventilator 2 Hi Lo 96 Capacity of outdoor unit KW Engine operation time hours hours 10 Previous periodic check time hours hours 10 Right compressor operation time hours hours 10 Left compressor operation time hours hours 10 Starter on off count times times 100 Engine on off count times times 100 Right compressor on off count times times 100 Left compressor on off count times times 100 Main micro computer version Engine micro computer version High pressure MPa 39 i i i i 6 Hi 66 Engine cooling water temperature 68 Engine exhaust air temperature 69 Heat exchanger liquid temperature j 90 Indoor unit individual request frequency Hz 000080 a 1 098 9 Indoor unit request frequency Hz Indoor unit expansion valve angle step Indoor unit intake temperature Indoor unit operation status 3 5 3 TROUBLE DIAGNOSIS AND REPAIR Command Mode This mode allows the instruction of the indoor units and engine revolutions The function of each switch Switch status Switch function 7 segments LED display description Change code numbers from small number to large number Only pressing 00 gt 01 gt 98 99 00 01 gt Code Ne Change code number from large number to small number Only pr
156. irm and review the setting of the addressing switch 2 Perform indoor unit power checks and reviews 1 Check the setting of the remote controlled operation mode 3 TROUBLE DIAGNOSIS AND REPAIR Details of Address Setting Errors 1 2 Type or Outdoor Unit Indoor Unit Switch Alarm Display Ad 1 Switch Address Setting Status 49 48 0 to 47 U49 Addressing error Automatic 0 to 47 0 to 47 E3 E46 UO to U47 0 to 47 49 48 U49 Addressing error 0 to 47 49 48 U49 Addressing error Manual 0 to 48 49 48 0 to 47 U49 Addressing error 27 Oto 48 49 48 49 48 Not to be used control unit Notes 1 Automatic addressing settings are not stored into memory when E12 is displayed 2 E3is displayed for the indoor units whose automatic address settings have already been stored into memory 3 The unit numbers listed above are for reference only 3 28 AISIN Aisin gas heat pump 3 3 Diagnostic Items Check Item Section To Be Normal Voltage Normal Resistance Remarks Measured Power circuit Red White 200 VAC breaker ELB 4 2 Power terminal Red White TB1 R s Outdoor unit circuit CN18 1 Red board 2 White Ventilation fan CN14 3 White 200 VAC 170 Q EFAN 10 Black Fan motors 1 and Fan 1 CN13 2 7 200 VAC Single speed type 2 FM1 FM2 I EM1 FATZ ON 9 White Black 24 60 10 Black Yellow 60 90 10 Two speed type FM2 White Black 24 60 1096 Orange Red 35 20 10 Red Black
157. its In more than 23 operating in cooling Setting temp 18 and in less than 23 operating in heating setting temp 30 Stopping all of connected indoor units Displaying as follows Press both Indoor unit select Clear for 1 second or more Reset in error Displaying as follows m m E 5 E Clear for 1 second or more Kan 3 4 AISIN Aisin gas heat pump 3 Monitor Mode This mode displays each input output status Function of each switch Change code numbers from small number to large number Code No 00 01 gt 98 99 00 012 Only pressing Change code number from large number to small number Code no 00 99 98 01 00 gt 99 98 n check each indoor unit data select the unit you wantto display n pushing the switch the address of indoor unit is changing Use in case more than the code no 80 The minimum of indoor unit address gt The maximum address The minimum address Only pressing Mode Selecting Change the mode Command mode Only pressing Clear Only pressing Set Only pressing Selecting indoor unit Code number codes in monitor mode Code no Throttle valve angle step 20 Fuel gas adjustment valve angle step Igniter output Liquid quantity adjustment valve angle step Calculated powered three way valve angle step Quantity adjustment valve angle step Output of powered equ
158. k the O2 level Check the stepping motor Check the oil pressure switch Confirm harness continuity and connector connections Confirm that the output of the starter capacitor is 12 V if necessary retighten the plus and minus terminals Check the coolant temperature sensor Confirm harness continuity and connector connections Check the fuel gas pressure Check the engine speed sensor Check the engine speed sensor for improper contact Check the outdoor unit circuit board Check the outdoor unit circuit board Alarm Code Maintenance Display of Board Remote Control Unit Code ci Contents AISIN Aisin gas heat pump Diagnosis and Repair Major Likely Causes Diagnosis Remedy 84 Engine program 1 Engine program writing error Check the outdoor unit circuit writing alarm board Outdoor heat exchanger liquid temperature sensor wire disconnections Outdoor heat exchanger liquid temperature sensor short circuiting Refrigerant high pressure sensor alarm Abnormal increase in compressor intake temperature Fault in motor driven three way valve hole IC 1 Outdoor heat exchanger liquid temperature sensor malfunction wire disconnections or improper connector connections 1 Outdoor heat exchanger liquid temperature sensor malfunction or short circuiting 1 High pressure sensor mal function or short circuiting 1 High pressure sensor mal function cord disconnections or conne
159. larm codes for short circuiting E37 E55 E54 Unconnected jumper detection temperature 40 C is detected continuously for 5 sec Indoor unit temperature sensor wire disconnections E7 10 C 10 8 kQ 20 C 6 2 30 C 4 0 kO 40 C 2 6 kQ Unconnected jumper detection 50 C 1 8 KQ temperature 40 C is detected continuously for 5 sec Indoor heat exchanger sensor disconnections E6 OFF 200 VAC Drain pump is operated ON VAC or Float switch OFF is detected ess Compressor ON in cooling and dehumidifying operated for 2min after compressor off 3 31 3 TROUBLE DIAGNOSIS AND REPAIR 3 4 Trouble Diagnosis and Check 3 4 1 1 2 If the System Does Not Operate Trouble Classification of Sub Classification Check and Remedy Likely Causes The system does not operate No data is displayed on the panel of the remote control unit 1 Faults in the power circuits 2 Faults in the remote control circuit 3 Faults in the communications circuit Data is displayed on the panel of the remote control unit but the system does not operate CN6 Checking the power circuits D Outdoor unit circuit board Incorrect power line wiring Wire disconnections or incomplete contact Control circuit fault Tripped ground leakage circuit breaker Wire disconnections or incomplete contact Fault in the remote control unit Incorrect communicati
160. ls and check for abnormality such as disconnections High tension cord No 1 5 7 22 High tension cord No 2 4 6 1 8 kQ at 20 C High tension cord No 3 3 5 1 3 3 42 AISIN Aisin gas heat pump 3 4 5 Coolant Temperature Alarms Trouble Classification of Sub Classification Check and Remedy Likely Causes PT Insufficient circulation of the coolant causes a significant temperature difference between the inlet and outlet of the radiator E80 80 display 1 Insufficient 1 Shortage natural evaporation or See 1 Checking coolant circulation of leakage of the coolant circulation status the coolant See 2 Checking the coolant level and for leakage 2 Coolant pump failure See 3 Checking the coolant Pump malfunction pump No output 3 Coolant pipeline clogging Thermostat does not open 7U7 ne Thermostat malfunction Although the temperature difference between the inlet and outlet of the radiator is normal if the temperature of the entire radiator is too high the heat release capability of the radiator is likely to be insufficient 2 Insufficient 1 Radiator intake See 5 Checking coolant heat release Too high air temperature heat release status of the Short circuiting radiator during cooling 2 Radiator fin clogging Clean the radiator fin 3 Outdoor fan failure See 6 Checking the outdoor Fan motor malfunction fan motors No output Fan capacitor
161. lues using a megohmmeter and diagnose for current leakage Leakage diagnosing procedure 1 Checking the 200 V units If the resistance value can be recovered by disconnecting the CN1 CN2 and CN4 connectors from the outdoor unit circuit board current is leaking from either of these connections Check each unit independently 2 Checking the indoor units If the resistance value can be recovered by disconnecting the power terminals from the terminal blocks of each indoor unit current is leaking from either indoor unit Note Do not connect the megohmmeter to the communications circuits Checking the remote control circuit Check the terminals of the indoor units and remote control unit for incomplete electrical contact and for wire disconnections Checking the DIP switches Check the DIP switches of the indoor and outdoor units and remote control unit for incorrect settings Outdoor unit No Indoor unit No mmun SW2 SW3 SW4 SW1 Outdoor unit No setting Indoor unit No setting 3 33 AISIN Aisin gas heat pump Example of DIP switch setting Indoor unit address SW1SW2 SW3 sw4 e Remote control unit 55 Refrigerant piping Communication cable Outdoor unit Outdoor unit address SVVI SVV2 0 0 SW1 SW2SW3 SW4 Remote control unit Remote control unit Setting of the slide switch of the remote control unit Sub SVV4 Main 3 TROUBLE DIAGNOSI
162. m CNIB 19 CN2 ola BIY R R OrY Y YY B B BkWW GrR OrY RW BKR Bk W Br UN Control Box re T eur Single s phase R Three a b a m Lx CN E iiy E36 s 2 nee Ma Fz FG BI Blue Y Yellow R Red W White Or Orange Bk Black Gr Green Description of operation 1 After the OPERATE switch has been turned on 12 VDC is applied between CN22 connector terminals 1 and 2 on the control circuit board at the same time the ventilation fan and the coolant pump operate and thus R 1 is activated 2 When R 1 is turned on 200 VAC is applied to the primary side of the transformer TR1 3 After rectification between the secondary side of the transformer and the diodes a voltage of 11 to 19 VDC is applied to the plus terminal of the starting motor 4 12 VDC is output from the CN21 connector terminals 1 and 2 on the control circuit board then R 3 is turned on and 11 to 13 VDC is applied to the starter pinion coil to activate the starter 3 35 3 TROUBLE DIAGNOSIS AND REPAIR Classification of Likely Causes 1 Intake exhaust circuit faults Trouble E83 74 display E84 84 display Engine starting failure 2 Ignition circuit faults 3 4 3 If the Engine Does Not Start Sub Classification 1 Fuel gas Gas valve does not open JE Gas valve malfunction No output 2 Significant A F ratio changes Air circuit T Air intake port clogging Air cleaner clog
163. malfunction E87 70 display 3 Sensor or Coolant temperature sensor detection See 7 Checking the coolant signal line error malfunction or incomplete contact temperature sensor faults or wire disconnections 4 Others Decrease in boiling temperature or 8 Checking the radiator malfunction in the radiator cap 1 Checking coolant circulation status A decrease in the amount of coolant circulation due to pipeline clogging causes a significant temperature difference between the inlet and outlet of the radiator Confirm this temperature difference to judge whether the circulation of the coolant is normal During operation also confirm the sensor detected temperature engine exit coolant temperature in the monitoring data indicating mode of the maintenance board functions Approximate temperature difference deg i between radiator inlet and outlet Operating Conditions During operation of Model J P280 2 Checking the coolant level and for leakage 1 Check the coolant level in the reservoir 2 Remove the radiator cap and check if the coolant level is at the upper limit mark CAUTION Be sure to use a genuine coolant Aisin Coolant S condensation 65 3 43 3 TROUBLE DIAGNOSIS AND REPAIR 3 Checking the coolant pump 1 Confirming coolant pump output Check the maintenance board and the outdoor unit circuit board terminals and make sure that an output voltage of 200 VAC is supplied d
164. mperature sensor Confirm the sensor detected operating discharge temperature using the data display function of the maintenance board and measure an actual temperature Judge from these temperatures whether the sensor is normal Characteristics of the discharge temperature sensor Standard Temperature Resistance Value 182 9 2 70 4 20 2 7 0 3 7 3 56 AISIN Aisin gas heat pump 4 Checking the liquid flow regulating valve and the capacity regulating valve 1 2 3 Checking the mechanical lock of the liquid flow regulating valve electronic expansion valve The motor when driven with the mechanical section of the liquid flow regulating valve locked runs idle and generates weak click sounds When the lock is normal these sounds are heard under the fully closed status of the valve during power on and no such sounds are heard under the open status of the valve The lock is abnormal if such sounds are heard under both the fully closed status and open status of the valve Replace the liquid flow regulating valve in that case Confirming motor coil resistance values Measure resistances between motor coils red white red orange brown yellow and brown blue and make sure that measured values are as listed below Reference resistance value 1500 10 Confirming the continuity of the connectors and wiring After checking for connector disconnections disconnect the connectors and confirm the co
165. n Liquid t piping pipe Fuel gas pipe Gas pipe Exhaust drain pipe 12 7 flare connection 25 4 flange connection 125 Equivalent length 100 Actual length m 50 Outdoor unit at top 40 Outdoor unit at bottom number 1 to 12 P22 to P224 mm Pipe dimensions Permissible pipe length Permissible difference in elevation between indoor outdoor unit Permissible difference in elevation between indoor units Connectable indoor units Legal freezing capacity The cooling heating capability and electrical characteristics data shown in the above table was measured 2 The operating sound level shown in the above table was measured in an anechoic room subject to the relevant provisions of JIS Under actual conditions the operating sound level shown above is usually exceeded since it is affected by ambient noise and the echoes of the installation room 1 9 I SPECIFICATIONS City gas 13A 12A specifications Model No TGMP280B2N Cooling rating 28 0 Operating Sound dB Nomal57 Silent Mode 55 mes 16 Exterior color DIC 227 V A Running current 5 0 5 9 2 9 3 4 A 5 3 6 1 3 1 3 5 Poweroonsumpion 0 96 1 15 ew 1 01 1 19 96 97 96 98 95 98 94 98 Single phase 200 Power So ree Three phase 200 Starting current Power ratio Heating kW Heating mption N u Consu 22 4 Water cooled vertical type 4 cycle 3 cylinder
166. n the shaft of the throttle will temporarily operate to fully close the throttle valve and then open it to the specified angle So as to initialize the stepping motor Check if the initial operation of the shaft is normal Shaft 2 Measure conducting resistance between the connector terminals of the stepping motor Motor coil conducting resistance values Measuring Point Resistance Value Between white and red Between red and orange Between blue and brown 140 Q Between brown and yellow Between white and orange Between blue and yellow 280 Q 3 Checking the starter driving circuit for incomplete contact 4 Incomplete contact of the starter driving terminals may cause engine stall due to noise Check the following sections in particular 1 Capacitor connection terminals 2 Diode connection terminals and body grounding connection terminals 3 Terminals for cord connection to the starter Checking the ignition circuit for noise Insufficient insertion of the high tension cord into the connector or internal disconnection of the cord itself may result in sudden engine stall due to noise and or in malfunction due to an oil pressure or coolant temperature alarm whose cause cannot be readily identified 1 Check that the high tension cord connectors are connected to the ignition plugs and the ignition coils properly 2 Measure the internal resistance between the high tension cord termina
167. n Coolant S G0954 3252 of the required concentration to compensate for insufficiency The required concentration is 65 to 75 percent coolant 0 7 water 0 3 which is equivalent to a concentration of 53 to 60 percent in the case of measurement with an optical concentration meter 6 Use Aisin Engine Oil L 10000 to add engine oil 10 11 12 13 14 5 2 AISIN Aisin gas heat pump 5 2 Periodic Maintenance Procedures 5 2 1 Changing Engine Oils 1 Operate the engine for about 5 minutes Level gauge before changing the oil Il Reference Oiling port 1 2 After stopping the engine pull out the level gauge from the oil sub tank and then drain the oil using an oil changer Or after clamping the hosing across the joint by use i of hose clippers and removing the joint drain x Le the oil and then return the joint to the original kes position Joint pa m 10 3 Add the specified amount 35 liters of new engine oil from the oiling port of the oil sub tank 4 After operating the engine for about 3 minutes stop the engine and after about 3 minutes confirm the oil level using the oil level gauge AN CAUTION Be s re to use Aisin specified oil L10000 Keep oils away from belting and pulleys When clamping the hosing at the joint confirm the traces of clamping on the hosing and mount it properly at its original position
168. n an actual instrument such as a thermometer This state however is not abnormal Auto swing display Shows swing louver status MODE switch Allows operation mode selection FAN SPEED switch Allows the selection of a fan air flow rate AUTO SWING switch Starts and stops the swing louver automatically SET switch TEMP TIME INTAKE GRILL switch Use the switch to set the timer clock Allows room temperature setting timer clock setting and intake grill vertical movement 2 7 2 CONTROL 2 3 Switches for Function Selection 1 Indoor unit Jumper wire connection Function Setting Description Louver angle selection Connected ON TKTW TKTC Indoor unit types only Not connected OFF TKTS TKE TKK Connected ON TKT High ceiling control orma Not connected OFF High ceiling control J L ver control Connected ON Intermittent operation Not connected OFF Stop at any position J3 Fan speed with heating thermovalve Connected ON Weak air blowoff of Not connected OFF J4 Filter sign Connected ON On after 600 hours Not connected OFF Connected ON Operation control CN T input ON Operation enabled Not connected OFF OEF Operation inhibited Connected ON Automatically identified J6 Expansion valve control Not connected OFF New angle fixed DIP switch assembly SW5 setting No uto Setting 20100 ON mem 1 Edge input 0063105550 ee en ne F d ti
169. n the segment of the part which you want to turn on is blinking if Set is pressed the part is operated The operation time of Starter is 5 seconds those of other parts are 3 minutes elndividual operation of parts OFF 1 oCheck mode Position of each part is following 1 Compressor R 2 Compressor L 3 Fuel gas electromagnetic valve 1 4 Fuel gas electromagnetic valve 2 5 Starter 6 Starter transformer 7 Coolant pump 12 Electrical equipment for ventilator 1 13 Electrical equipment for ventilator 2 L 14 Electrical equipment for ventilator 2 H 15 Hot gas bypass valve 1 16 Hot gas bypass valve 2 17 Oil return valve 1 18 Oil return valve 2 19 Compressor heater 20 Drain filter heater 21 Coolant heater 26 Four way changeover valve 27 Ventilator fan When pressing Set one segment is blinking Then if pressing Code no UP each segment is blinking from small to large number one by one like 12 52752841 If pressing Code no DOWN each segment is blinking from large to small number one by one like 152827 221 When the segment of the part which you want to turn on is blinking if Set is pressed the part is operated When all segments are blinking if set is pressed all parts are stopped AISIN Aisin gas heat pump eSupply water mode oCheck mode C m Display of the current supply vvater status vz LI Ex Water supply OFF The display is flashing in pressing Set W
170. nance board 5 Protect each plug hole with a waste cloth 6 After injecting a valve cleaner from the hole in the mixer for about 20 seconds leave the hole intact for about 10 minutes 7 Manually rotate the engine pulley through one full turn 8 Close the head cover and crank the engine by activating the starter use the maintenance function of the maintenance board 9 Open the head cover and rotate the crankshaft to where the clearance corresponding to the 2 IN cylinder can be adjusted 10 Repeat steps 4 to 8 above 11 Remount the ignition plugs the air hose and the igniter connectors 12 Disconnect the mixer head cover blowby hose from the head cover and start the engine 13 Inject about a half can of valve cleaner from the disconnected blowby hose into the mixer Perform the injection intermittently with care so as not to allow the engine to stall or to overspeed AN WARNING When the engine is running be extra careful so as not to get your body or clothes caught in movable sections such as pulleys 14 Reconnect the hose and then after letting the engine run until no white smoke has come out from the exhaust trapper stop the engine 15 Confirm compression If compression is not recovered repeat steps 1 to 11 above 3 39 3 TROUBLE DIAGNOSIS AND REPAIR Cleaning with a valve cleaner Intake valve Gas mixer 1 Disconnect the mixer T pipe blowby hose from the T pipe 2 S
171. nding lowboy concealed type TKFU Unit 2 12 Outside air processing unit with a direct expansion coil unit TKSA Unit Q PCH511K007A 9 9 13 6 45 3 22 7 RR sues ee Ras cu Pene s2 sa eo r 13 Intake air processing unit TKUS Unit Q Po ssasttaso 23 es Po 24 42 14 Floor standing type TKF Unit Q 5 AISIN Aisin gas heat pump S starter 9 Body ground B M Infinity B Body ground Infinity M Body ground 0 01 Terminal S Terminal B FM1 E Motor coil ES heat resistance z exchanger Black Red 28 36 Q 10 value 5 fan motor Yellow reference S g Red White Red Orange Mixer stepping motor Mixer fuel valve stepping motor 6 MAINTENANCE DATA STANDARDS 6 4 Coolant Related Components Thermostat 1 Opening start 62 C Temperature Lift amount Aisin Coolant S 4 L can Coolant 22 4 kW 28 kW 14 L including reservoir Amount 33 5 kW 15 5 L including reservoir Volumetric concentration 65 35 C antifreeze liquid AISIN Aisin gas heat pump 6 5 Thermister Characteristics Temperature C Resistance value kO 50 Coolant temperature sensor Outside air temp sensor Accumulator inlet temp sensor Compressor intake temp sensor Heat exchanger gas temp sensor Heat exchanger liquid temp sensor Discharge temp sensor Resistance value
172. ng green and five times yellow alternately Description for error signal error LED Outdoor unit failure Flashing continuously High Periodic inspection Flashing continuously Forcible addition of engine oil Flashing 9 times Error stop Flashing 7 times Intake air avoidance Flashing 6 times Priority for display Exhaust air avoidance Flashing 5 times High pressure avoidance Flashing 4 times Water temperature avoidance Flashing 3 times Low pressure avoidance Flashing 2 times Normal OFF Low 10 times flashing is one cycle ex Flashing 7 of 10 times How to change to each mode Check mode Press MODE switch for 1 seconds or more gt Press Set and Clear switch for 2 seconds or more It is possible to change to CHECK mode more 3 minutes after power on or compressor off Note It is impossible to change to COMMAND mode and CHECK mode 10 minutes after connected or disconnected to PC checker 7 segments LED The description of 7 segments LED is as follows If necessary code no and indoor Data unit address is lighting alternately AISIN Aisin gas heat pump Code Number List Code Eunet n Monitor Command Check Bemark No Mode Mode Mode 01 10 Previous error 1 10 1 Actual engine RPM min pls pl E Requested engine RPM_ min p cin ss h Calculated engine RPM_ min enke 1 Throttle valve angle step 15 o a RE 18 Igniter output Liquid quantity adjustment valve angl
173. ng type RC Remote control unit 0 blank Closer to left SA US control units 1 3 I SPECIFICATIONS 1 2 2 Combination of Indoor Unit and Outdoor Unit 1 Model P224 outdoor unit TGMP224 4 3 2 way compact cassette type Built in cassette type TKR Ceiling embedded high static pressure duct type TKU Ceiling embedded medium static pressure duct type Ceiling suspended type TKE Wall mounted type TKK Floor standing lowboy exposed Floor standing lowboy concealed Outside air processing unit with a direct expansion coil unit TKSA Air feed processing unit TKUS Ceiling suspended oil resisting type Floor standing plenum type Floor standing duct type TKFD Floor standing type TKF Outdoor unit capacity ratio Approx 50 to 130 Total capacity of indoor units P112 to P291 Number of connectable p 1 to 12 units indoor units Note The capabilities of indoor units slightly decrease during the simultaneous operation of these units in excess of a 10096 outdoor unit capacity ratio Capacity available 1 4 AISIN Aisin gas heat pump 2 Model P280 outdoor unit TGMP280 Model No 4 3 2 way cassette type 4 3 2 way compact cassette type TKTC 2 way cassette type TKTW 1 way cassette type TKTS Built in cassette type Ceiling embedded high static pressure duct type Ceiling embedded medium static pressure duct type Ceiling suspended
174. nger and heats the refrigerant to contribute to the improvement of heating and evaporating capabilities In cooling mode when there is no need for heat to be released through the double pipe heat exchanger an increase in the coolant temperature changes over the motor driven three way valve to the radiator and returns the coolant to the coolant pump after heat has been released through the radiator Fuel The fuel gas is passed through a dual type gas operated solenoid valve unit then depressurized to an atmospheric pressure by a gas regulator and supplied to a gas mixer The high pressure section of the fuel line is isolated from the engine room to ensure safety Intake air and exhaust gas Intake air is passed into the mixer through a silencer and an air cleaner then mixed with the fuel and enters the engine cylinders Exhaust gas releases heat in the exhaust heat exchanger and then the gas itself is released to the atmosphere through the exhaust air pipe The condensate that has been generated by the release of heat from the exhaust gas is temporarily collected into a drain filter and then released from the unit through a drain hose Engine Exhaust air heat exchanger Double pipe heat exchanger Exhaust air pipe Gas mixer Temperature control valve Reservoir tank Oil sub tank Gas regulator Electric three way valve Radiator Gas electromagnetic valve Coolant inlet Drain filter Air cleaner Coolant pump Exhaust air drain hose Intake
175. no DOWN gt When the one place is blinking bush Set The display is blinking E ae Then push Set to fix the angle set range 90 step to 493 step gt gt gt uus gt The display change from blinking to flashing ex 99steps eFuel gas adjustment valve angle oCheck Mode E d When push Set Jido is blinking When Jido is blinking push Code no UP Code no Down The hundred s place of the current fuel gas adjustment valve angle is blinking Ex step the blinking place changes from the hundred s place the ten s place to one s place of the current angle In pushing Code no UP In pushing Code no DOWN In pushing Set When the one s place is blinking push Set The display is blinking bi ES Then push Set to fix the angle set range 10 steps to 140 steps The display is from blinking to flashing continuously Ex 123 steps eLiquid quantity adjustment valve angle oCommand mode EE mode In pushing Set Jido is blinking When Jido is blinking push Code UP Code no Down The thousand s place of the current refrigerant liquid quantity angle is blinking L Ex 60 steps Ll In pushing Set the blinking place changes from the thousand s place the hundred s place the ten s place to one s place of the current angle In pushing Code no UP gt gt o gt m Tai
176. no uogejedo LHX Dunes NO ZSMS 40 130 SN n n luo smoys siu O pexieui 1080002 Z 01 YUI dois uonejedo j indu vonesedg 440 JO 1367 S JON osnj A peau 4 indui voneisdg NO ESMS JO 1030 LW uonduoseq joquiAs uonduoseq JoquiAs uonduoseq joquiAs sjoquuAs jo uonduos ql yun Ionuoo Jowo uondo procs ccc ctr ese wu sede 1 1 8 n nm Wu 2 Cr uonoun Bumll one ue novun in op sr jeued e 10 paim jou ee one SI AOQE Z DOXJEUJ PNOO 9U L f mola Qvo ld I JN TKTC uohoun Er zr Ir BuiBuims ojne ue jnoyym f ued e JO pepi oJd jou Ajjenjoe 51 AOQE pyu POLU PNO eu L ocdd woo oQ PMS EMS CMS LMS pa c err Oeren Wee 3 12 hoera esie sle M pels bioelg dj e6uei9 Zio MS Molle 99uD euuoN oO 3 9 r4 id woQ rot 2 don eseud ejBuis J D 290 AG 5 200 Joopul ueamjeg leu IS saui uono uuoo Jeyooyo J E Le soul jeuBis yun o L I I u 1 t 4 4 I t 1 I I I I I I t U t I I b ZH 09 08 OVA 002 eseud ejDuis sju
177. nsumption A change in oil level mm x 132 cm h 7 Hours of operation h Standard value 1 0 to 3 0 cm h Excessive consumption causes carbon to accumulate at the electrodes of the H ignition plugs resulting in an engine starting failure due to incomplete ignition In such a case driving valve parts stem seals and piston rings are likely to be Xum malfunctioning 2 Checking the oil pressure Oil level If the oil strainer clogs and the oil is not supplied properly the required oil gauge pressure will not be obtained Apply a pressure gauge to the mounting hole PT1 4 of the oil pressure switch and measure the oil pressure Also check the oil level using the oil level gauge Add 2 to 3 liters of oil if the oil level is too low near the L level mark Standard value 0 147 to 0 490 MPa at 1800 min 3 46 AISIN Aisin gas heat pump 3 Checking the oil pressure switch Checking during shutdown 1 Check the oil pressure switch terminals for improper electrical contact due to backlash 2 Check for normal operation of the oil pressure switch by examining for electrical continuity between the terminals Engine Status Oil Pressure Switch Terminal Stop Continuity No continuity 4 Checking the starter driving circuit for improper electrical contact Improper electrical contact between the starter driving terminals may cause an oil pressure alarm due to induced noise Check the following se
178. ntinuity of the wiring 3 4 12 Communications Trouble and Indoor Unit Circuit Trouble Trouble Classification of Sub Classification Check and Remedy Likely Causes Communications 1 Indoor and If an unusable address is assigned trouble display outdoor unit Indoor unit address number overlapping Check the assigned address E2 2 display humber Outdoor unit address number assignment address number E3 3 4 display E4 display E10 display E14 1 E31 31 display Sub unit address number assignment error errors error See the item on function ndoor unit address number assignment error select D P svvitches 4 display Too many indoor units connected Outdoor unit address number overlapping E6 96 display 12 Indoor unit 1 Heat exchange sensor See 1 Checking the E 7 97 display disconnections sensor Sensor malfunction temperature sensor short circuiting Incomplete contact or wire or wire disconnections Intake sensor Sensor malfunction Incomplete contact or wire disconnections E8 8 display Heating Heating overload See 2 Confirming indoor overload Indoor unit heat exchanger thermistor unit marg Stats alarm See 1 Checking the malfunction DEA temperature sensor Indoor unit circuit board fault Thermistor input circuit fault E9 95 display 14 Drain water Drain water accumulation See 3 Testing for normal float switch Drain piping defects drainage on Ri
179. ode no Down The L or H the current status of the electrical equipment for the ventilator 2 is blinking Ex The duty ratio of the electrical equipment for ventilator 2 L is 5096 When the L or H is blinking If pressing Code no UP the electrical equipment for ventilator 2 H is set If pressing Code no DOWN the electrical equipment for ventilator 2 L is set If pressing Set the number is blinking When the number is blinking If pressing Code no UP the duty ratio become plus 596 If pressing Code no DOWN the duty ratio become minus 5 af the data is blinking After that pressing set the data is o 1 4 The display changes from blinking to flashing continuously ex The duty ratio of the electrical equipment for ventilator 2 H is 2096 3 TROUBLE DIAGNOSIS AND REPAIR 3 12 AISIN Aisin gas heat pump eOutput Description oMonitor Mode The description of indicator is following Four way changeover valve Electrical equipment for ventilator I Comp heater Starter lectromag Electromag Oil return 1 Gas tic valve3 netic valve electromag valve 1 Electrical netic e I Drain filter quipment_for ventilator 2 L Starter i ranstorme Gas electromag Comp netic L valve2 Ventilator fard mu neater Electromag Electrom Oil return Hot gas bypass Oil supply netic valve4 agnetic valve2 valve 2 Tap 2 valve 2 Electrical l valve2 Coolant heater
180. oejes e Due sAjen uoisuedx3 or uoroejes iqluul lqeu uoge1edo Sr uDis 1 ll d or eoeld s l ON HUN ZMS goed 901 ON HUN LMS uoisuedxe Sluono 104 JOJOW Buidd lsS ws Josues eDueuoxe H IU L Josues Jie v lu L Wa 404 S eje1 Aietixny z bX WJ 101 10 9e U09 oneuDeuionoe 3 426 W4 36r HOMO JO 101014 Wal Joquis sjoquuAs jo uonduoseg GMS Z GMS Joquis uonduoseq 090 d va bulan a a m z yun Ionuoo eJoweH Bnuy 330 soul jeus yun Joopyno Er o PMS EMS ZMS IMS 0 JeuuoN rk r 031 9 031 WHO 290 Jeyosyo auo EMUI MUI REUEN 9210 2 MO A LJ MOJIBA Oe ebuelo ebuelo 8740 ZH 09 09 OWA 002 eseud sjueuijeJinbeJ JoMOd 2 47 2 CONTROL TKFPP224 280M5 280S5 Aiesseoeu l lniosqe si Hunnos Jeijeyed ji p pl lus esf s u Jemod 19470 ndino 2QA ZL 1ndino y uo VIX 9aA ZL indino NO oway L EX 0015 i uones do J indui uogejedo 440 ndino OA ZL 1ndino Bune H HX ndino OGA ZL 1ndino uonejedo LHX f indul uonejedo NO UM u Saul y oq Jeoids pu p sol peysew Joy99uU0D
181. of remotely controlled heat exchanger temperature in operation test mode Float switch 1 Detection of drainage alarm OFF 200 VAC FASTON Normal ON ON 10 VAC or less 9 5 Abnormal OFF 1 Cycle time self learning and control by power feeding Voltage applied 5 VDC CNS to motor immediately after power on Rated current 5 mA Vane position Limit switch 2 Louver horizontal position detection Rotary 1 Indoor unit addressing with blue SW1 and SW2 SVV1 Address 10 s place Manual addressing 0 to 47 SVV2 Address 1 s place Automatic addressing 49 2 Outdoor unit addressing with green SW3 and SW4 Manual addressing 0 to 47 Automatic addressing 49 switches SVV3 Address 10 s place SW4 Address 1 s place 6 HA terminals 1 OPERATE STOP instruction The operation control signal waveform is shown Based on Japanese Electric CNZ pins Machine Industrial Standard 1 and 2 below JEM1427 1987 HA This signal is used for the gas heat pump to reverse the OPERATE STOP signal level cla gt Pte Ti Tp Pulse on time 200 300 msec Ti Pulse interval 200 msec or more peration monitoring signa pins 2 0 i itoring signal CNZ pi Gas heat pump on off status output signal 3 and pem Static signal HA 4 5 Operation Operation control signal Operation i lt monitoring signal Tr Tr Tr Response time 300 msec or less 2 CONTROL Electrical Compon
182. olant concentration 5096 Volumetric concentration 10 After driving the coolant pump in Check Mode 34 Refilling Mode of the maintenance board open the radiator cap and check the coolant level in the radiator Refill the radiator if the coolant level is too low 11 Repeat step 10 above until the coolant level in the radiator has stopped decreasing 12 Start the engine and check for oil leakage coolant leakage and other abnormalities 4 6 4 3 Compressor Replacement 1 Components tools and materials required R variable 623404 11010 1 621030 11010 1 623187 30010 Components Compressor Assy Spare parts kit Dryer filter Materials Tools Vacuum pump except Weightometer general purpose Gauge manifold tools Belt tension gauge Digital temperature gauge 2 Disassembly procedure 1 Remove the compressor 2 Remove the compressor with the bracket mounted and then remove the compressor from the bracket 3 Reassembly procedure 1 Assemble a new compressor bracket 2 Remove the port cover of the compressor and mount 3 4 5 new O rings in the grooves Note Coat new O rings with new refrigerator oil and mount the O rings taking care so as not to damage them Inlet side 24 4 mm in inside diameter 2 3 mm in wire diameter Outlet side reducing side 17 4 mm in inside diameter 2 3 mm in wire diameter Add the required amount of new refri
183. onduoseq uonduoseq joquwAs sjoquiAs jo uonduos q L c r o z O e lt lui yun lou i sJ Quo SP Los Sur HUA palesu si Jejeeu m l jeuondo ue Jey sewnsse aAoge eui payjop e u pesojoue jinoJio Jejeeu eu L White White 4 c Black 9 LJ Ae Oo Kelp eig Loer mollaa mollo poy poy sueio ebue o E 42 Eg i s x x 9 o t S o Black Black Signal Power ENUO ZNUO MOEI voerd poy NUS vvv s yoayg EULON M IUL Meld xoelg pay A 222 yeaa Hvo 031 9 031 zuo 0 345 s ul jeus y n o L ZHO9 0S OVA 002 eseud e p yunoul Jeyeeu 94149919 YIM ZH 09 09 OWA 002 eseud ejbuis SjueujeJinbau JoMOd p b c p 2 2 30 AISIN Aisin gas heat pump TKRP112 140M5 14085 S1O O uuoo auO pue pym 2440 eu eDueuo1ejur peysew 1iojo uuoo ZO vu 0015 L uonejedo j indu uonejedo 440 osn a pie u uissonoyg j induruonejedO NO suoneoyioeds inss ld one s uBiu 104 Jeojds pu p so O sn e s jeuuou sa ndwovonIy 4 q31 9 dai1 eld s ON Hun 100pino jesseoeu Ajaynjosge 51
184. onitor Mode ex Engine micro computer communication error 84 3 when the operation time is 9130 hours UL G tFlashing in 2 seconds eRequested Engine RPM oCommand Mode i E In pushing Set Jido is blinking Jido is blinking E Code no UP Code Ne Down dB El EE The current engine RPM is Dak Ex 900 min In pushing Code no min n pushing Code no min In pushing Code no Code no Jido is blinking Push the Set to fix the RPM From the minimum requested RPM to the IL The display changes blinking to flashing continuously ex 1250min eCalculated Engine RPM oCommand Mode H UN In pushing Set Jido is blinking When Jido is blinking E E no UP Code no Down 4 CI The current calculated RPM is ex min In pushing Code no UP min In pushing Code no Down min In pushing Code no UP Code no Down du is inl e RPM Set range From the minimum to the maximum The display changes from blinking to z continuously Ex 1250 min 3 8 AISIN Aisin gas heat pump eThrottle valve angle oCheck Mode R When Jido is blinking push Code no UP Code no Down The hundred s place of the current ans valve angle is blinking step In pushing Set the blinking place changes from the hundred s place the ten s place to one place of the current angle In pushing Code no UP In pushing Code
185. ons line wiring Wire disconnections or incomplete contact Incorrect DIP switch settings Incorrect wiring Wire disconnections or incomplete contact Control circuit fault iY Y BI BI Bk W W See 1 Checking the power circuits See 2 Checking the control section See 3 Diagnosing for current leakage See 4 Checking the remote control circuit Check the communications lines for disconnections and internal short circuiting See 5 Checking the DIP switches See 2 Checking the control section GROrY Single Three phase 1 Check that the power lines of the indoor and outdoor units are connected properly in accordance with the installation manual 2 Check that a supply voltage of 200 VAC is applied to the power terminals of the indoor and outdoor units Checking the control section 1 Outdoor unit If the green LED on the circuit board does not blink in spite of 200 VAC being applied the power transformer or the power board is likely to be malfunctioning Confirm the input and output voltages Indoor unit 2 Similarly confirm the input and output voltages of the indoor unit transformer as well If 200 VAC is not applied there may be a broken fuse s 3 32 Red White 8V 200 V Red Blue White TAM Blue 3 4 5 Diagnosing for current leakage If the ground leakage circuit breaker trips measure insulation resistance va
186. ontrol unit and information that has been detected by sensors are transferred to the outdoor control section Based on the information received from the outdoor control section output signals and display signals are transferred to the terminals of various system Communi Remote cations control Power line line Louver angle setting except for TKT Detection of indoor drain alarm Alarm code E9 95 Serial communications Indoor unit to remote control unit 1 Start stop signal 2 Operation mode Cooling heating blowoff or dehumidification 3 Fan speed flow 5 User set temperature 6 Filter sign 7 Ready for heating 8 Centralized control 9 Indoor unit address 10 Alarm code 11 Room temperature 12 Periodic check display Remote control unit to indoor unit 1 Start stop signal 2 Operation mode Cooling heating blowoff or dehumidification 3 Fan speed 4 Direction of air flow 5 User set temperature 6 7 4 Direction of air Filter reset signal Remote control unit sensor temperature for remote control unit with sensor Operations 1 Start stop signal components and to the remote control unit respectively 2 Operation mode 3 Fan speed 7 4 Auto swing Polarized tri conductor 5 User set room temperature Serial communications User set time Outdoor unit to indoor unit Indoor unit to outdoor unit p Timer mode A 7 Filter reset sign
187. oquiAs uonduoseq Joqus uonduoseq joqu As YUN Jouoo eyouiey uonounj BuiBuims ojne ue novlu jeued e 104 jou Ajjenjoe si e oqe ks Pe ueui PNOO eu L 48 an x 399uO JeuuoN 42 OO 1349940 wo 9 VM Whi u White ite Orange e6ueo 0300 260010 TOAD fuf sus 4 ZO HM Eoo bus o eButio ivo Q aydung E iy n White White or Or White 3 oquu s jo uonduoseq ene Ge Oes HDE AUD r D 10 24 40 22 zug ZHBE 2 0 AA White AND Red gt Blue ANP hieer soul jeuBis yun o L ZHO9 OS OVA 002 eseud e pejunoui Jezeey lk l uM ZH 09 08 OWA 002 eseud ejBuis SjueujeJinbaJ Jo Mod 2 27 Ceiling cassette type 1 way blowoff TKTS TKTSP28 36 45 56M5 2 CONTROL Jeoijds pue peso g peysew 1080009 Z 0 YUI eoeld sy ON HUN ZMS fuesseoeu Ajeiniosge si euwe NOLSV uono l s dAL mi 0 s 01 ON HUN LMS Bunnoi joj e1ed ji seJiw pepielus esf seuij Jemod 1eujo O peyew yoolq jeuruue L uonoejes ejDue A PA uorsuedx43 9r uoisuedxe 01 104 JO OWW Buidd S NS UUM ul s uli jo3uoo ejoujeJ jou oq yms ejewig uono l s yq yu jqeu uonejedo Sr Joy eds ys S UII Jomod ey wou
188. or R on off count 52 eCompressor L on off count 53 oCheck mode 5 The present on off number is flashing Ex Engine on off count is 0 When pressing Set each place is blinking from large to small place 1000 100 10 1 If pressing Code no UP the number changes from small to large like 0 9 0 9 If pressing Code no DOWN the number changes from large to small like 9 0 9 0 If pressing Set when one s place is blinking all data is blinking Then if pressing Set the data is fixed Setting range 0 to 9999 100 times The data indicator changes from blinking to flashing continuously Ex 123400 100 times ePeriodic inspection reset eAutomatic address erase oCheck Mode Displayed OFF Press Set 7 H Displayed Go Press Set in more 2 seconds or more to fix the indication Note Power off after automatic address erase If not power off error E1 will happen eMain Microcomputer Version eEngine Microcomputer Version oMonitor Mode Ex Engine Micro Computer version Ver 1 10 AISIN Aisin gas heat pump ePressure displayed oMonitor Mode Ex mg pressure 0 n MP eTemperature displayed peas mode 1 2 pin temperature BB LIB elndoor unit and periphery Ex When connecting indoor unit no oln not selecting indoor unit Ex Indoor unit 3 Displaying indoor unit intake temperature 11 eve
189. or unit address number setting error Less phase error Power supply connection error Excessive increase in compressor air discharge temperature Compressor air discharge temperature sensor alarm AISIN Aisin gas heat pump Diagnosis and Repair Major Likely Causes Diagnosis Remedy 13 indoor units or more are connected to one outdoor unit 1 8 PS building use multi type 13 units or more 2 10 PS building use multi type 13 units or more 3 13 PS building use multi type 13 units or more Indoor heat exchanger temperature sensor fault or short circuiting Harness short circuiting Outdoor unit address overlapping UO to U47 Outdoor unit address number setting error 1 T phase of three phase power supply is disconnected 2 Mistaken power supply sub circuit connector 1 In connection of three phase power supply the setting of power supply on the sub circuit board is single Shortage of refrigerant refrigerant flow channel clogging compressor compression error Improper heat release from condensing unit Entry of non condensed gas 1 Discharge temperature sensor fault or harness short circuiting 3 23 Reviewing the number of indoor units which are connected 1 8 PS building use multi type 12 units or less 10 PS building use multi type 12 units or less 13 PS building use multi type 12 units or less Confirm temperature display using the maintenance board Check if the indoor
190. ot generate operating sounds under a voltage applied status proceed to step 3 below n the other cases proceed to step 4 below Checking the electronic expansion valve Measure with a tester the resistance value between pin connections see a to d below of the connector at the electronic expansion valve and if the measured value is 0 ohms or an infinity replace the coil The normal value is about 40 ohms a Between orange and gray c Between yellow and gray b Between red and gray d Between black and gray 3 50 4 Confirming the opening of the electronic expansion valve AISIN Aisin gas heat pump Operate the indoor unit and check for passing sounds of the refrigerant inside the refrigerant pipeline during the operation of the unit If no passing sounds are heard the electronic expansion valve is malfunctioning However check the heat exchanger temperature and make sure that the heat exchanger is not in a stopped status for the purpose of antifreezing Verify that temperature control is not stopped either 3 4 9 High Pressure Alarms During Heating E40 76 86 Refrigerant high pressu re alarm During heating Classification of Likely Causes 1 Heat exchange inside the condenser of the in door unit is obstructed N Refrigerant 1 Sub Classification Indoor fan failure Presence of an obstruction Interference No output Fan motor malfunction Fan capacitor fault
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192. parks will be generated v The above check can be performed by operating the starting motor alone for 5 seconds in the component check mode of the maintenance board Check mode 31 Checking the ignition plug electrodes Check each plug for thermally or physically damaged dirty or unusually worn electrodes Reference electrode gap 0 4 to 1 0 mm Note To remount the plug hand tighten it first and then retighten to a 20 to 25 N m torque using a plug wrench Checking the high tension cords 1 Make sure that each high tension cord is fully inserted 2 Internal cord disconnections check Verify that the resistance values of the high tension cord terminals are as listed below 35213 3 37 3 TROUBLE DIAGNOSIS AND REPAIR 5 Checking the igniter 6 1 Checking the output voltage of the igniter Make sure that the corresponding LED on the maintenance board is on and that an output voltage of 12 VDC is developed between the E1 B terminal and B A terminal of the igniter The above check can be performed by switching on the igniter alone for 3 minutes in the component check mode of the maintenance board Part code 02 Ignition coil Bey assembly n WOODOHOH GO 3 o 2 s g p al 2 Checking the ignition coils Check the primary and secondary ignition coils for
193. place it in that case Closed normal I Open error 0 05 0 15 Mpa 3 4 11 Refrigerant Discharge Temperature Alarms AISIN Aisin gas heat pump Trouble Classification of Sub Classification Check and Remedy Likely Causes E36 91 display 1 Too high compressor intake temperature The discharge temperature increases with increases in compressor intake temperature Discharge superheating level tempera ture alarm 1 Too high superheating level Refrigerant undercirculation Shortage of refrigerant Leakage or mere shortage Refrigerant channel blocking Indoor unit electronic expansion valve malfunction Dryer filter clogging Check valve clogging 2 Hot gas leakage to intake port Leaks in four way changeover valve Valve malfunction 3 Injection error Injection shortage Liquid injection valve malfunction Liquid injection pipe clogging 2 Too high The discharge temperature increases with condensing increases in condensing pressure pressure 1 Insufficient heat release Indoor air filter clogging during heating Indoor heat exchanger fin clogging during heating Outdoor heat exchanger fin clogging during cooling 2 Intake air Inappropriate environmental conditions or short circuiting during cooling o 2 B o E o o o L o o o a E 2 3 To refrigerant supply line Check the operational
194. play Check the discharge temperature sensor and connector connections Check the refrigerant high pressure switch Confirm harness continuity and connector connections Check for clogging of the heat exchanger near the condenser and for abnormal operation of the fan Check the refrigerant system check for refrigerant leakage clogging etc using refrigerant system diagrams A B D and Q Confirm temperature display compare an actual temperature value and the resistance value Confirm engine room temperature sensor and connector connections Confirm exhaust temperature sensor and connector connections Confirm temperature display using the maintenance board Check for the harness wire disconnections Check for improper connector connections Check for harness short circuiting Confirm temperature display compare an actual temperature value and the resistance value Confirm the accumulator inlet temperature sensor and connector connections Alarm Code Maintenance Display of Board Remote Control 55 Gas pipe ER Gas pipe sensor alarm Contents temperature sensor wire disconnections temperature short circuiting Refrigerant low pressure AISIN Aisin gas heat pump Diagnosis and Repair 1 Gas pipe temperature sensor fault wire disconnections or improper connector connections 2 Gas pipe temperature sensor fault or short circuiting Improper heat rel
195. r temperature sensor vvire disconnections ndoor intake temperature sensor vvire disconnections ndoor unit drain vvater alarm Addressing alarm Remote control unit intake temperature sensor vvire disconnections Diagnosis and Repair mproper connection of the outdoor unit signal line during operation disconnected or loosened Communication error betvveen the outdoor and indoor units due to noise or others Povver off interruption or out of phase during the operation of the indoor and outdoor units driven by independent povver supplies Power supply cable disconnection of the outdoor unit circuit board or outdoor unit circuit board fault Outdoor unit circuit board fault the outdoor unit circuit board or CPU has become abnormal during the operation of the power supply Indoor heat exchanger temperature sensor malfunction defective element wire disconnections Improper connection of the sensor connector Indoor unit circuit board fault heat exchanger sensor input circuit fault Indoor intake temperature sensor malfunction defective element wire disconnections Improper connection of the sensor connector Indoor unit circuit board fault sensor input circuit fault Check the drain piping Float switch malfunction Drain pump fault drain pump wire or connector disconnections Mismatching of the address Switch settings Remote control unit sensor wire disconnections 3 22 Major L
196. r unit board CN7 9 12 On the outdoor unit board CN8 17 18 On the outdoor unit board CN8 3 4 On the outdoor unit board CN7 3 4 On the outdoor unit board CN8 1 2 On the outdoor unit board R CN6 7 8 L CN6 5 6 On the outdoor unit board CN6 11 12 Starter malfunction EIL Engine speed too high 820 0 Engine speed control error 744 4 Engine speed huningenor me _ Engine micon communication enor sis Kr m ay xum Tn Engine coolant temperature too high coolant temperature too high 800 0 Engine coolant temperature sensor short No engine coolant coolant Engine coolant temperature sensor vvire nn Engine oil pressure error oil pressure error Engine oil pressure switch wire disconnections Refrigerant high pressure switch wire disconnections Refrigerant high pressure error High pressure sensor error EN Refrigerant low pressure error Refrigerant low pressure switch wire disconnections No refrigerant Compressor discharge temperature too high Compressor discharge temperature sensor short circuiting R Compressor discharge temperature sensor short circuiting L Compressor discharge 77 sensor vvire disconnections Compressor discharge meus sensor wire disconnections Compressor intake E sensor wire disconnections Compressor intake temperature sensor short circuiting Compressor intake temperature too
197. r ionos Displaying Code no and indoor unit address alternately oln selecting indoor unit monitor mode is displayed Displaying the indoor unit intake 25 of Indoor unit 11 2 Pushing Indoor unit select Ex Display indoor unit intake temperature of Indoor unit address 45 18 Pushin unit select EE the number is more than the number of connected indoor units the indoor unit address EE to the minimum number address oln selecting indoor unit command mode and check mode Ex Connecting 2 set Or s F soes the operation status Stop of indoor unit address 11 Pushing unit select Ex Display the operation status of indoor E g unit 45 Air ventilating Pushing indoor unit select Select all sets of the connected indoor units p p Display the operation status of the minimum mi number of indoor unit Pushing indoor unit select l wie OE HAE 3 TROUBLE DIAGNOSIS AND REPAIR When the number is more than the number of connected indoor units the indoor unit address retums to the minimum number address elndoor unit expansion valve angle oCheck mode de IE m In pressing Set Jido is flashing When ind is blinking pressing both Code no UP and Code no The present oil return condition is Ex Oil return is OFF When pressing Code no UP the oil return is ON When pressing Code no DOWN the oil return is OFF When pressing
198. rant circuit Indoor unit electronic expansion valve malfunction Liquid flow regulating valve malfunction Refrigerant high pressure switch malfunction L Refrigerant high pressure switch circuit fault improper contact or wire disconnections High pressure switch malfunction L High pressure switch circuit fault improper contact or wire disconnections Throttle returning failure Throttle lever malfunction or stepping motor malfunction 1 Checking the refrigerant high pressure level Check and Remedy See 1 Checking the refrigerant high pressure level See 6 Checking outdoor fan motors in 3 3 5 Clean the heat exchanger fins See 2 Confirming the operating environmental conditions See 3 Checking the check valve angle Repair the faulty section Check if the ball valve is fully open See 6 Checking the electronic expansion valves See 4 Checking the liquid flow regulating valve in 3 3 11 See 4 Checking the refrigerant high pressure switch See 5 Checking the refrigerant high pressure sensor Check the throttle operation Measure refrigerant pressure levels from the high pressure detection ports on the right side of the engine room If measured data oversteps the ranges listed below the heat exchange section of the condenser or the refrigerant circuit is malfunctioning Operatin refrigerant pressure values for reference onl during operat
199. re duct type TKUMP22 28 36M5 lines between Connection indoor units NUD C pele OIE joerg PON pela apum era Heo Pe UAT Pela Black Red NE Ak van an vH J zoo aL Yellow Red Power J9 oel HUT l 319 s ul jeufis Sux yun 1oopino F 0 D R a ZH09 0S OWA 002 59 seyd pejunoui Jejeeu 9149919 uyu ZH 09 09 OVA 002 eseud ejBuis sSjueuijeJinboeJ JoMOd 2 CONTROL TKUMP45 56 71 90M5 S10j2euuoo Pel Ju pue liuA Z4UD eui eBueuojejur suoneoyioeds inss id Sne s uiu 104 essegeu Ajaynjosqe 51 Bunos JejjeJed ji pepjerus esf seui Jemod 19470 uy ur s uli jouoo BY jou oq S UII Jomod ey Woy Ajayesedas soul jeuBis v eno sun u wq q s uli jeuDis o uuo2 o pue y n ey o s uli jeufis j2euuoo o g pue v 0 sejqeo 1ojonpuoo z x WW Q0 z 9270 Ip uuoO syoolq eUBIS A G ejouep g pue y HL E p nop eu pun JOOpuI juo smoys ureJBelp SIUL S JON yun Ionuoo eJoweH o c O White WhiteO White 5 m o Red EMS ZMS LMS u aal ECT E ypeig Pea pou Rk n yan 9 031 spel SHUMA peld VL Hu HNUQ pela M vH J zoo 16x29u5 349 Jeoijds pue peso O peysew
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201. secseesdersnSeevsacetuouevsesessoetsasdersters 6 2 Refrigerant Related Components Leere ee ee eee ee eee neenon netta seen nets seen setas sse sse Sao Sotaren aoas 6 4 Electrical EquipMent cs uqun Y R R H R 6 5 Coolant Related Components s 88 s8e ss soto seta sesta setas estas setas seen il n 6 10 Thermister Characferisfies 6 11 AISIN Aisin gas heat pump SPECIFICATIONS Chapter 1 LI 1 2 1 3 1 4 1 5 1 6 SPECIFICATIONS Product External Views Product Specification 1 2 1 Model Number and Product Name 1 2 2 Combination of Indoor Unit and Outdoor Unit 1 2 3 Structure Drawing 1 2 4 Outdoor Unit Specifications Outside Drawing of Outdoor Unit Outdoor Unit Internal Structure Various Characteristics 1 5 1 Cooling and Heating Capabilities and Gas Consumption for Each Indoor Unit Connection Capacities 1 5 2 Allowable Cooling and Heating Temperature Ranges 1 5 3 Changes According to Piping Length 1 5 4 Fuel Consumptions 1 5 5 Outdoor Unit Operating Sound Characteristics System Flow Chart 1 6 1 Refrigerant Circulation Diagrams and Description 1 6 2 Coolant Fuel Air Circulation Diagrams and Description 1 1 I SPECIFICATIONS 1 1 Product External Views 4 3 2 way cassette type FTKTPOOOM5 1 vvay cassette type
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203. ser or sloped See 4 Checking the Drain pump failure No output Incomplete contact or disconnections Pump malfunction Float switch malfunction drain pump See 5 Checking the float switch 3 57 3 TROUBLE DIAGNOSIS AND REPAIR 1 Checking the temperature sensor Confirm the sensor detected temperature using the data indication function of the maintenance board and measure an actual temperature Judge from these temperatures whether the sensor is normal Judgment criteria for temperature sensor Temperature C Standard Resistance kQ 2 Confirming indoor unit intake status 3 4 Make sure that the intake port of the indoor unit is free from blocking that the filter is not clogged and that the fan motors operate properly Testing for normal drainage 1 Slowly supply about 1 liter of water seeing the left view below 2 Connect the remote control switch and start the system in cooling mode When the compressor is turned on the drain pump will start rotating 3 Test for normal drainage while confirming the rotating sounds of the drain pump Insert about 20 to 30 mm of a water hose facing Drain pipe downward and supply Body water Drainage status can be confirmed through the transparent socket Remove the grommet Remount it after the test The water may not be drained from the drain pipe even though the drain pump is in operation or the possible backflow
204. sition of the louver differs according to the type of indoor unit used J 1 connected TKTS or TKE type J 1 not connected Other types 10 Drain pump 1 On during cooling or dehumidification when 200 VAC FASTON compressor is on tab 2 On when float switch is off 4 and 5 3 Turned off two minutes after float switch on 11 Fan controller 1 The fan speed from the TKU type of indoor unit can 200 VAC be continuously adjusted with the appropriate control 2 12 2 4 2 Outdoor Unit Input Output Specifications Specs Refrigerant high pressure Switch Heat exchanger liquid temperature sensor Heat exchanger gas temperature sensor Outside air temperature sensor Compressor discharge temperature sensor Compressor intake temperature sensor Accumulator inlet temperature sensor Engine coolant temperature sensor High pressure sensor Low pressure Switch Stoppage judgment associated with unusually high pressure 2 Detection of refrigerant high pressure switch wire disconnections 1 Answer frequency calculation correction of supercooling 2 Wire disconnection short circuiting detection for heat exchanger liquid temperature sensor 1 Frosting detection during heating 2 Refrigerant high pressure error avoidance control during cooling 3 Wire disconnection short circuiting detection for heat exchanger gas temperature sensor 1 System operation inhibition ambient temperatur
205. tart the engine 3 Inject about a half can of valve cleaner from the disconnected blowby hose into the mixer Perform the injection intermittently with care so as not to allow the engine to stall or to overspeed 4 Reconnect the hose 5 Let the engine run until no white smoke has come out from the exhaust trapper and then stop the engine AN WARNING Be extra careful so as not to get your fingers clothes etc caught at the pulley or other rotating bodies when cleaning 9 Mixer fuel valve check Remove the fuel valve harness from the mixer and confirm the resistance values between each connector terminal connection on the stepping motor Terminal Resistance between Terminals 20 C B1 S1 32 20 B1 S3 32 20 2 52 32 2 2 54 32 20 51 53 64 4 2 54 64 4 Fuel stepping motor Connector 3 40 AISIN Aisin gas heat pump 3 4 4 If the Engine Stalls Trouble Classification of Sub Classification Check and Remedy Likely Causes PT Engine stall with the throttle open implies the insufficiency in engine output E85 75 display 1 Insufficiency in engine output 2 Throttle control circuit faults 3 Noise or others 1 2 Fuel circuit malfunction Inappropriate air to fuel ratio Air cleaner clogging Ignition circuit malfunction Ignition plug malfunction Deposits or moisture Plug gap out of specs High tension cor
206. tates smoothly 5 2 10 Checking the Operational Sounds 1 Check that the outdoor unit does not generate unusual sounds during operation 2 Listen very carefully for rattling sounds from the cylinder head and for interference sounds from rotating sections around the engine 5 2 11 Prevention of Valve Damage Cleaning with a valve cleaner Intake valve 1 Disconnect the mixer T pipe blowby hose from the T pipe ZZ Carbon 2 Start the engine 3 Inject about a half can of valve cleaner from the disconnected chamber blowby hose into the mixer Perform the injection intermittently with care so as not to allow the engine to stall or to overspeed 4 Reconnect the hose 5 Let the engine run until no white smoke has come out from the exhaust trapper and then stop the engine AN WARNING Be extra careful so as not to get your fingers clothes etc caught at the pulley or other rotating bodies when cleaning 5 2 12 Replacing the Fuel Gas Hose 1 Remove the hose clipping and disconnect the fuel h Has nose Grommet 2 Remount the hose clipping to connect a new hose Hose regulator Changing period Atleast every 10 years or 20 000 hours Grommet Bolt with washer Regulator assembly Fuel pipe 5 6 AISIN Aisin gas heat pump MAINTENANCE DATA STANDARDS MAINTENANCE DATA STANDARDS 6 1 Engine Related Components 6 2 Refrigerant Related Components 6 3 El
207. the seal ability of the gasket Before tightening the bolts therefore be sure to wipe with a waste cloth N Knock pin hole 3 Place the gasket on the cylinder head and then mount the cylinder head Tighten the 14 bolts in the numerical order shown in Fig 6 and in two split operations See Figs 5 and 6 Fig 5 Tightening torque 34 N m 4 Insert the push rods in the order that they were removed 5 Mount the stem cap on the valve and then mount the rocker shaft assy See Fig 7 Note Tighten the nut so that the adjust screw fits into the cup of the push rod Rocker shaft assembly fastening torque 20 N m Adjust the valve clearance Clearance adjustment value 0 25 0 05 mm Remount the following removed parts 6 7 1 Head cover 2 Air suction hose and oil hosing Exhaust pipe replace the gasket Exhaust heat exchanger stay Ignition plugs and high tension cords Harness Gas mixer ignition coils and coolant temperature sensor 7 Coolant hosing O O1 4 5 AISIN Aisin gas heat pump Remove all fragments of the old gasket and dirt Water outlet Water inlet 4 MAINTENANCE OF MAJOR FUNCTIONAL COMPONENTS 8 Measure compression force using a compression gauge Specified compression force 1 4 MPa or more 9 After removing all hose clippers open the radiator cap and add coolant until the radiator has become full Co
208. tions Pickup coil wire disconnections Connector disconnections Gas electromagnetic valve output error Fuel circuit malfunction Ignition circuit malfunction Improper compression 1 Insufficiency in engine output 2 Stepping motor malfunction or others Oil pressure switch malfunction Harness wire disconnections or connector disconnections Engine coolant temperature sensor wire disconnections Harness wire disconnections or connector disconnections Engine speed hunting alarm Engine microcomputer communications error 3 26 Major Likely Causes Diagnosis Remedy Confirm whether when the starter is turned off 12 VDC is applied to the starter pinion coil Confirm whether when the starter is turned off 12 VDC is applied to the starter driving relay Check the starting motor Check the starting motor pinion connector and pinion harness Check the pickup coil Check the outdoor unit circuit board Make sure that connector CN10 I is not disconnected Make sure that connector CN33 X is not disconnected Check the outdoor unit circuit board Check the outdoor unit circuit board Check the gas operated solenoid valve and the regulator Check the ignition plugs plug gap 0 4 to 0 1 mm and the high tension cords Confirm compression at least 12 0 kg cm and check the O2 level Check the clearances INO 35 mm EXO 0 35 mm Confirm compression at least 11 0 kg cm and chec
209. type TKE Wall mounted type Floor standing lowboy exposed Floor standing lowboy concealed Outside air processing unit with a direct expansion coil unit Air feed processing unit TKUS Ceiling suspended oil resisting type Floor standing plenum type Floor standing duct type TKFD Floor standing type TKF Outdoor unit capacity ratio Approx 50 to 130 Total capacity of indoor units P140 to P364 Number of connectable 1 to 12 units indoor units Note The capabilities of indoor units slightly decrease during the simultaneous operation of these units in excess of a 10096 outdoor unit capacity ratio Capacity available 1 5 I SPECIFICATIONS 3 Model P355 outdoor unit TGMP355 0 compact cassette type TKTC 2 vvay cassette type TKTVV 1 vvay cassette type TKTS Built in cassette type TKR Ceiling embedded high static pressure duct type TKU Ceiling embedded medium static pressure duct type Ceiling suspended type TKE VVall mounted type TKK Floor standing lovvboy exposed Floor standing lovvboy concealed Outside air processing unit vvith a direct expansion coil unit TKSA Air feed processing unit TKUS Ceiling suspended oil resisting type Floor standing plenum type Floor standing duct type TKFD Floor standing type TKF Outdoor unit capacity ratio Approx 50 to 13096 Total capacity of indoor units P178 to P462 Number of connectable
210. ud ejBuis SjueujeJinboeJ Jewog TKTVVP71 80 90M5 7155 2 26 AISIN Aisin gas heat pump TKTVVP112 140 160M5 14085 NO JO NO NO uz seuil 440 NO NO 440 ul Jamod ey wouy Ajayesedas s uli jeu amp is oy dudo duo NO ug Silun s ull eUBIS j5euuoo oy zems LEMS zems 16MS exon pue jun ey o seui jeufiis 1o uuoo o g pue vaN ZH 09 B N 2405 V o s lqeo Jojonpuoo z x WW 00 Z 9270 199uuoO 640014 jeuruue oul 20615 A G ejouep g pue v AL BULA lis uo sejouep Sul eu S UOMHMS SynoJro jun Joopul juo swous weuBeip SIU L 16 exejur our s o Mol q lqe eu z sn suoneoyioeds jeued Bunyi ojne 10 pepi oud jou ndino OGA ZL 1ndino Bune H CX dois uonejedo j indui uonejedo 440 indino 20 21 indino uogejedo LHX k Duisie es jnduruogejedo NO peyew iojo uuoo Z yug oeld s ON Hun JOOPINO osn d eoe d S 0L ON Hun 400pinO sn e s jeuuou 1ejndujoooJoI A q31 9 031 oeld s l ON HUN oyeolpul smiejs 40949 pes 031 4 031 eerd s 01 ON lun JOJSUEA IEA 10 009 y Buikueduioooe 18jsiuuJ9u L Jeuuojsuel HL Josues eDueuoxe ye H uonoejes dAL 8 r JOSUSS JIE V uL uonoejes ojbue onjen uorsuedx3 9r s
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213. ultiple errors the errors are displayed alternately Left 2 digits error main code Right 2 digits error sub code Ex Errorcode Case 80 0 Case 5 20 Case no error Only pressing Display error stop status Error Code In case of multiple errors the errors are Code no displayed alternately The description is the same as the case of Code no UP Display indoor units operation stop status by 7 segments Indoor unit 0 is the minimum indoor unit address In case of the number of connected indoor units is 16 sets ghigss operating indoor unit LED is lighting Indoor unit 1 quM Indoor unit Indoor unit Only pressing Code Ne In case the number of connected indoor units is more than 17 sets display as follows every 2 seconds alternately The operating indoor unit LED is lighting Indoor unit Only pressing Selecting Indoor unit Indoor unit Indoor unit Indoor unit Indoor unit UBQULE ndoor unit ndoor unit Displav of indoor units which number is more than 16 Only pressing Mode Selecting Change mode gt monitor mode Only pressing Clear No function Only pressing Set Display of each part output status by 7 segments LED Please refer to Code no 27 for the description Operating all of connected indoor units Displaying as follovv Press both Indoor unit r 1 for one second or more Sending operating command operating mode command and setting temperature to all of indoor un
214. unit upper 50 m Outdoor unit lower 40 m Difference in elevation between indoor units 15 m max Approx 130 or less Capability decreases in proportion to the excess amount of capacity AISIN Aisin gas heat pump MAINTENANCE OF MAJOR FUNCTIONAL COMPONENTS Chapter 4 MAINTENANCE OF MAJOR FUNCTIONAL COMPONENTS 4 1 Engine Body Replacement 4 2 Cylinder Head Replacement 4 3 Compressor Replacement 4 1 4 MAINTENANCE OF MAJOR FUNCTIONAL COMPONENTS 4 1 Engine Body Replacement 1 Components tools and materials required Description Part No Components Engine assy set Aisin Coolant S Aisin Gas Engine Oil L 10000 Hose clipper Belt tension gauge Timing light Torque wrench Wooden piece 2 Disassembly procedure 1 Remove the compressor belt 2 Drain the engine oil See Fig 1 1 Clamp the engine oil sub tank oil hose using hose clippers 2 Remove the plug of the oil pan and drain the oil using an oil changer Or remove the joint and drain the oil 3 Also drain out the oil from the oil sub tank similarly 4 Remove the engine oil sub tank oil hosing 3 pieces from the engine 3 Drain the coolant See Figs 2 and 3 1 Clamp the coolant hosing in two places 2 Loosen the coolant drain plug and drain the coolant 3 Remove the coolant hosing 2 pieces from the engine 4 Remove the harness See Figs 2 and 3 1 Starter 2 places
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216. ure data from the high pressure detection ports measure the pressure applied when the switch operates continuity is lost The Switch is normal if it turns off at 2 8 MPa Checking the refrigerant high pressure sensor 1 Comparing pressures under a stopped status High pressure level Code No 60 on maintenance board pressure level Code No 60 on maintenance board Confirm on the maintenance board the pressure detected by the high pressure sensor and compare this value vvith the pressure indicated by a high pressure gauge Use a Noreen c imin m n calibrated gauge to perform measuremenis and zero adjust the gauge before starting the measurements Temprerature difference between these positions bi Check valve a The sensor is normal if the difference in pressure is within 0 1 MPa b If the pressure displayed on the maintenance board is between 0 0 and 0 1 MPa in spite of the gauged pressure being higher check for connector disconnections and proceed to step 3 below c If the pressure displayed on the maintenance board is 2 9 MPa or more skip to step 5 below d In cases other than b and c above check pressure with the system in operation and then proceed to step 2 below 2 Comparing pressures under the operational status The sensor is normal if the difference in pressure is within 0 15 MPa Proceed to step 3 below if the difference is not within
217. uring operation If in spite of the fact that the corresponding LED on the maintenance board is on the required output voltage is not supplied the switching circuit on the board is likely to be faulty 2 Checking the coolant pump body Check for normal operating sounds If the pump does not operate confirm the resistance values of the motor coils Motor coil reference resistance value 58 4 O 10 ded an zur EP ALI z LI DE nbus 2 MILL Rj 2 Buz 4 Checking the thermostat If despite the coolant pump being normal the circulation rate of the coolant is not normal the thermostat may not have opened properly Check the operation of the thermostat Coolant pump Lift amount mm Thermostat 1 Opening start 62 C Thermostat changeover temperature Opening start 62 Lifting amount 12 mm Full opening 72 C Lifting amount 18 5 mm 5 Checking coolant heat release status of the radiator during cooling Canopy top Although the temperature difference betvveen the inlet and outlet of the radiator is normal if the temperature of the entire radiator is too high perform the follovving checks 1 Check for significant increases in the If shrot circuited ambient temperature of the radiator due to short circuiting or other unusual events l Hot air from the outdoor unit located next to the fans 2 Check the radiator fins for clogging and dirt 3 44 A
218. uring replacement of Residual quantity accumulator 500 cc Independent replacement During replacement of oil Residual quantity If replacement is made with that of tab p 5 id other components add oil considering separator c other quantities of addition During replacement of other components other than compressor Quantity actually required 6 3 Electrical Equipment AISIN Aisin gas heat pump Coil resistance value Reference value Motor coil resistance value Reference value Outdoor unit system Indoor unit drain pump Gas operated solenoid valve coil Four way valve coil Ignition coil Primary side Cam angle sensor Compressor clutch coil AC DC converter trans former Board relay R2 R3 Primary side Cold status Hot status Brown Blue 1 0 5 Brown Black 2 gt 0 6 Blue Black 3 0 30 Secondary 4 3 2 way cassette type TKT 2 way cassette type TKTW 1 way cassette type TKTS Built in cassette type TKR Medium static pressure duct type TKUM 210 1 3 kO x 20 2 2 to 3 4 O C10 to 50 C 2 8 to 4 4 50 to 100 C 1100 150 Q 20 C 4 4 gt 0 2 5 0 10 6 gt 0 10 side Ignition coil D Secondary rimay side Transformer for AC DC converter Secondary side 6 e M L Primary side Common to all models
219. ushing Code no oui Meere IMP o DOWN Eidi m gt When the one s place is blinking push Set The display is blinking Then push Set to fix the angle set range 60 steps to 2000 steps The display changes from blinking to flashing continuously Ex step AISIN Aisin gas heat pump eOutput of electric equipment for Ventilator 1 oCommand mode Check mode a In pushing Set Jido is blinking When Jido is blinking push Code no UP Code no Down The current duty ratio of the electrical equipment for ventilator 1 is blinking ex The current duty ratio of the electrical equipment for ventilator 1 is 10 E pressing Code no UP In pressing Code no DOWN In pressing Code no UP Code no DOWN is blinking Press Set to fix the setting range Jj Wiz display changes from blinking to flashing LI continuously ex The current duty ratio of the electrical equipment for ventilator 1 is 10096 eOutput of electric equipment for Ventilator 2 oMonitor mode Ex The electrical equipment of ventilator 2 is stopped miz I IC Ex The duty ratio of the electrical equipment for ventilator 2 L is 100 CHE OIC Ex The duty ratio of the electrical equipment for ventilator 2 H is 30 2440 oCommand mode check mode El E a E E In pressing Set is blinking When is blinking push Code no UP C
220. utdoor unit is powered off or the CPU on the circuit board of the outdoor unit is uncontrollable The address number of the outdoor unit is not set properly 3 21 1 Measure the supply voltage at the power terminal block of the indoor unit Confirm power W the power fuses and the power transformer Confirm the electrical continuity insulation and polarity of the remote control signal line Confirm the color and voltage of the remote control signal line black or red 10 VDC Cut off the noise induction route and or shield the remote control cable If the abnormality cannot be corrected even by resetting the power system confirm the circuit board of the indoor unit Confirm the address number settings of the indoor unit indoor unit address Nos UO to U47 must be free from overlapping Measure the supply voltage at the power terminal block of the outdoor unit Confirm power W the power fuses the power transformer the power circuit board and the outdoor unit circuit board Check if the outdoor signal lines are connected properly Check and if necessary correct the assigned indoor and outdoor unit address numbers Check and if necessary correct the assigned outdoor unit address numbers 3 TROUBLE DIAGNOSIS AND REPAIR Alarm Code Maintenance Display of Board Remote Control Unit Code 5 error betvveen the indoor and outdoor units Contents 2 3 ndoor heat exchange
221. valve does not shift from heating mode hot air will be supplied even during operating in cooling mode Such a state implies that the output voltage remains applied to the electromagnetic coil or that the valve inside the main unit is malfunctioning 3 60 AISIN Aisin gas heat pump 3 4 14 If Sufficient Heating Cannot Be Obtained Trouble Classification of Sub Classification Check and Remedy Likely Causes Insufficient 1 Electromagnetic 1 Electromagnetic clutch malfunction See 1 Checking the heating clutch of the Trouble with the clutch itself 0 clutch in compressor is ncomplete contact 3 3 13 not engaged No output Control section 2 Indoor temperature sensor malfunction See 1 Checking the Short circuiting temperature sensor in Sensor fault 3 3 12 Adequate air conditioning cannot be obtained since the indoor temperature is mis judged to be higher than its actual value Electromagnetic 1 Automatic activation of refrigerant circuit Confirm circuit protector clutch is protector status disengaged immediately No error is displayed until the refrigerant circuit protector has repeated its after being automatic activation and automatic resetting several times During this engaged automatic resetting cycle therefore the clutch is repeatedly engaged and disengaged Improper indoor 1 Insufficient ventilation Clean the indoor unit air unit heat Indoor unit air filter clogging filter
222. visions of JIS Under actual conditions the operating sound level shown above is usually exceeded since it is affected by ambient noise and the echoes of the installation room AISIN Aisin gas heat pump Class A propane gas specifications Type x Number of units Scroll type x 2 TEES Exclusion capacity 60 5 cm 7rev x 2 5 2280 to 4655 min Cooling New Refrigerant Model P355 9 2 1 Type Building Use Multi Unit 3 Revolution range 2280 to 4845 min 5 Heating 8 Specified refrigerator oil NL10 Refrigerator oil enclosure q ty 4L 58 dB 56 dB in silent mode Poly V belting Exterior color Munsell 5 Engine radiator 5 0 5 9 2 9 3 4 A Cooling Running current 5 3 6 1 3 1 3 5 A Heating Exhaust heat collection method Refrigerant heating 0 95 1 15 kW Cooling Povver consumption 1 10 1 19 kW Heating Type x Number of units Propeller fan x 2 96 97 96 98 Cooling Ou Power ratio 95 98 94 98 Heating 5 Rated air amount 210 m min Single phase induction 29 9 kW Cooling rating Type motor 6P Consumption 29 6 kW Heating rating Motor 6P Rated output 0 22 kW Water cooled vertical type 412 7 mm 4 cycle 3 cylinder OHV Refrigerant Flare connected piping i 431 8 mm Flange mounted Fuel gas pipe R3 4 Exhaust drain pipe 15 mm dimensions Heat exchanger Electrical characteristics Type Liquid pipe Exhaust volume 952 cm 7 c 2 7 5 o 2
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