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1. HIGH meS The alarm code that identifies the last fault that has occurred in Unit number COOL Li ttt j IA the displayed unit and alarm code a The unit number of the connected unit or the unit number for displayed TEK which the checking mode was selected previously ADDS Number of the Indoor Unit in No Cycle After TE F me RN No Refrigerant Cycle seven A ithin seven seconds to chec seconds another unit Forward Press the switch to increase from 00 to 01 to 02 Ter Backward COOL calh Press the O switch to decrease from 15 to 14 to 13 Check mode 1 rams AIC CHECK Se Press O to see the previous indication rar Press to see the next indication COOL ist ie I AIG CHECK Pres OK for more than 3 seconds X HIGH Unit number COOL Oo m a Press to see the next data ADDS RN fanl Pam and alarm code wel Press O to see the previous data displayed CHECK After seven See A seconds HIGH An Check mode 2 COOL Fu Press Refer to Check NE t mode 1 for details Inthe Check mode 2 the data of the first three units that are connected serially to a remote control switch are available Pres OK for Pal HIGH aa ae more than 3 SERT You can press the OK
2. 20 Discharge pressure y high x 0 1 MPa m a 21 a low H Pa i Lf This is an indication for internal information for the remote i control switch This does not have any specific meaning 22 Control information H f f 23 Ope ation frequency LOL BER This is an indication for frequency of inverter Hz ae a tt Indoor unit capacity indication 24 Indoor unit capacity j i H The capacity of the indoor unit is indicated as shown in the table n below i Capacity code of indoor unit 1 rag Indication code Equivalent capacity HP 25 Outdoor unit code 1 06 38 but J poy 08 TO T 10 1 3 13 1 5 Refrigerant cycle v l 14 1 8 26 number bt l ht l 16 20 T 20 2 5 22 2 8 Refrigerant cycle he ror 26 3 0 3 5 27 number tt et 32 40 l 48 6 0 64 8 0 Expansion opening indication ey 10 0 Indoor unit expansion i r a indicates the total number of Indoor Units valve opening Im I bn bt I H H r fo E E u 1 9 10 11 12 13 14 15 16 J3 01 16 01 when shipment DSW5 Decimal indication Outdoor unit J4 00 OF 00 when shipment DSW5 Indication with 16 numbers 29 expansion valve L a a In case of models without the expansion valve MV2 the same figure MV1 opening is displayed Outdoor unit 30 expansion valve i 1 1
3. Ab i Z 4 If the transmission between the indoor unit and the outdoor unit is 15 normal operation E i l f not performed during three minutes the Indoor Units are stopped n this case the stoppage cause is d1 06 and the alarm code occurrence counter fame J In thi the st is d1 06 and the al de 03 J may be displayed 5 In the system 20 will be indicated at the diference between indoor Instantaneous power east units 16 failure occurrence E P G l counter in indoor unit Santa ee Countable up to 99 l Over 99 times 99 is always displayed Transmission error q7 occurrence counter m i a NOTE between remote control Jan aml Dal Pama switch and indoor unit 1 If a transmission error continues for three minutes one is added to y the occurrence counter Abnormal operation _ Z 2 The memorized data can be cancelled by the method which is 18 occurrence counter on E of rare explained in section 7 3 1 Self checking Procedure of PCB by inverter L I anan means of the Remote Control Switch Indication of automatic louver condition 19 Louver sensor i i 1 SMGB0059 rev 0 04 2009 447 Troubleshooting HITACHI Inspire the Next Service Manual Compressor pressure frequency indication
4. 5 Soa 5 When the unit is applied the excessive surge current due to n A 0 0 OH lighting or other causes it is indicated this alarm code 04 or Sesa Y n E 0 DN the inverter stoppage code ITC 11 and the unit can not be Ba operated In this case check to ensure the surge absorber SA ee Z E on the noise filter NF1 If the inside of the surge absorber is 2 L A normal turn OFF the power once and wait for PCB2 s LED OFF a and turn ON again i ME GB oo o 20 112 SMGB0059 rev 0 04 2009 Troubleshooting Service Manual HITACHI Inspire the Next Alarm code Description 2 i Abnormal operation of DC fan motor protection E The RUN LED flickers and ALARM is displayed on the remote control switch E The unit number the alarm code and the unit code are alternately displayed on the set temperature section The unit number and the alarm code are displayed on the display of the outdoor unit PCB1 The fan motor is stopped when the revolution pulse out put from the DC fan motor is 10 min 1 or less after 10 seconds from the fan operation starting After that if it occurs more than 9 times in 5 minutes this alarm is indicated The abnormality occurs when the DC fan motor is stopped Restart operation PCB1 Control PCB in Outdoor Unit PCB2 Inverter PCB Yes lt Doe
5. between faston No Is LED1 red on terminal R1 and Check the fuses of the PCB1 ON N1 of PCB1 220V outdoor unit power supply or 240V m Remove CN8 of PCB1 Is connector 1 PCN2 CN11 Yes a Plug PNC2 and CN11 for the transformer correctly loosened Is LED3 yellow Yes PCB1 ON Yes 3 on Deanne ae gt Replace the fuse S 5 No O No Is LED3 yellow d on PCB1 flickering No Faulty PCB1 more than once in gt 10 seconds Connect CN8 of PCB1 F No s PCB setting non pole gt Set it correctly operating Yes To next page 78 SMGB0059 rev 0 04 2009 Troubleshooting HITACHI Inspire the Next Service Manual From previous page Is LED3 yellow ON even if CN2 of PCB is removed Is LED3 on PCB ON Faulty PCB gt Check other Indoor Units Is LED 3 yellow on PCB No Check the wiring between the flickering more than once in 10 gt outdoor unit and the indoor seconds units units or the fuse EF1 for PCB Yes Does refrigerant system setting between DSW1 RSW1 on PCB1 and DSW5 RSW2 on PCB correspond No gt Set it correctly Indoor Unit Yes No Does the alarm occur with all gt Faulty PCB the indoor units Yes Faulty PCB1 1 In case that terminal resistance DSW5 1P is OFF when H Li
6. Indoor unit air inlet A l Temperature displayed 2 temp at thermistor by Z ct i Normal C Ind it 4 h Thermistor is open circuited ee aa al e ae Abormal 7 or PCBis defective 3 air temp at thermistor 21 B C mt aml l ml r l iq Temp for top of comp Indoor unit heat ee P et 4 exchanger liquid pipe h f ct i temp C EE Thermistor is short circuited l FE or PCB is defective 5 Temperature at remote LI p g or sensor C bt ml I l JEE a4 l S or 6 Outdoor unit ambient Le rm var Temp for top of comp temp C Ltt Cot wz t t Refer to section 7 3 1 Self Checking Indoor unit heat Procedure of PCB by means of the Remote 7 exchanger gas pipe h i Pa k Control Switch temp C Ti pite During the transient periods such as starting time and other the indicators or 1 may be displayed for a limited time Outdoor unit This is indicated only when a remote sensor is connected The indicator is normally displayed l RPK series cannot connect a remote sensor a Therefore the indicator is 9 Control information 71 ME J This indicates the internal information for the remote control Discharge gas temp switch In case of SET FREE this indication shows the operation 10 at the top of the comp by H f compressor quantity chamber C m Ex During the operaton of several compressors the average temperatu
7. Replace PCB2 1 Regarding replacing or the checking method for inverter parts refer to the item Procedure of checking other main parts 2 Before checking of diode module refer to the item Procedure of checking other main parts 3 Regarding the setting value of activation current refer to the item Specifications of inverter 108 SMGB0059 rev 0 04 2009 Troubleshooting HITACHI Inspire the Next Service Manual Alarm code Description 2 Abnormality of current transformer E The RUN LED flickers and ALARM is displayed on the remote control switch E The unit number the alarm code and the unit code are alternately displayed on the set temperature section The unit number and the alarm code are displayed on the display of the outdoor unit PCB Incase that the abnormality of alarm code 51 or 54 occurs three times within 30 secons the alarm code of abnormality occurred for the thirs time is indicated Retry operation is performed up to second time of abnormality occurrence Condition of Activation When the frequency of the compressor is maintained at 15 18Hz after the compressor is started one of the absolute values of the running current at each phase U U V and V is less than 1 5A including 1 5A PCB1 Control PCB in Outdoor Unit PCB2 Inverter PCB Restart the
8. Power supply Control AC 400V cable Keep a distance between each wiring ter minal and attach insulation tape or sleeve as shown in the figure Correct Incorrect Rear cover Wiring method with clamp 1 Insert the wires by into the cord clamp and clamp them as shown in the oN figure Perform wiring so that wires do not touch the N nsulation tape or sleeve Earth compresor refrigerant the caulking portion of the terminal If a single wire is used connect the wire direct as shown in the figure wire Do not use a solderless terminal when a single wire is used If used it causes abnormal heating at RO Power supply pipes or edge of the covers Make a loop of the wires so that disconnecting the wirings for replacing parts is not required CAUTION When using conduit do NOT lead it in the outdoor unit If the conduit wiring touches the compressor and refriger cable ant cycle in the outdoor unit it may cause to damage them Piping cover Earth wire Control cable Rubber bush Accessory Conduit Power supply cable A CAUTION Fix the shielded operation wires between the indoor unit and outdoor unit with a cord band at only one point You must connect the shielded operation wires to the earth of the indoor unit only 4 Before turning ON the main switch check the item below
9. Operation stops for 6 minutes in 2 minute cycles When the indoor unit is at thermo OFF during the heating operation the indoor fan operates and Start at random OFF NOTE When the indoor fan is stopped by another control it is not available to operate indoor fans E Night Shift Low noise Press PSW1 and select the setting condition 1 at the night shift low noise m Then this function can be set The outdoor fan operation is controlled by fan controller as shown below The night shift operation shall be applied in case that the cooling capacity has the margin to be allowed for the capacity decrease and the low sound operation is required especially in the nighttime Outdoor Fan Maximum rotation rotation ratio 50 100 22 25 30 33 Outdoor temperature C i NOTE temperature The maximum rotation is always 100 rotation ratio for the standard unit No limitation of the outdoor 42 SMGB0059 rev 0 04 2009 Available optional functions Service Manual E Frequency range Cooling operation HITACHI Inspire the Next Outdoor Unit Capacity Minimum Frequency Maximum Frequency Conditions HP Hz Hz 8 15 68 When night shift is not set Except for the 10 85 m ni 0 conditions on the right 12 100 Outdoor Unit Capacity Minimum Fr
10. Insufficient connection switch or incorrect connection of the indoor unit PCB in the remote control switch Check the connectors Correctly connect the connector Failure of the remote control switch Check the remote control switch by means of the self check mode 1 Replace the remote control switch if it failed Unconnected wires to PCB Failure of PCB Check the connectors Correctly connect the wires Failure of PCB Check PCB by means of the self check mode 2 Replace PCB if it failed Incorrect wiring connection Take action according to the procedure that is displayed in TEST RUN TY 9 Refer to section Self checking of remote control switch 62 SMGB0059 rev 0 04 2009 Refer to section Self checking of PCB using remote control switch Troubleshooting Service Manual E RUN LED on the remote control switch Flickering every 2 seconds HITACHI Inspire the Next Phenomenon Cause Check item Turn OFF the main switch Action Disconnection or insufficient contacting of the remote control cable Check the cable and the connections Repair the cable or connect the cable Incorrect wiring connection incorrect polarity Check the wiring and the connections Repairing Failure of the remote control switch Check the remote control switch by means of the self check mode Replace the remote control switch
11. Turn ON No 2 pin Set Dial No 5 DSW and RSW setting before shipment is 0 Maximum in setting refrigerant cycle No is 63 Troubleshooting HITACHI Inspire the Next Service Manual Alarm code Description lt 2 Incorrect indoor number setting E The RUN LED flickers and ALARM is displayed on the remote control switch E The unit number the alarm code and the unit code are alternately displayed on the set temperature section The unit number and the alarm code are displayed on the display of the outdoor unit PCB1 This alarm code is indicated 5 minutes after power is supplied to the outdoor unit when the indoor unit No connected to the outdoor unit is duplicated by setting of DSW and RSW NOTE In the case of H LINK System this alarm code is indicated when DSW4 and RSW1 of the outdoor unit PCB1 and DSW5 and RSW2 of the indoor unit PCB are incorrectly set In this case set them correctly after turning OFF the main switch and again turn ON the main switch When the refrigerant number setting of outdoor unit H LINK II and the one of outdoor unit H LINK are duplicated the alarm 35 may go ON and OFF repeatedly PCB1 Control PCB in Outdoor Unit SMGBO0059 rev 0 04 2009 101 HITACHI Inspire the Next Troubleshooting Service Manual Alarm code Description ya Abnormality of picking up circuit for protection l l Outdoor Unit stoppage The RUN LED
12. I gt ry X Tripping of the protection device in the outdoor unit ro lt Decrease in the discharge gas superheat I mi m T Increase in the discharge gas temperature X DJ Pressure ratio decrease protection activating X X Low pressure increase protection activating X mr High pressure increase protection activating X lt Low pressure decrease protection activating You can check these alarms by means of the check mode 1 Follow the action that is indicated in each alarm chart You can clear these alarms only by turning OFF the main switch to the system However you must pay careful attention before starting because there is a possibility of causing serious damages to the compressors Alarm code Description h 2 Incorrect indoor unit setting Measurement The RUN LED flickers and ALARM is displayed on the remote control switch E The unit number the alarm code and the unit code are alternately displayed on the set temperature section The unit number and the alarm code are displayed on the display of the outdoor unit PCB1 35 is indicated in the disply of the remote control switch This alarm is indicated under the following conditions Turn OFF the power supply and check the setting of DSW and RSW Conditions More than 17 non FSN2 Series Indoor Unit H LINK are connected to one system Non FSN2 Series Indoor Unit H LINK
13. If cooling capacity or heating capacity is not enough under the long distance piping condition this function can be set the target compressor frequency higher than normal target value E Low noise setting Press PSW1 and select the setting condition 1 so the low noise setting gfi can be set The outdoor fan maximum rotation is set lower than normal setting regardless of outdoor temperature However continuous operation can not be operated under the condition below a Outdoor temperature is over 40 C b Total combination horsepower is over 100 SMGB0059 rev 0 04 2009 45 H ITACH l Available optional functions Inspire the Next Service Manual E Fixing of demand function Press PSW1 and select the setting condition 1 so that the fixing of demand function E can be set However it is not necessary to short circuit the demand input terminals on the outdoor unit PCB Refer to the item Input 3 Demand Current Control The table below is the limit of the running current for this function Control Function No Demand Running Current Control 1to5 100 6 60 7 70 8 80 9 100 This function can be activated when demand function is selected at one of the input terminal indications and J In case that multiple demand functions are set at the input terminal indications and 3 the demand running current is selected as bel
14. Input terminal indication 1 Input terminal indication 2 Input terminal indication 3 Output terminal indication 1 Output terminal indication 2 3 After the input output terminal indication is selected select your required control function No by pushing PSW2 or PSW3 while PSW1 is being pushed This number is increased by 1 by pushing PSW2 while PSW1 is being pushed gt This number is decreased by 1 by pushing PSW3 while PSW1 is being pushed 4 After selecting the function No return No 6 pin at the OFF side on the DSW2 The selected contents are memorized in the outdoor unit printed circuit board and the function selection mode is stopped The memorized data is maintained even power source lines are disconnected The connecting details of each function are described and the required parts are also indicated in the table SMGB0059 rev 0 04 2009 35 Available optional H ITACH l functions Inspire the Next Service Manual E Input 1 Fixing heating operation mode Control function No 1 E Input 2 Fixing cooling operation mode Control function No 2 In the case that the fixing input terminals of the operation mode on the outdoor unit PCB1 are short circuited the operation mode can be fixed at the cooling or heating mode Short circuit between Terminals 14 and 2 of CN1 Fixed Heating Operation Mode Short circuit between Terminals 2 and 3 of CN1 Fixed
15. 11 7 Guideline for selecting the drain pipe for the indoor unit E Method for selecting the drain pipe diameter 1 Calculation of the Drain Flow Volume Calculate that the drain flow volume is approximately 3 I hr per 1HP of the nominal capacity of the indoor unit For Example Common drain pipe for four 2 5HP indoor units Total horsepower of the 4 x 2 5 10HP indoor unit Total drain flow volume 10HPx 3 I hr x HP 30 I hr 2 Select the drain pipe from the Table A and the Table B Horizontal common pipe with VP 20 for the above example the slope 1 50 Horizontal common pipe with the slope 1 100 Vertical common pipe VP 25 for the above example Table A Permissible drain flow volume of the horizontal vinyl pipe JIS symbol Inner diameter Permissible flow volume I hr mm Slope 1 50 Slope 1 100 VP20 20 39 27 VP25 25 70 50 VP30 31 125 88 VP40 40 247 175 VP50 51 472 334 NOTE VP20 and VP25 Not Applicable to the Common Pipe VP30 VP40 and VP50 Applicable to the Common Pipe Table B Permissible drain flow volume of the vertical vinyl pipe JIS symbol Inner diameter Permissible flow volume I hr mm VP20 20 220 VP25 25 410 VP30 31 730 VP40 40 1400 VP50 51 2760 VP65 67 5710 VP75 77 8280 NOTE VP20 VP25 and VP30 Not applicable to the common pipe VP40 VP50 VP65 and VP75 Applicable to
16. Fi Code Cause i Automatic stoppage of the transistor module IPM Error overcurrent decrease voltage increase temperature Instantaneous overcurrent J Abnormal inverter fin thermistor I Electronic thermal activation Inverter voltage decrease Insufficient Voltage al 5 Voltage increase mn Abnormal Inverter transmission Reset of micro computer for inverter q Abnormal power source phase m Abnormality of detection for fan motor position i Fan controller retry 128 SMGB0059 rev 0 04 2009 Troubleshooting H ITACHI Inspire the Next Service Manual 1 Protection control code is displayed on 7 segment when a protection control is activated 2 Protection control code is displayed while function is working and goes out when released 3 When several protection control are activated code number with higher priority will be indicated see below for the priority order Higher priority is given to protection control related to frequency control than the other Priority Protection control Priority Protection control 1 Pressure ratio control 9 Demand current control running current limit 2 High pressure rise protection control 3 Current protection 10 High pressure fall protection 4 Inverter fan temperature rise protection 11 Oil return control 5 Discharge gas temperature rise protection 12 TdSH fall protection 6 Low
17. Replace PCB1 and check the operation Replace PCB1 if faulty Indicated pressure value is excessively high or low Malfunction of the pressure sensor due to a faulty check joint Check the check joint for clogging Replace the check joint SMGB0059 rev 0 04 2009 99 HITACHI Inspire the Next Troubleshooting Service Manual Alarm code Description X of Incorrect capacity setting or combined capacity between Indoor Units and l l Outdoor Unit The RUN LED flickers and ALARM is displayed on the remote control switch E The unit number the alarm code and the unit code are alternately displayed on the set temperature section The unit number and the alarm code are displayed on the display of the outdoor unit PCB1 This alarm code is indicated when the capacity setting dip switch DSW3 on the outdoor unit PCB14 is not set all the settings from 1 to 4 are OFF or mis setting This alarm code is indicated when the total indoor unit capacity is smaller than 50 or greater than 130 of the combined outdoor unit capacity Are 1 6 of DSW3 on the indoor unit PCB1 set incorrectly No Are 1 4 of DSW3 on the indoor unit PCB set incorrectly Set th ity for PCB1 vr Set the capacity for PCB gt Set the capacity for PCB Yes PCB1 Control PCB in Outdoor Unit Indoor Unit PCB Yes Are the setting of DSW4 and RSW
18. the check mode is not available Failure of the Indoor Unit of PCB Disconnected wiring to PCB Check the connectors Correctly connect the wiring Failure of PCB The LED and the LCD on the remote control switch remain ON Failure of PCB in the indoor unit or the remote control switch Check PCB by means of the self check mode 1 Replace if PCB fails 4 9 66 Refer to section Self checking of PCB using remote control switch SMGB0059 rev 0 04 2009 Refer to section Troubleshooting in check mode by remote control switch Troubleshooting Service Manual Abnormal operation of the devices Cont HITACHI Inspire the Next Phenomenon Insufficient cooling process Cause Indoor heat load is greater than the cooling capacity Check item Calculate the heat load Action Turn OFF the main switch Use a bigger unit Excessively low suction pressure Gas leakage or shortage of refrigerant Measure superheat Correctly charge the refrigerant after repairing the gas leakage Excessively small diameter tube or long piping Measure and check the field supplied pipes Use the correct pipes Incorrect activation of the check valve of the outdoor unit Check whether or not the temp difference exists before after the check valve Replace the check valve for the outdoor unit Check for clogging Remove
19. 3 Attaching P Plate za Diode Module Assy 24 Transistor Module Attaching P Plate 25 Printed Circuit PV041 S for Inverter Printed Circuit P0081 S Boae Board 26 Plastic Material Collar 6 Printed Circuit PO084 27 Plastic Material Bush Board 28 Plastic Material Spacer 7 Printed Circuit PO083 S 29 Mag Contactor CMC1 Fuji Electric Co Ltd FC 0 Board sp 8 Plastic Material Spacer 30 Resistor RS1 RS2 9 Plastic Material Spacer 34 Reactor DCL 19 Transt rmer 32 Capacitor 400VAC14700pF 11 Terminal Board 4P M5 600VAC 50A for Power 33 Saddle Source 34 Fin Cover 12 Terminal Board 4P M4 250VAC 20A for Transmitting 35 Thermistor Fin Thermistor 13 Capacitor 440VAC 7uF 36 Resistor R1 14 Capacitor 440VAC 8uF 37 Resistor R2 15 Capacitor 440VAC 10uF 38 Screw 16 Noise Filter 39 Stay 17 Plastic Material Holder 40 Capacitor Assy Herness PC301 CS1 CS2 18 Fuse Holder 41 Noise Suppressor ZNR Assy 19 Fuse 40A SMGB0059 rev 0 04 2009 137 Servicing Service Manual 9 Servicing HITACHI Inspire the Next Contents 9 Servicing 137 9 1 Outdoor Unit FSNM E 138 9 1 1 Removing service cover 138 9 1 2 Removing air outlet grille 138 9 1 3 Removing upper cover 138 9 1 4 Removing the lower part of service cover and rear cover 139 9 1 5 Removing outdoor fan motor 139 9 1 6 Removing Electrical Box 140 9 1 7 Removing compressor 142 9 1 8 Removing high pressure switch 145 9 1 9 Removing high pre
20. Check the activation of the drain up mechanism Check the activation during the cooling process Good Not good 28 Air inlet temperature of the indoor unit DB WB C DB C WB 29 Air outlet temperature of the indoor unit DB WB C DB C WB 30 Air inlet temperature of the outdoor unit DB WB C DB C WB 31 Air outlet temperature of the outdoor unit DB WB C DB C WB 32 High pressure switch kg cm G 33 Low pressure switch kg cm G 34 Operating voltage V 35 Operating current A 36 Instructions to the client for cleaning the air filter Done Not yet 37 Instructions to the client about the cleaning Done Not yet method 38 Instructions to the client about the operation Done Not yet SMGB0059 rev 0 04 2009 178 Field work instruction Service Manual HITACHI Inspire the Next 11 11 Service and maintenance record by means of the 7 segment display E FSN2 Customer s Name Date Outdoor Unit Model Serial No RAS Serial No JRAS Serial No 1 Operation mode 2 Start time of the test run 3 Start time of the data collection 4 Read out data from 7 Segment display Protection control code 52C 52C 52C 52C 52C MFC3 MFC4 Pn 52C 52
21. Conditions Abnormal current to the transistor module such as short circuited or grounded or Abnormal temperature of the transistor module PCB1 Control PCB in Outdoor Unit or PCB2 Inverter PCB Control voltage decrease Turn off power disconnect U V W from compressor terminals and restart Does the protecting function activate 3 No Check the compressor If there is a short circuit between phase lines replace the compressor Normal Replace the transistor module Check the transistor module 1 2 Check the PCB2 Good Abnormal Replace PCB2 and the transistor module Is the silicon grease coated all over between No the transistor module and the radiated fin Coat the silicon grease to all Is the fixed screw on the transistor module loose the touched face between the transistor module and the radiated fin fully Fix the Yes screw correctly 4 Is the heat exchanger Yes of outdoor unit clogged Remove clogging Replace the PCB2 1 Regarding replacing or checking method for the inverter components refer to item Procedure of checking other main parts 2 Before the checking of inverter components refer to item Procedure of checking other main parts regarding electrical discharge 3 Turn ON the No 1 switch of the dip switch DSW1 on PCB2 when restarting with disconnecting the terminals of the compressor After troubleshootin
22. If the nominal voltage for the outdoor unit is 415V change the connector CN4 to CN5 of the transformer TF in the electrical box as shown in the figure below Connector for 220V cN5 1 2 Connector for 24ov SMGB0059 rev 0 04 2009 21 HITACHI Inspire the Next Quantity and location of DIP switches Push switch PSW1 manual defrost Push switches PSW2 PSW3 Ckecking by 7 segment PCB1 Electrical wiring Service Manual SEG2 SEG1 S S PSW1 PSW3 6 Saan Coc atten LED2 o LED3 N 3s O DSW5 PSW2 DSW6DSW3DSW1 NO F100 aaa box oer Year he Vier To DSW2 DSW4 Rew O NOTE a Ma i The mark m indicates position of dips switches Figures show setting before shipment or after selection Not mark a indicates pin position is not affecting A CAUTION Before setting dips switches firstly turn off power source and set the position of the dips switches If the switches are set without turning off the power source the contents of the setting are invalid Dip switches setting DSW1 Test operation and service setting 1 Setting is required for test operation and operating the compressor Setting before shipment DSW1 am Na om gt E Test cooling operation mL NED ond An Test heating operation aca NOE on A Compressor forced stop amu Na ond gt O Number 3 pin shou
23. MV2 opening 7 Z7 Estimated electric current indication 31 Compressor Running m4 p ag Current A bn l Returns to Temperature indication The total current is displayed when several compressors are running In case of the inverter compressor the running current of the primary side of the inverter is displayed 118 SMGB0059 rev 0 04 2009 Troubleshooting H ITACHI Inspire the Next Service Manual E Contents of the Check mode 2 When more than three indoor units are connected to one remote control switch the latest data of only the first three indoor units that are connected serially are displayed If you press the part of the TEMP switch the next display appears If you press the part Q of the TEMP switch the previous display appears Temperature indication Indication of the category code ear Indication of the temperature etc Indoor unit air inlet 1 temp at thermistor a f l C Ae Normal Temperature displayed Indoor unit discharge m rr 2 oe at thermistor y Zt Thermistor is open circuited CC c _ Abormal p orPCB is defective Indoor unit heat 2 uni ay 3 exchanger liquid a J Z 2 J 4 Temp for top of comp pipe temp freeze a protection
24. Replace the fan motor Excessively high discharge pressure Excessively high air temp to the indoor unit heat exchanger Check whether or not the short circuited air exists Remove the cause of the short circuited air Excessively charged refrigerant Check expansion valve opening Correctly charge the refrigerant Non condensate gas in ref cycle Check each temp and pressure Recharge the refrigerant after the vacuum pumping Clogging of the discharge pr piping Check for clogging Remove the clogging process Check the temp difference at the inlet and Malfunction or internal leakage of the 4 way valve Replace the 4 way valve the outlet of the 4 way valve Check the temp difference Malfunction of the check valve of the outdoor unit at the inlet and the outlet Replace the check valve of the check valve Failure of the bypass Check for leakage of the Replace the solenoid valve solenoid valve solenoid valve Excessively high suction pressure Malfunction or internal Check tNetemp diference at the inlet and the outlet Replace the 4 way valve leakage of 4 way valve of the 4 way valve Check the expansion Replace the failed expansion Discharge temp of the indoor unit is unstable valve of the indoor unit in P pan valve of the indoor unit the same system 1 Refer to chapter 7 of TC 70 SMGB0059 rev 0 04 2009 Troubleshooting Service Ma
25. SMGB0059 rev 0 04 2009 55 Test run HITACHI Inspire the Next OO ef 0 00O0 0 00 00 ooo Service Manual 6 4 Judgement system for refrigerant amount You can check the excess or the deficiency of the refrigerant by means of the data that is provided by the check mode of the 7 segment display The following checking procedure is useful during the test run and the maintenance Before the checking procedure 1 Operate all the indoor units at the TEST RUN mode and operate all the indoor units at the HIGH speed 15 20 30 Indoor air temp C 2 Check the following items in order to make sure that the refrigerant cycle is stable Outdoor air temp C 1 The continuous operation lasts more than 20 minutes 2 Td SH is 25 to 45 C in cooling or 15 to 45 C in heating 3 Ps is 0 4 to 1 1 MPa in cooling or 0 2 to 1 1 MPa in heating 4 Pd is 2 0 to 3 5 MPa in cooling or 1 6 to 3 5 MPa in heating Td SH Discharge gas temperature superheat Ps Suction pressure Pd Discharge pressure 3 Collect the checking data that is provided by the check mode of the 7 segment display 4 Perform the checking according to the following procedure Judge according to the following target value Cooling Refrigerant flow charge is controlled by indoor unit expansion valve Heating Refrigerant flow charge is controlled by outdoor unit expansion valve Applicable air temperatures for the checking p
26. Service Manual HITACHI Inspire the Next No Part Name Remarks No Part Name Remarks 1 Cabinet Panel Shroud 42 Reversing Valve Saginomiya STF 0712G 2 Bell Mouse 43 Coil RVR Saginomiya STF 3 Air Grille Air Outlet 01AJ502D1 4 Handle 44 Check Valve Nichiden Kougyou ZGY S55B A 5 Cabinet Panel Service Cover 45 Pressure Switch a Saginomiya ACB eee Ever SSIVICE Rover 46 Solenoid Valve SVA Nichiden Kougyou SR10D i Gabinet Pangi Upper Cover 47 Coil for SVA Nichiden Kougyou 8 Protection Net SR10PA 9 Cabinet Panel Rear Cover 48 Strainer 10 Piping Cover Rear Piping Cover 49 PGC Joint 11 H Cover 50 Pressure Sensor Saginomiya NSK BD050F 102 12 Screw SUS M5 for Discharge Side 13 51 Check Joint 14 Motor Clamp 52 Oil Separator 15 Fan Motor DC Fan Motor MOF1 DC170W ee Stop Valve for Liquid Line 8P 54 Stop Valve for Liquid Line 16 Fan Motor AC Fan Motor MOF2 AC101W 55 Stop Valve for Gas Line oF 56 Valve Stay 17 Fan Motor as Fan Motor MOF2 AC115W 57 Saaw M5 18 Fan Motor AC Fan Motor MOF2 AC183W 33 Solenoid valve SVF Assy 6P Assy 19 Screw SUS M6 58 1 Solenoid Valve SVF Nichden Kougyou SR10D 58 2 Coil for SVF Nichiden Kougyou 20 Screw SUS M8 SR10PA 21 Propeller Fan 54
27. switch to disable the Check mode 2 seconds AIC Check mode 1 cannot be disabled even if you press the OK VENTI CHECK 7 switch Check mode disabled SMGBO0059 rev 0 04 2009 445 HITACHI Inspire the Next Although the wireless controller is used for the wall type indoor unit with the built in receiver part you can check the alarm code by connecting the PC ART Suction grille Connector for check E Contents of the Check mode 1 Troubleshooting Service Manual NOTES 1 The unit does not operate by pressing the operation switch 2 The above function is available only when the alarm occurs 3 The PCB check by means of the remote control switch is not available 4 The indication is the data when you are connecting PC ART The indication is not the data before the alarm occurs The next indication is shown if you press the part A of the TEMP switch If you press the part 7 of the TEMP switch the previous indication is shown Temperature indication Indoor unit temp setting C Indication of the category code Indication of the temperature etc pa yt pas 8 evaporating temp during heating C _ I yg 116 SMGB0059 rev 0 04 2009
28. 2 The wire sizes marked with in the table of this page are selected at the maximum current of the unit according to the European Standard EN60 335 1 Use the wires which are not lighter than the ordinary tough rubber sheathed flexible cord code designation HO5RN F or ordinary polychloroprene sheathed flexible cord code designation HO5RN F 3 The wire sizes marked with in the table of this page are selected at the maximum current of the unit according to the wire MLFC Flame Retardant Polyflex Wire manufactured by Hitachi Cable Ltd Japan 4 Use a shielded cable for the transmitting circuit and connect it to ground In the case that power cables are connected in series add each unit maximum current and select wires below 6 The earth cable size complied with local code IEC 245 N 577 e SMGB0059 rev 0 04 2009 27 HITACHI Inspire the Next Electrical wiring Service Manual A CAUTION Selection according to Selection according to MLFC EN60 335 1 at cable temp of 60 C Current i A Wire Size mm Current i A Wire Size mm 1 lt 6 0 75 1 lt 15 0 5 6 lt i lt 10 1 15 lt i lt 18 0 75 10 lt i lt 16 1 5 18 lt i lt 24 1 25 16 lt i lt 25 2 5 24 lt i lt 34 2 25 lt i lt 32 4 34 lt i lt 47 3 5 32 lt i lt 40 6 47 lt i lt 62 5 5 40 lt i lt 63 10 62 lt i lt 78 8 63 lt i 78 lt i lt 112 14 112 lt i lt 147 22 In the case that current exce
29. 2 of PCB1 of the outdoor unit heat exchanger s electric expansion valve No Yes K 1 Refer to Characteristics of Thermistor of Alarm Code 23 2 PCB1 Connector No is shown in the below CN10 CN11 RAS 26 42FSN2 MV1 MV2 MV3 MV4 MVB RAS 8 12FSN2 CN10 CN12 RAS 14 24FSN2 CN10 CN11 CN12 CN12 RAS 44 48FSN2 CN10 CN11 CN12 SMGB0059 rev 0 04 2009 84 Is the refrigerant correctly charged ie Is the gas leaking Ve Repair the leaks of gas Correctly charge the refrigerant connected properly No o gt No Remove the sudden changes of load like short path of an outgoing air to the air intake of the outdoor unit or the cause of frequent thermo ON OFF Plug the connectors 2 of PCB1 properly Charge the correct refrigerant volume Refer to TC ag Check the exp valve Troubleshooting Service Manual E Position of the Thermistor HITACHI Inspire the Next Thermistor ref Display Drive Number of Unit HP Thermistor position a compressors THM8 red Inverter 1 8 12HP THM9 Da7 2 14 16HP a p iio aka Constant 3 las THM13 Pf speed 4 30 36HP THM18 Pes 5 38 48HP Phenomenon Cause Check item ALO Turn OFF the main switch Ref cycle is different from th
30. H ITACH l functions Inspire the Next Service Manual E Input 3 Demand current control Control function No 6 to 9 In the case that the demand input terminals on the outdoor unit PCB1 are short circuited the compressor frequency is controlled that the maximum limit of the outdoor running current is set 100 80 70 and 60 The maximum limit of the outdoor unit running current can be selected according to the item Setting of external input and output functions If the outdoor unit running current decreases beyond the maximum limit the indoor unit is put under thermo OFF condition The stoppage code No 10 is given When the input terminal is opened during the demand current control its control is reset Setting Example Demand Current Control at Input 3 between 1 and 2 pins of CN2 Outdoor unit PCB1 i i 3P Connector SS3 Forced stoppage switch CN2 1 i SS3 Power fo 2 EP lol l2 source oj 3 x1 x1 Control circuit Wiring diagram example of demand current control Table 5 1 Specifications of required main parts Parts Specifications Remarks Mini Power Relay MY1F or 2F made Auxiliary Relay X1 X2 220V 240V by OMRON Changeover Switch SS2 SS3 Manual Switch 220V 240V PCC 1A Five Cords with 3 Pin Connector Cord Connected to JST Connector XARP 3 Connectors as One Set Cord Low Volt 0 3mm lower than 24V Inside of Unit 220 240V 0 5 to 0 75mm
31. LED2 the PCB1 and PCB2 Normal 5 g oe pai J g a alf Green Condition Flickering Abnormal E TRER E z Condition Activated or 5 Q g a RUE F l H Deactivated A POB jil 228 z BDS This LED3 indicates the z Ar FO ag a ku Pa ae Fi a fji uay I gt z transmission state between the J 20 el A Be ae k 4g LEDS indoor unit and outdoor unit F W rs od Yellow Normal Condition Flickering j ag Se BE Abnormal Condition Activated or i amp paues gt oo Deactivated a cols o 4 No Part Contents of functions No Part Contents of functions Name Name Test running for cooling or heating The outdoor 6 DSW6 Setting of height difference unit can be run for testing When testing has been 7 Psw1 Manual defrosting switch The defrosting operation is 1 DSW1 finished reset the function manually available under the forced defrosting area Forced stoppage of compressor When performing m A x e Checking switch push PSW2 for 3 seconds or more test running or inspection compressors can be 8 Psw2 to start finish the check mode Push PSW check forcedly stopped to ensure safety O SUT erie elec ome Me gt EES 3 DSW2 Seti ooienaind mode function is indicated to forward Send Or ORTONA ae Checking switch push PSW3 check mode function is 3 DSW3 Setting of capacity code 9 PSW3 indicated to backward 4 DSW4 and Setting of outdoor unit number 43 SEG1 These indicate the following alarm protective safety R
32. PCB2 Inverter PCB Turn off power disconnect U V W from compressor terminals and restart Does the protecting function activate 3 No Check the compressor If there is a short circuit between phase lines replace the compressor Normal Check the transistor Check the PCB2 Replace da module 1 2 module Good Abnormal Replace PCB2 and the transistor module Is the silicon grease coated all over between No the transistor module and the radiated fin Coat the silicon grease to all Is the fixed screw on the transistor module loose the touched face between the transistor module and the radiated fin fully Fix the Yes screw correctly 4 Is the heat exchanger Yes of outdoor unit clogged Remove clogging Replace the PCB2 1 Regarding replacing or checking method for the inverter components refer to item Procedure of checking other main parts 2 Before the checking of inverter components refer to item Procedure of checking other main parts regarding electrical discharge 3 Turn ON the No 1 switch of the dip switch DSW1 on PCB2 when restarting with disconnecting the terminals of the compressor After troubleshooting turn OFF the No 1 switch of the dip switch DSW1 on PCB2 4 Use the silicon grease provided as accessory Service Parts No P22760 Position of Surge Absorber SA 380 415V
33. Replace the pressure switch Faulty high pressure switch switch continuity after the if faulty decrease of the pressure Insufficient Measure the resistance by Fix the looseness Replace contacting means of the tester the connector Incorrect connection Check the connections Repair the connections 76 SMGB0059 rev 0 04 2009 Troubleshooting Service Manual HITACHI Inspire the Next Action Phenomenon Cause Check item Turn OFF the main switch Check for clogging Remove the clogging Activation of the high pressure switch due to the excessively high discharge pressure Faulty or malfunction of the expansion valve Check the connect wiring and the connectors Replace the connector Check the operation sound from the coil Replace the coil Check the discharge gas thermistor Replace the thermistor Check the attaching state of the discharge gas thermistor Reattach the thermistor Faulty gas bypass solenoid valve Check for clogging Replace the gas bypass solenoid valve Overcharged refrigerant Mixture of the non condensate gas in the refrigerant cycle Check the cycle operation temp Check the air temp and the pressure Charge the refrigerant correctly Recharge the refrigerant after the vacuum pumping Clogging of the discharge piping Check for clogging Remove the clogging Liquid line stop valve or gas line stop valve is
34. Retry operation is performed up to five times Conditions of Activation Inverter current with 150 of the rated current Turn off power and disconnect U V W from PCB1 PCB2 Control PCB in Outdoor Unit Inverter PCB Replace PCB2 Check the compressor Check the power source capacity Replace the transistor module Check the compressor Replace the diode module Replace PCB2 Check the power supply Restart operation compressor terminals No Faulty Does it trip soon Yes Turn ON 1 of DSW1 on Check PCB2 It trips PCB2 and restart 1 immediately Does it trip It trips No It trips after Good occasionally a certain ER period s there any Cause No of instantaneous gt voltage decrease Yes gt Good Check the transistor Faulty Replace PCB2 module IPM 1 gt y Is the compressor running Yes current as same as rated gt current 3 y No Check the diode Faulty module 2 gt Good y Are the input currents of Yes three phases nearly equal gt 3 No gt Is the supply voltage No O 380 415V 50Hz 10 gt Yes Is it 323V or more during No operation gt l Yes Is it 323V or more during No operation when other devices are operating Yes gt Check the capacity and wiring of the power source
35. Spare parts 8 1 RAS 8 12FSNM E Structural and cycle parts 8 2 RAS 8 12FSNM E Electrical parts Servicing Outdoor Unit FSNM E 9 1 1 Removing service cover 9 1 2 Removing air outlet grille 9 1 3 Removing upper cover 9 1 4 Removing the lower part of service cover and rear cover 9 1 5 Removing outdoor fan motor 9 1 6 Removing Electrical Box 9 1 7 Removing compressor 9 1 8 Removing high pressure switch 9 1 9 Removing high pressure sensor and low pressure sensor 9 1 10 Opening electrical box Power plate 9 1 11 Removing reversing valve coil and solenoid valve coil SVA SVF 9 1 12 Removing electronic expansion valve coil 9 1 13 Removing reversing valve 9 1 14 Removing electronic expansion valve 9 1 15 Removing solenoid valve 9 1 16 Remove the control PCB PCB1 9 1 17 Removing Relay PCB PCB3 PCB5 9 1 18 Removing inverter components 9 1 19 Removing other inverter components Main parts Inverter 10 1 1 Specifications of inverter Inverter 10 1 1 Specifications of inverter 10 1 2 Inverter time chart 10 1 3 Protective Function 10 1 4 Overload Control Thermistor 10 2 1 Position of thermistor 10 2 2 Resistance value of the thermistor Electronic expansion valve 10 3 1 Electronic expansion valve for the outdoor unit Pressure sensor Scroll compressor 10 5 1 Reliable mechanism for low vibrating and low sound 10 5 2 Principle of compression Field work instruction
36. TD3 j Ta S rr a 17 142 ce for 18 to 48HP Discharge gas temp on the top r L m 16 of compressor MC4 TD4 j Pm pa m 1 142 oe for 30 to 48HP 122 SMGB0059 rev 0 04 2009 Troubleshooting Service Manual HITACHI Inspire the Next No Item Indication Data Values Units Discharge gas temp on the top m m hi 17 of compressor MC5 TD5 j Pm T ji 1 142 oe for 38 to 48HP 18 Evaporating temperature TE1 Da pag bam a ae arcus oC at heating bn I L 127 Short circuited 7 Evaporating temperature TE2 m 46 80 C at heatin gt 127 Open circuited for 14 to ey L L L 127 Short circuited 7 Evaporating temperature TE3 m 46 80 T at heatin 127 Open circuited for 26 to fae I in bm 127 Short circuited F Evaporating temperature TE4 m L 46 80 ne at heatin 127 Open circuited for 44 to es L l L 127 Short circuited r rm 46 80 22 Ambient temperature Ta j f q 127 Open circuited C aa 127 Short circuited ag al 23 Auto Charge temperature j rm i pt C127 Open circuited C 127 Short circuited PEI EES 24 Supercooling temperature 127 Open circuited C 4 l la l l 127 Short circuited Estimated running current of pa a v Z 29 compressor MC1 vt I Z i 000 7255 A Estimated running current o
37. Wireless remote control switch Remote con trol MCU A Thermistor for inlet air Thermistor of discharge air Thermistor for gas pipe Thermistor for liquid pipe Transmission circuit Wireless transmission circuit Suction gas pressure sensor PS Discharge gas pressure sensor Pd Thermistor for ambient temperature THM7 Therm for heating evap temp THM18 HITACHI Inspire the Next Multiple signals lt Single signals Operation signals Discharge gas thermistor THM8 A D conversion circuit Protection circuit Remote control switch Remote con trol MCU A D conversion circuit ol Transmission circuit d 380 415V Power source Fin thermistor THM i y nn n ne Inverter power e c section S S Inverter one a 3 Outdoor unit MCU control E3 Es MCU A 45 5 OH E b a Electrical control expansion valve drive circuit Thyristor Electrical control control circuit Relay drive circuit expansion valve drive circuit D O To the transmission Relay drive circuit Inverter control for fan MCU y La CO 2
38. indicated when same phenomenon is occurred at two times within the next 30 minutes PCB1 Control PCB in Outdoor Unit PCB Indoor Unit PCB Yes Is there a leakage of SVA gt Replace SVA if faulty No Is the four way valve spindle Yes mounted at the middle position p Replace the four way valve if faulty No Is the low pressure sensor OK Replace the low pressure sensor if faulty Check whether the inlet air gt temperature of the indoor unit and the outdoor unit is too high Phenomenon Cause Check item AchHon Turn OFF Main Switch Leakage of solenoid valve SVA Check the outlet pipe temp of SVA Check the connect wires Replace SVA if faulty Valve stoppage at the medium position of the 4 way valve Measure the suction gas temp of 4 way valve Replace the 4 way valve if faulty Excessively low suction pressure Abnormal suction pressure sensor Check the connectors of PCB1 and the power source Replace the sensor if faulty Excessively high indoor unit and outdoor unit suction air temperature 104 SMGB0059 rev 0 04 2009 Check the indoor unit and the outdoor unit suction air temp thermistor Replace the thermistor if faulty Troubleshooting Service Manual HITACHI Inspire the Next Alarm code Description Li tot Activation for protecting the system from excessive
39. 0 0 1 9 1 0 2 0 Pressure MPa Pressure MPa Output characteristics of high pressure sensor Output characteristics of low pressure sensor SMGB0059 rev 0 04 2009 169 HITACHI Inspire the Next Main parts Service Manual 10 5 Scroll compressor eliabl I for 1 The rotating direction is definite 2 The pressure inside of the chamber is high pressure and the surface temperature of the chamber is 60 C to 110 C The gas is inhaled from the inlet port at the outer frame of the fixed scroll The gas inside of the compression space is compressed toward the center of the scroll The compression space is minimum at the center of the scroll and the gas compressed at the maximum is discharged from the outlet port of at the center of the scroll The above procedures Suction Compression Discharge is repeated continuously Gas Rotating scroll 170 Vv Compression space Fixed scroll Suction procedure Discharge process A SMGB0059 rev 0 04 2009 Compression process Field work instruction HITACHI Inspire the Next Service Manual 11 Field work instruction Contents 11 Field work instruction 169 11 1 Checking the power source and the wiring connection 170 11 2 Burnt out compressor due to an insufficient refrigerant charge 170 11 3 Insufficient cooling perfo
40. 46 compressor MC4 pi h il f If Z h J 0 9999 honra for 26 to 48HP Total accumulated hours of E 7 x10 times 47 compressor MC5 a Li f Z Z J 0 9999 hours for 44 to 48HP Total accumulated hours of td a Da E x10 times ag compressor MC1 a l t i Cio ere hours Total accumulated hours of m x10 times 49 compressor MC2 Z ie f La f Z Z i rf 0 9999 hours for 14 to 48HP Total accumulated hours of f f w x10 times 50 compressor MC3 Z Li ut x 4 0 9999 hours for 18 to 48HP Total accumulated hours of m x10 times 51 compressor MC4 Li uw 0 WEE hours for 26 to 48HP Total accumulated hours of m m x10 times 52 compressor MC5 AN a E E T o 9999 hours for 44 to 48HP 53 The latest alarm code cause of pa w ra lo 99 stoppage at outdoor unit yt hm pnt Cause code of stoppage at a _ 54 inverter pn eee 55 Cause code of stoppage at fan pag m Ws v 0 16 motor controller 1 9 pet pt 56 Cause code of stoppage at fan pag w i a lo 46 motor controller 2 J Po hu im l SMGBO0059 rev 0 04 2009 125 Troubleshooting HITACHI Inspire the Next Service Manual No Item Indication Data Values Units Hystory No 1 v ya Integrated hours at alarm in The latest failure yey ot ptt l indicated _ Hystory No 2 r yc ie H L HH Cause of stoppage Failure Z history a fp Wc ITC indication Indication is au
41. C Thermistor is short circuited za l EE or PCB is defective 4 Outdoor temperature Es oa C ct 2 or Indoor unit heat re 7 or 5 exchanger gas pipe a Temp for top of comp a 04 temp C Oz Refer to section Self Checking Procedure 6 Evaporating temp EVE v of PCB by means of the Remote Control i at heating C et bt ot Switch 1 Notes 1 During the transient periods such as starting time and other the indicator may be displayed for a limited time 2 All the data during the check mode 2 will be changed to 00 if a power failure occurs during alarm indication 7 Control information ry i Discharge gas temp T j i Loe This indicates the internal information for the remote control switch 8 atthe top of comp om 12 a chamber C fam _ This does not have any specific meaning The average temperature of running compressors is indicated SMGBO0059 rev 0 04 2009 449 HITACHI Inspire the Next Compressor pressure frequency indication 9 Discharge pressure 10 11 y high x 0 1 MPa mi 10 Suction pressure low 10 11 mons x 0 01 MPa we tt 11 Control information om h f Lf 12 Operating frequency 7 wee Hz th to Expansion opening indication 13 Indoor unit expansion
42. Connect them correctly indoor unit and outdoor unit incorrectly connected Note In the case of H LINK connection check the refrigerant cycle setting on the PCB1 of the No outdoor unit and the indoor unit PCB Check whether the inlet air gt temperature of the indoor unit and the outdoor unit is too high Action Phenomenon Cause Check item ete Turn OFF Main Switch Excessively high discharge pressure Leakage of SVA outdoor unit Check the connection Replace Check the outlet temp of SVA SVA if faulty Closed stop valve Check the stop valve Open the stop valve Abnormal high pressure sensor Replace the pressure sensor if Check the connectors for PCB faulty Excessively high air inlet temp of the indoor unit and the outdoor unit Incorrect connection between indoor unit and outdoor unit Check the thermistor for inlet air temp of the indoor unit and the outdoor unit Replace the thermistor if faulty Check electrical system and ref Correctly connect cycle Locked Ex valve with fully closed opening Repair connector for PCB or ex Check the connector for PCB valve Replace it if faulty Stoppage of the indoor fan wall type 1 0 to 3 0 only Blown out fuses Check the continuity of fuses Replace the fuses Faulty PCB Replace PCB and check the operation Replace PCB if faulty SMGBO0059 rev 0 04 2009 105 l HITACHI Inspire the Next
43. Cooling Operation Mode During this fixed heating or cooling mode no cooling or heating operation is available The indoor units under the cooling or dry operation or heating operation will be changed to the Thermo OFF condition during this mode and stoppage code No 20 is given Setting Example Fixing Heating Operation at Input 1 between 1 and 2 pins of CN4 Fixing Cooling Operation at Input 2 between 3 and 2 pins of CN1 Outdoor unit SS3 Operation mode fixing switch 3P Connector SS2 Changeover switch 1 D Power source 3 Heat X2 X1 Cool X2 Heat Control circuit Wiring diagram example of fixing operation mode E Input 3 Demand stoppage Control function No 3 In the case that the demand input terminals on the outdoor unit PCB1 are short circuited compressor s is stopped In this case the indoor unit s is put under Thermo OFF condition Cooling operation Air flow setting Heating operation Lo setting The stoppage code No 10 is given By disconnecting the demand switch contact restarting is available Setting Example Demand Stoppage at Input 3 between 1 and 2 pins of CN2 Outdoor unit se Connector PCB1 SS3 Demand stoppage switch 1 SS3 2 Power source x1 X1 Control circuit Wiring diagram example of demand stoppage 36 SMGB0059 rev 0 04 2009 Available optional functions HITACHI Inspire the Next Service Manu
44. Cord Low Volt 0 5 to 0 75mm lower than 24V Outside of Unit 220 240V 2mm NOTES 1 Make the wire to the terminals as short as possible 2 Do not run the wires along high voltage cable crossing is applicable If necessary to run wires along high voltage cable insert the low voltage cable s into metal tube and ground it at one end If sealed wires are used at the low voltage wire side ground it at one end of shield wires The maximum length should be 70m 38 SMGB0059 rev 0 04 2009 Available optional functions HITACHI Inspire the Next Service Manual The following signals can be picked up from the outdoor PCB Refer to the table 5 2 for the required main parts E Output 1 Operating signal Control function No 1 Auxiliary relay contacting RYa is closed during the operation Operating signal will be sent when the indoor units are operating Even when one 1 indoor unit is operating the signal will be sent This function can be used for circulator or humidifier operation Setting Example Operation Signal at Output 1 between 1 and 2 pins of CN7 Auxiliary relay 3P Connector housing D N Outdoor unit PCB1 CN7 Connector Wiring diagram example of operation signal E Output 2 Alarm signal Control function No 2 D Auxiliary relay contacting RYa is closed when the alarm occurs Alarm signal will be sent when the alarm occurs from the indo
45. Flange Connecting No leakage shall exist torque of squeezing flare Overheating of compressor Work Insufficient torque of squeezing flanges Insufficient cooling or heating Air Tight Test compressor failure Holding of Vacuum Suspend the refrigerant piping at certain points and prevent the refrigerant piping from touching weak parts of the building such as walls ceiling etc If touched abnormal noises may occur due to the vibration of the piping Pay pism special attention in case of short piping length j t EI z Fire proof i section Pa treatment In order to fix the piping to wall or ceilings use suspension Indoor unit and clamping systems as shown in the following figure SMGB0059 rev 0 04 2009 15 HITACHI Inspire the Next Piping installation Service Manual 1 Flaring connections smaller than a diameter of 19 05 are generally used However if incorrect flaring is performed it will cause serious refrigerant leakage 2 Shape after Flaring it should be rectangular and flat and no uneven thickness cracks and scratches should exist Nominal diameter Od Dimension 90 2 inches mm A 0 0 0 4 mm x 9 1 f 13 2 16 6 19 7 It is impossible to perform the flaring work In this case use a joint selected from the table in point 3 When tightening the flare nuts use two spanners as shown in the fig
46. Following the Council Directive 89 336 EEC and its amendments 92 31 EEC and 93 68 EEC relating to electromagnetic compatibility next table indicates maximum permissible system impedance Zmax at the interface point of the user s supply in accordance with EN61000 3 11 MODEL Zmax 0 RAS 8FSN2 RAS 10FSN2 RAS 12FSN2 3 Make sure that the power supply voltage is within 10 of the rated voltage 4 Check the capacity of the electrical wires If the power source capacity is too low you cannot start the system due to the voltage drop 5 Make sure that the ground wire is connected 6 Main Switch Install a multi pole main switch with a distance of 3 5 mm or more between each phase 20 SMGB0059 rev 0 04 2009 Electrical wiriing Service Manual HITACHI Inspire the Next 3 2 Electrical wiring for the outdoor unit E FSNM E The electrical wiring connection for the outdoor unit is shown beside 1 Connect the power supply wires to L1 L2 L3 and N for 400V 50HZz for the three phase power source on the terminal board Connect the ground wires to the terminals in the electrical box 2 Connect the control cables between the outdoor unit and the indoor unit to the terminals 1 and 2 on the terminal board 3 Do not run the wires in front of the fixing screw of the service access panel If you do so you cannot remove the fixing screw L1 L2 L3 N 1 2
47. Function No Input 1 CN17 1 2 Fixed Heating Operation Mode 1 Input 2 CN1 1 2 Fixed Cooling Operation Mode 2 Input 3 CN1 2 3 Demand Stoppage 3 CN2 1 2 Snow Sensor Outdoor fan ON OFF 4 Forced Stoppage 5 Demand Current Control 6 to 9 Output 1 CN16 1 2 Operation Signal 1 Output 2 CN7 1 2 Alarm Signal 2 Compressor ON Signal 3 CNT 1 3 p ignal 3 Defrosting Signal 4 SMGB0059 rev 0 04 2009 34 Setting before Shipmen Available optional functions HITACHI Inspire the Next Service Manual In the case that the setting change only with the mark of the table in the previous page is required at site perform the following procedures 1 Set DSW2 6 of the outdoor PCB at the ON side while the main power to the outdoor unit is being supplied By setting function selection mode is available and the following appears on the 7 segment display The setting should be performed during the outdoor unit stoppage Also set DSW1 4 of outdoor unit PCB at the ON side before performing in order to prevent the malfunction of compressor l Lo Input Output Terminal Indication N Control Function No This display indicates that the control function No 1 Fixed Heating Operation Mode is set at input 1 2 By pressing the push switches PSW2 and PSW3 input output terminal indication is changed The following shows the display changes when PSW2 and PSW3 are pushed
48. If the 4 Way Valve does not switch check for insufficient refrigerant Indoor fan does not operate when the compressor operates Discharge pressure does not increase higher than 1 5 MPa due to the insufficient refrigerant Check the operation pressure 1 Add the refrigerant Disconnected Wiring for the Indoor Fan Check the wiring Connect the wiring correctly Failure of AC chopper Check AC chopper Replace AC chopper 4 Refer to chapter 10 of TC SMGB0059 rev 0 04 2009 71 HITACHI Inspire the Next 7 2 Troubleshooting procedure Troubleshooting Service Manual If the RUN LED flickers for 2 seconds there is a failure in the transmission between the Indoor Unit and the Remote Control Switch Possible causes are Broken remote cable Contact failure in the remote control cable Defective IC or defective microcomputer In any case ask your retailer for service If the RUN LED flickers 5 times 5 seconds with the unit number and the alarm code displayed make a note of the alarm code refer to the table below and ask your retailer for service Abnormal Indoor Abnormal Refrigerant H Alarm code table Unit No Cycle No Pr rt gee COOL MED rm Alarm Code AIC ABNE Indicated for Model Code a second alternatively Model Code coot men E Off I ADDS 5 hal Indicat
49. Make a drain hole at the lowest part of the conduit Before installation work check the availability of the following parts that are packed inside the outdoor unit Accessory Quantity Purpose Pipe with flare nut for 1 refrigerant piping mt l H SMGB0059 rev 0 04 2009 5 HITACHI Inspire the Next E Installation place Units installation Service Manual Install the outdoor unit where good ventilation is available and where it is dry Install the outdoor unit where the sound or the discharge air from the outdoor unit does not affect neighbors or surrounding vegetation The operating sound at the rear or right left sides is higher than the value in the catalog at the front side Check to ensure that the foundation is flat level and sufficiently strong Do not install the outdoor unit where there is a high level of oil mist salty air or harmful gases such as sulphur Do not install the outdoor unit where the electromagnetic wave is directly radiated to the electrical box Install the outdoor unit as far as practical being at least 3 meters from the electromagnetic wave radiator When installing the outdoor unit in snow covered areas mount the field supplied hoods at the discharge side of the outdoor unit and the inlet side of the heat exchanger Install the outdoor unit where it is in the shade or it will not be exposed to direct sunshine or
50. and 3rd fan at inverter speed YMEC3 4 Relay for 2nd and 4th fan at constant speed SMGB0059 rev 0 04 2009 121 H ITACH i Troubleshooting Inspire the Next Service Manual O Note Shadowed items are applicable only to FSN2 series No item Indication Data Values Units Total of Thermo ON indoor unit E pa x pa ra E 02 capacity yc j pt 9 9999 x1 8 HP Running frequency of inverter l v l T ee compressor MC1 yt q 07115 n Number of running y Nag Z _ 0a compressors pn Ln 0 5 05 Air flow rate Fl D jo t6 a Outdoor expansion valve MV1 a Z Ld a _ 06 opening yc c i it O 100 Outdoor expansion valve MV2 r L 07 opening rer fe ee eed e i z 0 100 for 14 to 48HP Outdoor expansion valve MV3 m Li 08 opening mo ioc Si z 0 100 for 26 to 48HP Outdoor expansion valve MV4 Li L 09 opening fm Z i yz 0 100 for 44 to 48HP Outdoor expansion valve MVB s pag 2 pa re 10 opening j Z J pa 0 100 11 Discharge pressure high Fl ft A PF o 55 5 52 MPa 12 Suction pressure low PoP ett Bey Pf jo22 221 MPa Discharge gas temp on the top y7 a pa y 5 13 of compressor MC1 TD1 pt mt oz 17 142 C Discharge gas temp on the top m m r 14 of compressor MC2 TD2 j oo oc ja oy 17 142 XC for 14 to 48HP Discharge gas temp on the top m m 15 of compressor MC3
51. field wiring to protect electrically noise obstacle Total length of shielded wire shall be less then 1000m and size of shielded wire shall comply with local codes 3 Check to ensure that the terminal for power source wiring terminals L1 to L1 and N to N of each terminal board AC 380 415V terminals R to L1 and S to L2 of each terminal board AC 220V If not some component will be damaged SMGB0059 rev 0 04 2009 51 HITACHI Inspire the Next 6 2 Test run procedure from the outdoor unit side Test run Service Manual The test run procedure from the outdoor unit side is shown below You can set this DIP switch while the power source is ON Setting of Dip Switch before shipment DSW1 O 1 Test run A Warning COOL HEAT setting 2 ON Heating operation OFF Cooling operation 3 OFF mixed Do not touch any other electrical components while you are setting the switches on the PCB Do not attach or detach the service access panel when ON Els 1234 ON Set DSW1 4 at OFF immediately and the indoor unit is under the Thermo OFF condition When DSW1 4 is OFF the compressor starts to operate after the cancellation of the 3 minute guard the power source for the outdoor unit is ON and the 1234 outdoor unit is operating 4 Manual compressor OFF S
52. filter Deodorant filter Duct connection flange Duct connection flange Fresh air intake kit Fresh air intake kit 3 way outlet parts T duct connecting kit Branch pipe Header 60199790 60199791 60199793 60199794 60199795 60199796 60199797 60199799 60199801 70522001 70522002 70522004 70522005 70522007 Code 60199798 70522008 SMGB0059 rev 0 04 2009 Figure a a ig ae SPECT TT xi HITACHI Inspire the Next 0 HITACHI Inspire the Next Name HR 500 HR 800 HR 1000 HR 1500 HR 2000 STL 30 200 L600 STL 30 250 L600 STL 30 300 L600 STL 30 355 L600 STL 30 450 L600 xii Description Energy exchanger for KPI heat recovery Sound attenuator Heat energy recovery SMGB00589 rev 0 04 2009 Code 70550101 70550102 70550103 70550104 70550105 70550200 70550201 70550202 70550203 70550204 Figure Model codes and decriptions Service Manual Units installation HITACHI Inspire the Next Service Manual 1 Units installation This chapter provides information about the procedures you must follow to install the Set Free FSNM E outdoor units Contents 1 Units installation 1 1 General installation notes 1 2 Transportation and handling 1 2 1 Hanging method 1 2 2 Center of gravity 1 3 Outdoor units installation 1 3 1 Before installation 1 3 2 Installa
53. flickers and ALARM is displayed on the remote control switch E The unit number the alarm code and the unit code are alternately displayed on the set temperature section The unit number and the alarm code are displayed on the display of the outdoor unit PCB1 This alarm code is indicated when AC 220V or 240V is not detected in A or B during inverter compressor Faulty PCB1 Check wiring connection or other PCB1 This alarm is also by PSH disconnecting p or faulty Check alarm code 02 also Is AC220V or AC240V applied No between terminals 1 and 3 of PCN9 on PCB1 connector during the stoppage Yes PCB1 is normal A Ql 7 o SEG2 SEG1 poney ae N E l E p a a ae TTL TT 7p saa eee kuue es n r duueuu skedel Phenomenon Cause Action Check item Turn OFF Main Switch Starting outdoor unit at activation of pickig up Activation of picking up circuit circuit for protection Alarm Code Hist 02 and 09 before 38 Refer to Alarm Code 02 and 09 for protection Incorrect connection Faulty PCB1 Check the voltage that is supplied to the connectors Repair the wiring connections Replace PCB1 102 SMGB0059 rev 0 04 2009 Troubleshooting Service Manual HITACHI Inspire the Next Alarm code Description E pa tot Activation for
54. float switch E For the outdoor unit 1 Compressor Sound and vibration Check for abnormal sounds and vibrations Activation Check that the voltage drop of the power supply line is within 15 at the start and within 2 during the operation 2 Reverse valve Activation Check for any abnormal activation sound 3 Strainer Clog Check that there is no temperature difference between both ends 4 Ground wire Ground line Check for the continuity to earth 5 Oil heater Activation You should activate the oil heater at least twelve hours before the start up by turning ON the main switch SMGB0059 rev 0 04 2009 177 HITACHI Inspire the Next 11 10 Service and maintenance record Field work instruction Service Manual No Check item Action Judgement 1 Is the service area sufficient Yes No 2 lIs there a short circuit of the discharged air Yes No 3 Any heat influence Yes No 4 Is the ground wire connected Yes No 5 Refrigerant piping Good Not good 6 Fixing the units Good Not good 7 ls there any damage on the outer surface or the Yes No internal surface 8 Checking the screw and the bolts Tighten if loosened Tightened Not tightened 9 Tightening the Terminal Screws Tighten all the terminal screws with a Phillips Tightened Not tightened screwdriver
55. frequency when the output current decreases lower than 88 of the rated one However if the frequency order is smaller than the maximum value the operation is performed according to the order c Cancellation of Protection Function After the operation described in the above item b is performed for 10 seconds this control is canceled 164 SMGB0059 rev 0 04 2009 enn HITACHI Inspire the Next Service Manual 10 2 Thermistor 10 2 1 Position of thermistor Thermistor f hermistor holder Thermistor fixing plate IIS gt Thermistor for dicharge gas temp Heat exchanger liquid pipe Thermistor for evaporating temp gt e value of the therr E Thermistor for upper part temperature of compressor 200 for prevention of discharge gas overheating 200 a There is a thermistor that checks the temperature of the upper part of the compressor in order to prevent the discharge gas from overheating If the discharge gas temperature increases excessively the deterioration of the lubrication oil and its lubrication properties will occur This will cause a shorter compressor life R25 200kQ B 3920k 100 b If the discharge gas temperature increases excessively the compressor temperature increases In the worst case the winding of the compressor motor will burn out 0 Resistance value of thermistor KQ 14 2 8 32 1 O 25 30 100 12
56. if the remote control switch is faulty Failure of PCB in the indoor unit and the remote control switch Disconnected wire to PCB Check the connectors Correctly connect the wires Failure of PCB Check PCB by means of the self check mode 2 Replace PCB if it failed 1 Refer to section Se f checking of remote control switch 2 Refer to section Self checking of PCB using remote control switch SMGB0059 rev 0 04 2009 63 HITACHI Inspire the Next In the case that no abnormality Alarm Code is indicated on the remote control switch and normal operation is not available take necessary action according to the procedures mentioned below Troubleshooting Service Manual Phenomenon Cause Check item Action Turn OFF the main switch RUN LED is ON and the LCD is indicated However the system does not operate For example the indoor fan the outdoor fan or the compressor does not operate Failure of the indoor unit fan motor Disconnected coil Burnt out coil Measure the coil resistance by means of the tester Measure the insulation resistance Replace the Indoor unit fan motor Failure of the outdoor unit fan motor Disconnected coil Measure the coil resistance by means of the tester Burnt out coil Measure the insulation resistance Replace the outdoor unit fan motor Failure of the magnetic switch for the outdoor unit
57. is directly radiated to the electrical box remote control cable or remote control switch Install the indoor units and components as far as practical or at least 3 meters from the electromagnetic wave radiator Prepare a steel box and install the remote control switch in it Prepare a steel conduit tube and wire the remote control cable in it Then connect the ground wire with the box and tube Install a noise filter when the power supply emits harmful noises This unit is exclusive non electrical heater type indoor unit It is prohibited to install a electrical heater in the field Mount suspension bolts using M10 W3 8 as size as shown below Wooden Bar Insert 100 to 60mm to 150 kg 90mm square Je yer y Concrete Anchor bolt Steel bean W3 8 or M10 Steel Anchor bolt W3 8 or M10 Wooden Beam Concrete Beam Steel Beam Wooden Beam Do not put any foreign material into the indoor unit and check to ensure that none exist in the indoor unit before the installation and test running Otherwise a fire or failure may occur E Note Hitachi indoor units are designed for free air discharge Static Pressure Pst 0 except ducted indoor units as RPIM which require to be connected to discharge air ducts For these units see flow static pressure chart SMGB0059 rev 0 04 2009 3 HITACHI Inspire the Next 1 2 Transportation and handling Units installation Service Manual Transport t
58. is not completed until the next day or even over a longer period of time braze off the ends of the piping and charge the pipe with oxygen free nitrogen through a Schrader valve type access fitting to prevent moisture and particle contamination entering Do not use insulation material that contents NH3 NH3 can damage the cooper pipe material and can be a Correct Incorrect amrai BIT SMGB0059 rev 0 04 2009 13 HITACHI Piping installation Inspire the Next Service Manual e Insulation Attach the pipe insulation to each branch using vinyl tape Attach also insulation to field supplied pipes in order to prevent the capacity decrease according to the ambient air conditions and dewing on the low pressure pipe surface Note When polyethylene foam is applied it is recommended the usage of a wall thickness of 10 mm for the liquid piping and 15 mm to 20 mm for the gas piping A caution Perform the insulation work after the pipe surface temperature decreases to the room temperature if not the insulation material may melt Ifthe ends of the piping system are open after ending the piping work attach caps or vinyl bags securely to the ends of the piping avoiding moisture and dust entering 14 SMGB0059 rev 0 04 2009 Piping installation HITACHI Inspire the Next Service Manual pri ples p j In case of using refrigerant R410A in the refrigera
59. not in operation Check the stop valves Fully Open the stop valves Clogging of the check valve Check for clogging Replace the check valve SMGB0059 rev 0 04 2009 77 Troubleshooting HITACHI Inspire the Next Service Manual Alarm code Description i H Abnormal transmission between the indoor units and the outdoor unit E The RUN LED flickers and ALARM is displayed on the remote control switch E The unit number the alarm code and the unit code are alternately displayed on the set temperature section The unit number and the alarm code are displayed on the display of the outdoor unit PCB1 This alarm is displayed when an abnormal operation is maintained for three minutes after the normal transmission between the indoor units and the outdoor unit Also an abnormal operation is maintained for 30 seconds after the micro computer is automatically reset The alarm is displayed when the abnormal transmission is maintained for 30 seconds from the starting of the outdoor unit Investigate the cause of the overcurrent and take the necessary action when the fuses are blown out or the breaker for the outdoor unit is activated PCB1 Outdoor unit printed circuit board PCB Indoor unit printed circuit board Is DSW5 1P terminal No resistance on PCB1 al Set it correctly ON Is the voltage
60. on the control PCB PCB1 of the electrical box 4 Hold the electronic expansion valve coil slightly rotate and then pull it up Refer to the figure below and replace the electronic expansion valve coil The lock mechanism is equipped with the electronic expansion valve coil Check to ensure that the electronic expansion valve coil is locked Electronic expansion valve coil ma c WW wm nS s d 1 150 SMGB0059 rev 0 04 2009 N OO fF WD aa HITACHI Inspire the Next Service Manual Remove the service cover and rear service cover according to the item Removing service cover and the item Removing lower part of service cover and rear cover Collect the refrigerant from the check joint according to the item Removing compressor Remove the reversing valve coil according to the item Removing reversing valve coil and solenoid valve coil Remove the electrical box according to the item Removing electrical box Remove two 2 fixing screw for valve stay Remove the stop valves from the valve stay by removing four 4 screws Remove the reversing valve assemblies from the designated positions 4 brazing parts Remove the brazing of the reversing valve and the stop valve at gas side by cooling with wet cloth Protect the connecting wires and pipe insulation from brazing work Remove the reversing valves from the assemblies 4 portions with mark in the figure below Perform the brazing to re
61. picking up phase signal The RUN LED flickers and ALARM is displayed on the remote control switch E The unit number the alarm code and the unit code are alternately displayed on the set temperature section The unit number and the alarm code are displayed on the display of the outdoor unit PCB1 This alarm is displayed when the main power source phase is reversely connected or one phase is not connected PCB1 Outdoor unit printed circuit board Single phase Yes Is there any phase which is not Correctly connect each phase of connected the power source PCB1 is normal y Yes PCB1 is normal Correctly connect each phase of the power source Reverse phase connection Yes Is there any excessive voltage Abnormal operation with the decrease at the power source power source PCB1 is normal No Faulty PCB1 or other cause gt see below Voltage for unit to be suspended Running voltage 342 456 V gt _ Setting voltage Less than 323 V Action Phenomenon Cause Check item Turn OFF the main switch Check it according to the f Replacing Urea ORSU Reverse or single phase is tightening screws or correct electrical wiring Activation of reverse phase wiring sensor in the outdoor unit Faulty outdoor unit PCB1 Replace PCB1 if faulty 82 SMGB0059 rev 0 04 2009 Troubles
62. pressure fall protection FSN2 Discharge gas superheat decrease or protection 7 4 way valve switching control 8 Low pressure rise protection In relation to retry control the latest retrial will be indicated unless a protection control related to frequency control is indicated Code Protection control Code Protection control J a mar ot High pressure increase retry a si D a X Pressure ratio control Vacuum discharge gas temperature increase retry w al 4 a mr High pressure rise protection X x x gt ZI mag Mg Inverter current protection Discharge gas SUPERHEAT decrease retry i gt oa 1 lt ng I Inverter fin temp rise protection Inverter trip retry 7 X Discharge gas temperature increase protection Low pressure decrease protection 4 m gt Daad mr Insuffcient voltage excessive voltage retry LE Er E bee x ad ae m7 D ar r Hifh pressure decrease retry X gt D i r High pressure decrease protection 1 iea Daad ma The retry indication continues for 30 minutes unless a protection control is displayed The retry indication disappears if the stop signal comes In the case that degeneration control is activated is from all the rooms NOTE The protection control code that is displayed on the 7 se
63. retry Pd 0 1 Ps 0 06 lt 1 8 the alarm code 43 is displayed i Low pressure increase Ps gt 1 5MPa When it activates three times in 30 minutes rote a retry the alarm code 44 is displayed x High pressure increase Pd gt 3 8MPa i pa When it activates three times in 30 minutes retry the alarm code 45 is displayed m m Overcurrent retry Current 2 Maximum value 1 or Current lt 1 0A When it activates three times in 30 minutes of constant speed the alarm code 39 is displayed compressor 130 SMGB0059 rev 0 04 2009 Troubleshooting Service Manual HITACHI Inspire the Next Code Protection control Activating condition Remarks 4 a i A Vacuum discharge gas temperature increase retry In Case of Ps lt 0 09MPa for over 12 minutes or discharge gas temperature 2 132 C for over ten minutes or discharge gas temperature 2 140 C for over five seconds When it activates three times in one hour the alarm codes 47 Ps or 08 Discharge gas are displayed 4 a gt ao Discharge gas SUPERHEAT decrease retry Discharge gas SUPERHEAT less than ten 10 degrees is maintained for 30 minutes When it activates three times in two hours the alarm code 07 is displayed 4 lt a I Inverter trip retry Automatic stoppage of transistor module activation of electronic thermal or abnorma
64. sensor by use of two spanners Wire twisting should be within 3 winds oH Tightening position shadowed Spanner size 14 mm Use two spanners Tightening position shadowed Spanner size 17 mm Fi This part should be sealed with tapes DO NOT apply spanners to this part Tightening torque 30 Nm 9 1 10 Opening electrical box erp gt 1 Remove the service cover according to the item Removing service cover 2 Remove five 5 screws fixing the electrical box Open the power plate by rotating 90 degrees to the left Check to ensure the LED201 Red of the inverter PCB PCB2 is OFF when opening the power plate NOTE Do NOT touch the electrical components when the LED201 Red is ON to avoid electrical shock Top view of electrical box Upper cover Power plate bS IN GR 2 screws lt a Se Power plate Power plate opening direction 4 SMGB0059 rev 0 04 2009 148 aaa HITACHI Inspire the Next Service Manual 9 1 11 Removing reversing valve coil and solenoid valve coil SVA SVF 1 Remove the service cover according to the item Removing service cover 2 Open the power plate according to the item Opening electrical box Power plate Check to ensure the LED201 Red of the inverter PCB PCB2 is OFF G NOTE Do NOT touch the electrical components when the LED201 Red is ON to avoid electrical shock 3 Remove the connectors
65. serial No Piping lenght m Additional refrigerant charge kg 1 General No Check item Result 1 Was the DIP switch DSW6 for the piping length in the outdoor unit set 2 Are the power supply wires of the transmission cable making contacts on the piping 3 Was a ground wire connected 4 Is there any short circuit 5 Is there any voltage malfunction among the different phases L1 L2 L2 L3 L3 L1 L1 N 2 Refrigerant cycle a Cooling heating process No Check item Result 1 Operate all the indoor units TEST RUN mode 2 Operate all the indoor units at the HIGH speed b Sampling data cooling heating process if the indoor temperature is between 21 C and 30 C No Check item Result 1 After operating for more than 20 minutes 2 Check Pd and Td Is TdSH 15 to 45 degrees 3 Is Ps 0 2 to 1 1 4 Is Pd 1 0 to 3 5 If the outdoor temperature is high the Pd becomes high SMGB0059 rev 0 04 2009 53 HITACHI Inspire the Next 3 Check item after sampling data a Cooling process if the outdoor temperature is higher than 15 C Test run Service Manual No Check item Standard Causes Result 1 Is H1 compressor frequency Running horsepower of the Low excessive refrigerant abnormally low or high indoor units X 8Hz High insufficient refrigerant I
66. should be 16 or less SMGB0059 rev 0 04 2009 114 Troubleshooting H ITACHI Inspire the Next Service Manual Use the OK switch of the remote control in the following cases ea wes pois HEE Sy 1 When the RUN LED is flickering HEAT Lowe ADDS PRN HR Baal Jar 3 DRY AC ee SERVICE ABNLI 1 1 R 2 To trace back the cause of the malfunction after restarting from the stoppage AUTO VENTIHSTRG HIE TRUNICHEK while the RUN LED is flickering So TEMP 3 To check during the normal operation or during the stoppage O AN 4 To monitor the inlet air temperature and the discharge air temperature e eee EE 4t VENTI LOUVER DAY SCHEDULE gt Check mode 1 Current data will be displayed OO i Ves Check mode Check mode 2 The data which was held gt immediately before the failure will be displayed G Notes The indication will delay as the transmission between the remote control switch and the indoor unit takes about ten seconds Normal mode All the data may be displayed as FF or Mor 255 These transient data which are produced temporarily by the software do not affect the device Pres OK for functions at all The alarm code may also be displayed as FF more nan Ifitis not indicated check mode 1 it has possibilities that the transmission between remote control switch and indoor unit is not connected
67. supply wiring and the terminals for the intermediate wires between the indoor unit and the outdoor unit coincide correctly The terminals for the power supply wiring are L1 to L1 L2 to L2 L3 to L3 and N to N of each terminal board For the operating line the terminals for the intermediate wires are 1 and 2 to 1 and 2 of each terminal board for DC 5V Otherwise you may damage some components When you are installing the electrical wiring follow the local codes and the local regulations Connect the operation wiring to the units in the same refrigerant cycle You should connect the refrigerant piping and the control wiring to the same indoor units If you connect the refrigerant piping and the control wiring to the units in the different refrigerant cycle an abnormal operation may occur You must connect the shielded part to earth only in one cable side Do not use more than three cores for the operation wiring H LINK II Select the core sizes according to the national regulations If there are multiple outdoor units that are connected to one power supply wire open a hole near the connection hole for the power supply wiring The recommended breaker sizes are shown in the table of electrical data and recommended wiring Ifa conduit tube for the field wiring is not used fix the rubber bushes on the panel with adhesive All the field wiring and the equ
68. the lower part of service cover and rear cover 2 Collect the refrigerant from the check joint according to the item Removing compressor 3 Remove the solenoid valve coil according to the item Removing reversing valve coil and solenoid valve coil 4 Remove the brazing and flare nuts as shown in the figure below Solenoid Valve SVA 2 brazing parts Solenoid Valve SVF 2 flare nuts Perform the brazing to remove and reassemble the solenoid valve by cooling with wet cloth Protect the connecting wires and pipe insulation from brazing flame Remove the flare nuts with two spanners to avoid twisting Reassemble the parts in the reverse order of removing order SVA S Brazing r SVF Fy Flare connection Flare connection SMGBO0059 rev 0 04 2009 153 HITACHI oe Inspire the Next Service Manual 1 Remove the service cover according to the item Removing service cover 2 Disconnect all the wires connected with the control PCB PCB1 3 Clamp the hook of the four 4 holders by long nose pliers and remove by sliding toward front side G NOTES 1 Use the long nose pliers when disconnecting faston terminal R1 N1 R2 T2 S2 2 In case of replacing the control PCB PCB1 set all the dip switches and jumper cables as the same position before replacing If not malfunction pay occur 9 1 17 Removing Relay PCB PCB3 PCB5 1 Rem
69. the evaporating temperature during the heating process The resistance values of the thermistor are shown in the figure above SMGB0059 rev 0 04 2009 167 10 HITACHI Inspire the Next 10 3 Electronic expansion valve Main parts Service Manual Micro computer Pulse signal 2 Phase permanent magnetic pulse motor Control 0 to 500 pulse by 1 pulse Refrigerant flow control Precise control Needle Pulse motor Items Specifications Applicable to the models For the main cycle of RAS 8 10FSNM E Type UKV Series Refrigerant Working temperature range R410A 30 C 65 C Operation time of the coil less than 50 Mounting direction Drive shaft in vertical direction within an angle of 45 as maximum Flow direction Reversible Drive method 4 Phase canned motor method Rated voltage DC12V 1 8V Drive condition 80 5PPS Pulse width at ON 36mm sec OFF 60mm sec 1 2 Phase excitation Coil resistance each phase 469 3Q at 20 C Wiring diagram Drive circuit and activation mode Wiring diagram Drive circuit Activation SMGB0059 rev 0 04 2009 168 Main parts HITACHI Inspire the Next Service Manual 10 4 Pressure sensor High pressure control Low pressure control A high pressure sensor detects the hig
70. units are connected to the same refrigerant cycle If not it will cause an abnormal operation and a serious accident B Check to ensure that the electrical resistance is more than 1 megohm by measuring the resistance between ground and the terminal of the electrical parts If not do not operate the system until the electrical leakage is found and repaired C Check to ensure that the stop valves of the outdoor unit are fully opened and then start the system D Check to ensure that the switch on the main power source has been ON for more than 12 hours to warm the compressor oil by the oil heater E Check that the refrigerant piping and the electrical wiring conform to the same system and check that the dip switch setting of the refrigerant cycle No DSW1 amp RSW1 O U DSW5 amp RSW2 I U and the unit number RSW for the indoor units apply to the system Confirm that the dip switch setting on the printed circuit board of the indoor units and the outdoor units are correct Especially pay attention to the setting of lift between indoor units and outdoor unit the refrigerant No and the end terminal resistance Refer to the chapter 6 Electrical Wiring F Check to ensure that the electrical resistance is more than 1 megohm by measuring the resistance between ground and the terminal of the electrical parts If not do not operate the system until the electrical leakage is found and repaired Do not impress the volt
71. with electrical parts If contacted electrical parts will be damaged Checking procedure PSW switches A To start checking press PSW2 switch for more than three seconds Mania v hees A To proceed checking forward press the PSW2 switch for less than two O O O seconds PSW1 PSW2 PSW3 To go back to the previous item backward press the PSW3 switch for less than two seconds 7 segments display To cancel this checking press the PSW2 switch for more than 3 seconds The dfisplay will change to the indication one step before Then press the PSW2 SEG2 SEG1 switch once again for more than three seconds A B AJB A caution Make sure that the checking mode is cancelled after the checking Otherwise you may cause a malfunction No lItem Indication Data Values Units 01 Output state of micro computer k see figure below see table below Y20CHG YCH1 Y52C1 PCB Relay Part name O ee Q se Qe see ee 8 Relay for solenoid valve S x S Q Y20A1 A5 SVA1 5 a y2005 S By24 gt purc gt C Y20B ise S S Ry 3 S var Relay for solenoid valve gt S 2 SVB C G CHG F 1 rN VAN VAN YammN y20cHe DC FAN2 DC FAN1 Y20A1 Y52C4 Y20F1 Y52C1 5 Relay for compressor Y211 y212 Relay for 4 way valve YCH1 Relay for crankcase heater DC FAN1 2 Relay for 1st
72. 0 1 Inverter Main parts Service Manual Aplicable model RAS 8 12FSNM E Aplicable power source 3 Phase 380V 415V 50 Hz Output voltage 380 415V Output current 25A Control Method Vector Control Range Output Frequency 10 100HZ Accuracy of Frequency 0 01 Controlled Frequency 0 01 Hz at Applicable frequency range Output Characteristics Conditions 1 Power Source Voltage AC380 415V 2 Non Loading Free Output 3 Ammeter Type Volt Meter X1 1 V 400 F 380 300 200 100 Refer to the note in next page Soft start stop Protection function Excessive high or low voltage for Inverter 0 125HZz S 0 25HZS 0 5Hz S 1Hz S 3Hz S 5 steps Excessive Low Voltage at a voltage is lower than 350V DC Excessive High Voltage at a voltage is higher than 750V DC Abnormality of current sensor Stoppage at a current of compressor smaller than 1 5A Cause of Abnormality Failure of Current Sensor Failure of Transistor module Failure of Compressor Disconnected Wiring 160 SMGB0059 rev 0 04 2009 Main parts Service Manual HITACHI Inspire the Next Protection Function Overcurrent Protection for Inverter Protection of Transistor Module Detecting current is more than 150 of the rated current Rated Current x 150 Rated Currentx 105 p ee See Se eS Se ee Time Internal pr
73. 0 150 Temperature C Resistance characteristics of thermistor for discharge gas overheating protection c When the temperature of the upper part of the compressor increases during the heating process the unit is controlled according to the following method An electronic expansion valve of the liquid bypass opens and the high pressure refrigerant returns to the compressor through the accumulator This decreases the compressor temperature If the temperature of the upper part of the compressor SMGBO0059 rev 0 04 2009 165 HITACHI ee Inspire the Next Service Manual exceeds 132 C for 10 minutes the compressor will stop Even if an electronic expansion valve opens in that situation the compressor will also stop This way the compressor is protected Resistance values of the thermistor are shown in the figure d If the temperature of the upper part of the compressor exceeds 132 C for 10 minutes during the cooling process the compressor will stop according to the following method Operation Upper part temperature Defecting period of compressor Cooling Over 132 C 10 minutes continuously Over 140 C 5 seconds continuously Heating Over 132 C 10 minutes continuously Over 140 C 5 seconds continuously Defrosting Over 132 C 5 seonds continuously E Thermistor for the outdoor temperature THM7 When the outdoor ambient temperature decreases to 8 C or a lower temperature durin
74. 1 V or increases higher than 4 9V during the operation Is the connection CN4 of the outdoor unit PCB1 bad i Is 12 VDC applied across 1 and 3 of the connector CN4 of the outdoor unit PCB1 Yes Connect it correctly Faulty PCB1 Is the voltage under 0 1 VDC or over 4 9 VDC across 2 and 3 of the connector CN4 of the outdoor unit PCB1 No Faulty PCB1 Yes Repl the check joint Clogged check joint K a No Abnormal operation of high pressure sensor Action Phenomenon Cause Check item Turn OFF Main Switch Fault Check that the output voltage is Replace the pressure sensor if correct faulty Faulty high pressure sensor Repair the wiring and the Check the connections connections Incorrect connection Replace PCB1 and check the Faulty PCB1 operation Replace PCB1 if faulty Indicated pressure value is excessively high or low Malfunction of the pressure sensor due to a faulty check joint Check the check joint for Replace the check joint clogging SMGB0059 rev 0 04 2009 95 Troubleshooting HITACHI Inspire the Next Service Manual Alarm code Description 71 7 Abnormal operation of the thermistor for the outdoor temperature Vm Vom outdoor unit ambient thermistor E The RUN LED flickers and ALARM is displayed on the remote control switch E The unit number
75. 1 on the outdoor unit PCB1 and the setting of DSW5 and RSW2 on the indoor unit PCB totally same in a refrigerant cycle Yes Set them correctly 13 Total capacity of the indoor units is wrong Outdoor Unit PCB1 DSW4 RSW1 Indoor Unit PCB DSW5 RSW2 Phenomenon Cause Check item Action Turn OFF Main Switch Incorrect capacity setting of Indoor Unit Check combination of indoor units and capacity setting on PCB Correctly set dip switch DSW3 Incorrect capacity setting of Outdoor Unit Check capacity setting on outdoor unit PCB1 Correctly set dip switch DSW2 Total Indoor Unit capacity connected to the Outdoor Unit is beyond the permissible range Check outdoor unit model by calculating total indoor units capacity Ensure that total indoor unit capacity is from 50 to 130 100 Refrigerant cycle setting of the outdoor unit and the indoor unit is different SMGB0059 rev 0 04 2009 Check the refrigerant cycle setting on outdoor unit PCB1 and indoor unit PCB Set them correctly Refrigerant Cycle No Setting Setting Switch 10 digit 1 digit H u U u u u u Setting Position OFF inserti 123456 e sienes serewdsver gt g AN into the groove Outdoor Unit DSW4 RSW1 Indoor Unit H LINK 1 DSW5 RSW2 Ex In Case of Setting Refrigerant Cycle No 25 ON co t es Sunam ZTE 123456 ITA
76. 10 Are the compressor terminals tightly fixed Push all the terminals Pushed Not pushed 11 Insulation resistance Measure the insulation resistance with Good Not good an insulation resistance meter Comp and fan motor greater than 3MQ Others greater than 3MQ 12 Does the drain water flow smoothly Check the smooth flow by pouring some water Good Not good 13 Check for a leakage in the compressor Check for any leakage Good Not good 14 Check for a leakage in the outdoor heat ditto Good Not good exchanger 15 Check for a leakage in the indoor heat ditto Good Not good exchanger 16 Check for a leakage in the 4 way valve ditto Good Not good 17 Check for a leakage in the check valve ditto Good Not good 18 Check for a leakage in the accumulator ditto Good Not good 19 Check for a leakage in the strainer ditto Good Not good 20 Check for a leakage in the electronic expansion ditto Good Not good valve 21 Check for a leakage in the piping ditto Good Not good 22 Check the direction of the fans By viewing the airflow volume Good Not good 23 Voltage among each phase Higher than AC220V Good Not good 24 Vibration and sound Check the fan the compressor the piping and Good Not good others 25 Activation of each operation mode Check the activation of the COOL switch the Good Not good HEAT switch the STOP switch and the TEMP switch 26 High pressure cut out switch Check the actual activation value Good Not good 27
77. 14 16FSN2 6 16 RAS 44 48FSN2 16 75 Room R kg V m C kg m Countermeasure A 30 150 0 2 B 65 500 0 13 System A Outdoor unit System B Outdoor unit 100 oa z System A Zon System B JHP D 35 100 0 35 Refrigerant 35 kg Refrigerant 30 kg C D 35 200 0 175 E 35 50 0 7 2m min L L l L L 176 SMGB0059 rev 0 04 2009 E Floor 120m D Floor 0m Cc Floor 40m B A Floor 200m Floor 60m Heigth 2 5 m Ventilator 2m min Gas leak detector Opening 0 06m Field work instruction HITACHI Inspire the Next Service Manual 11 9 Maintenance work E For the indoor unit and the outdoor unit 1 Fan and fan motor Lubrication All the fan motors are prelubricated and sealed at the factory Therefore no lubrication maintenance is required Sound and vibration Check for abnormal sounds and vibrations Rotation Check the clockwise rotation and the rotating speed Insulation Check the electrical insulation resistance 2 Heat exchanger Clog Inspect the heat exchanger at regular intervals and remove any accumulated dirt and any accumulated dust from the heat exchanger You should also remove from the outdoor units other obstacles such as the growing grass and the pieces of paper which might restrict the airflow 3 Piping connection Leakage Check for the refrig
78. 2 38 30 20 18 Calculate value of IE Hold Hold Hold Hold Hold Total of iE a 138 32 38 30 20 18 Total frequency b 90 Judgement OK 0 7 lt a b lt 1 6 Heating process Indoor units Outdoor unit 2HP 2HP 2HP 2HP 2HP 10HP Ti indoor suction temperature 26 27 23 23 25 To outdoor temperature C 7 Total of oE a 42 Total of frequency b 100 Judgement OK a b 20 of target value SMGB0059 rev 0 04 2009 57 Troubleshooting Service Manual Contents 7 Troubleshooting 7 1 Initial troubleshooting 7 1 1 7 1 2 7 1 3 7 1 4 7 2 Troubleshooting procedure 7 2 1 7 2 2 7 2 3 7 2 4 7 2 5 7 2 6 7 2 7 T Troubleshooting HITACHI Inspire the Next 59 60 Emergency operation 61 Failure of the power supply to the indoor unit and the remote control switch Abnormal transmission between the remote control switch and the indoor unit Abnormal operation of the devices 62 63 64 72 Alarm code indication of remote control switch 72 Troubleshooting by alarm code 74 Troubleshooting in check mode 115 Troubleshooting by means of the 7 segment display 121 Running current of the compressor 127 Protection control code on the 7 segment display 129 Activating condition of the protection control code 130 SMGB0059 rev 0 04 2009 59 H ITACH i Troubleshooting Inspire the Next S
79. 201 white and AC fan motor connector from the PCB3 PCN404 white at the electrical box Cut off the plastic tie for fan motor lead wire fixing at the motor clamp with a nipper Remove four 4 M8 screws with spacer fixing the motor Upper cover eae Fan motor lead Motor clamp ie k a Wire Motor clamp Fan motor _ lead wire Fixing screw ZA DC fan IEA S motor Plastic tie b Cord clamp AC fan motor x Plastic tie Fan motor SMGB0059 rev 0 04 2009 141 Servicing HITACHI Inspire the Next Service Manual NOTES Fix the motor wire with the plastic tie or the cord clamp If not it may cause the disconnection to the fan Mount the rubber bush at the partition plate when inserting the motor wire through the partition plate If not it may cause the disconnection to the fan motor lead wire When mounting the motor ensure the cables point directly downward Fix the protection tube edge downward to ensure the water may not keep in it Adjust the clearance between shroud and propeller fan so that they do not contact Fix the motor wires onto the motor clamp with a plastic tie to prevent them obstructing the propeller fans Mounting Propeller Fan Insert the skidding protection part of fan boss in accordance with the cutting part of the motor shaft and fix the screw after exserting screw part of the shaft Tightening Torque of 20 Nem Wh
80. 4 58 3 Capillary Tube 22 Closing Nut Assy 23 Washer 58 4 Strainer 24 Piping Cover Bottom Piping Cover 59 Piping Assy S Pipe Assy 25 Cabinet Panel Side Cover 59 1 Strainer 26 Compressor E656DHD 65D2 59 2 PGC Joint 27 Vibration Absorber 59 3 Pressure Sensor Saginomiya NSK BD020F 102 28 Vibration Absorber for Suction Side 29 Nut 60 Thermo Attaching Plate 30 Oil Heater 40 8W 61 Screw SUS M5 31 Soundproof Cover 62 HITACHI Label 32 Rubber Cap 63 Thermistor TA 33 Heat Exchanger Lower Side 64 Thermistor TE 34 Heat Exchanger Lower Side 65 Thermistor TD 35 Heat Exchanger Upper Side 66 Accessory Pipe 36 Heat Exchanger Upper Side i 67 Accessory Pipe 37 Partition Plate Assy 68 Accessory Pipe 38 Accumulator 39 EVO Assy Assy 39 1 Expansion Valve MV Saginimiya UKV 32D28 39 2 Coil for MV Saginimiya UKV U029E 39 3 Strainer 40 Piping Assy 41 Piping Assy SMGB0059 rev 0 04 2009 135 Spare parts HITACHI Inspire the Next Service Manual View from P View from Q 136 SMGB0059 rev 0 04 2009 Spare parts Service Manual HITACHI Inspire the Next No Part Name Remarks No Part Name Remarks 1 Attaching P Plate 20 Power Plate Assy Assy 21 Power Plate 2 Attaching P Plate 22 Radiation Fin Assy
81. C 52C 52C 52C MFC3 MFC4 Fa l DC 20a 20a 20a 20a 20a 208 20c PC 20a 20a 20a 20a 20a 208 20c Outdoor micro computer input output sc Fan 1 2 3 4 5 Fan 1 2 3 s 20F 20G 20CGH 21 21 CH 20F 20G 20cGH 21 21 CH Total of running indoor unit capacity oP Inverter frequency at the compressor No 1 H1 Number of running compressors cc Airflow rate of the outdoor fan Fo oE1 oE2 Expansion valve opening 1 6 of the outdoor unit oE3 oE4 oEb Discharge presure MPa Pd Suction pressure MPa Ps Td1 Td2 Discharge gas temperature Td3 Td4 Td5 TE1 Heat exchanger liquid pipe temperature ues TE3 TE4 Outdoor temperature To Auto charge temperature Tch Supercooling temperature Tsc A1 A2 Compressor running current A3 A4 A5 Indoor Unit Unit number Expansion valve opening iE Heat exchanger liquid temp TL Heat exchanger gas temp TG Intake air temp Ti Outlet air temp To Capacity x 1 8HP CA Indoor Unit stoppage caude code d1 Restricted control for prevention of compresion ratio c11 decrease Res ricted control for prevention of high pressure c13 increase Restricted control for prevention of the temperature increase of the inverter fan eM Restricted control for prevention of discharge gas c15 temperature increase Restricted control for prevention of TdSH decrease c16 Restricted control for prevention of overcurent c17 SMGB0059 rev 0 04 2009 179 Field wor
82. CH difference between the pale era Excessively low suction Unit strainer inlet and the outlet of ind A pressure strainer indoor unl f os Check the temp Clogging of suction piping difference of each part Remove the clogging Is the outdoor unit heat Remove the cloggin exchanger clogged gging Are there any obstacles na at the inlet or the outlet of Remove the obstacles Insufficient air flow outdoor unit through the outdoor unit heat exchanger Is the service area for the Secure a sufficient service outdoor unit sufficient area Speck he Speed orne Replace the fan motor outdoor unit fan Excessively low air temp Check for any short Remove th ca se ofr the through the outdoor unit circuited air to the outdoor ae f short circuited air heat exchanger unit Defrosting is insufficiently Check the thermistor for completed the defrost operation Replace the thermistor for the defrost operation SMGB0059 rev 0 04 2009 69 HITACHI Inspire the Next Abnormal operation of the devices Cont Troubleshooting Service Manual Phenomenon Cause Check item Action Turn OFF the main switch Insufficient heating Insufficient air flow to the indoor unit heat exchanger Check the filter for a clogging Check for any obstacles at the inlet or the outlet of the indoor unit Remove the clogging Remove the obstacles Check the indoor fan speed
83. CHI oe Inspire the Next Service Manual Suction pipe Cover pipes with Wire is caught on the spring Vibration proof rubber A Vibration proof r bber B oe Oil heater Spring Hook Compressor position 1 2 3 4 Vibration proof rubber A O O O Vibration proof rubber B O Nut O O NOTES 1 The compressor is connected by brazing Check to ensure whether there are flammable things around or not when using a burner for pipe connections If not oil existing pipe inside may ignite 2 Do not expose the refrigerant cycle to the atmosphere for a long period in order to avoid mixing the water and foreign particles into the refrigerant cycle After removing compressor replace it quickly If exposed for a long period seal the suction pipe and discharge pipe 3 Remove the cap for the compressor just before replacing the compressor Before mounting the compressor seal the suction pipe and discharge pipe with a tape to protect the compressor from foreign particles Remove the tape at pipe connection 4 Match the terminal No with the mark band No when reassembling If the wiring is connected incorrectly the compressor may be damaged due to reverse rotation 5 Fix the lead wire for the compressor firmly not to contact with metal sheet edge and high temperature piping 6 If there is a clearance between the oil heater and the compressor due to wire overlapping excessi
84. Checking the power source and the wiring connection Burnt out compressor due to an insufficient refrigerant charge Insufficient cooling performance when a long piping is applied Abnormally high operation sound in the ceiling type indoor unit Alarm Code 31 Not cooling well due to insufficient installation space for the outdoor unit SMGB0059 rev 0 04 2009 HITACHI Inspire the Next 72 72 74 115 121 127 129 130 132 133 135 137 138 138 138 138 139 139 140 142 145 146 146 147 148 149 150 151 152 152 153 155 157 158 158 158 158 160 161 162 163 163 163 166 166 167 168 168 168 169 170 170 171 171 172 172 a a ON OTA FP WYN O HITACHI Inspire the Next 11 7 11 8 11 9 11 10 11 11 Guideline for selecting the drain pipe for the indoor unit Caution with the refrigerant leakage 11 8 1 Maximum permissible concentration of the HCFC Gas 11 8 2 Calculation of the refrigerant concentration 11 8 3 Countermeasure for the refrigerant leakage according to the KHK standard Maintenance work Service and maintenance record Service and maintenance record by means of the 7 segment display 11 11 1 Data Sheet for Checking by 7 Segment Display 11 11 2 Pump down method for replacing the compressor SMGB0059 rev 0 04 2009 Service Manual 173 174 174 174 174 175 176 177 177 179 Model codes and decriptions Ser
85. Current sensor is not passed operation through the power line of the compressor Perform rewiring correctly Compressor stops immediately gt Faulty PCB2 nearly 18Hz Replace it 2 How is the compressor operation when restarted Compressor does not operate P17 is displayed on the gt 7 segment display on the Outdoor Unit PCB1 Is the coil resistance of the No comp normal Replace the Compressor Yes Is output of PCB2 correct 1 x o Check PCB2 or the transistor Is output of voltage between U V module V W and W V normal Yes gt Replace PCB2 2 4 Perform the high voltage discharge work by referring to the item Procedure of checking other main parts before checking and replacing the inverter parts SMGBO0059 rev 0 04 2009 109 H ITACH i Troubleshooting Inspire the Next Service Manual Alarm code Description 2 lt Inverter error signal detection E The RUN LED flickers and ALARM is displayed on the remote control switch E The unit number the alarm code and the unit code are alternately displayed on the set temperature section The unit number and the alarm code are displayed on the display of the outdoor unit PCB IPM Transistor Module have detecting function of abnormality This alarm is indicated when the transistor module detect the abnormality 7 times in 30 minutes including 7 Retry operation is performed up to the occurrence of 6 times
86. E KPI 3002H1E EF 5NE List of accessories Name PC ART PSC A64S PSC A16RS PSC A1T viii Description Energy recovery ventilation units Econofresh kit Description Remote control switch with timer Central control Centralized ON OFF controller Programmable timer Code 70600001 70600002 70600003 70600004 70600005 70600107 7E774148 Code 70510000 60291479 60291484 60291482 Figure Figure Model codes and decriptions Service Manual SMGB00589 rev 0 04 2009 Model codes and decriptions Service Manual Name PC LH3A PC ARH PC ALH PC ALHD PC ALHZ PC ALHC PSC 5HR PCC 1A PRC 10E1 PRC 15E1 PRC 20E1 PRC 30E1 THM R2AE HC A32MB HC A16KNX Description Wireless remote control switch Optional remote controller Receiver kit for RCI FSN2E on the panel Receiver kit for RCD FSN2 on the panel Receiver kit for RCI RCD RPC RPI RPK RPF I FSN2 E on the wall Receiver kit for RCIM FSN2 on the panel H LINK relay Optional function connector 2 pin extension cord 2 pin extension cord 2 pin extension cord 2 pin extension cord Remote temperature sensor THM4 Building Management System Gateway to MODBUS systems Building Management System Gateway to KNX systems Code 60291056 60291486 60291464 60291467 60291473 Figure HITACHI Inspire the Ne
87. E Removing Transistor Module Disconnect all the wirings connected to the transistor module as shown below Disconnect the wirings of connectors C CN2 CN206 and PCN301 on the PCB2 Disconnect the wirings of P N U V W on the transistor module Remove the four 4 M3 screws for the PCB2 and then remove the PCB2 from the transistor module Remove four 4 M4 fixing screws on the transistor module Remove the transistor module from the electrical box NOTES Identify the terminal Nos with the mark band numbers when reassembling If incorrectly connected malfunction or damage will occur Check to ensure that the electrical wires will not be caught between the mounting electrical components and the mounting plates when the PCB2 is remounted Apply silicon grease evenly on the whole rear side of the diode module and the transistor module when mounting Silicon grease is available as a field supplied accessory SMGB0059 rev 0 04 2009 155 Servicing HITACHI Inspire the Next Service Manual Middle part of holder Holder PCB IPM IPM E Screw M3 Bush PCB2 and IPM Transistor module Fixing screw Sorew M5 Fixing screw for transistor for transistor module M4 module M4 LED201 Diode module PCN301 PCN302 Screw for PCB2 Screws M5 Fixing screw Fixing screw M5 M5 oe i Screws M5 N A z Screw for PCB2 Fixing screw z amp for transistor wm module
88. H 4 15 MPa R410A SMGB0059 rev 0 04 2009 Faulty CMC11 75 HITACHI Inspire the Next Troubleshooting Service Manual Phenomenon Cause Check item Action Turn OFF the main switch the excessively high discharge pressure Activation of the high pressure switch due to Insufficient air flow to the heat exchanger Outdoor heat exchanger during the cooling process or indoor heat exchanger during the heating process Check the heat exchanger for dust or for clogging Check the air filter for dust Remove the dust or the clogging Remove the dust Check for any obstacles at the inlet or the outlet of the heat exchanger Remove the obstacles Check the service area Secure service area Check the speed Outdoor Fan Cooling Indoor Fan Heating Replace the fan motor if faulty Malfunction of the expansion valve Disconnected of the Connector Fix the looseness or reconnect the connector Fully closed and locked Replace the expansion valve Excessively high temp air to the Indoor Unit Heat Exchanger Calculate the heat load Reduce the heat load or use a bigger unit Check for hot air near the ceiling Heating Provide good circulation Check for short circuited air Heating Remove the short circuited air Check for other heat source Remove the heat source Faulty pressure Measure the discharge pressure Check the
89. HI Inspire the Next Service Manual A CAUTION E Caution for Insulation Resistance If total unit insulation resistance is lower than 1 megohm the compressor insulation resistance may be low due to retained refrigerant in the compressor This may occur if the unit has not been used for long periods 1 Disconnect the cables to the compressor and measure the insulation resistance of the compressor itself If the resistance value is over 1 megohm then insulation failure has occurred of other electrical parts 2 If the insulation resistance is less than 1 megohm disconnect the compressor cable from the inverter PCB Then turn on the main power to apply current to the crankcase heater After applying current for more than 3 hours measure insulation resistance again Depending on the air conditions pipe length or refrigerant conditions it may be necessary to apply the current for a longer period of time Check the insulation resistance and reconnect the compressor If the leakage breaker is activated check the recommended size shown in Table 6 1 NOTES 1 Confirm that field supplied electrical components main switch fuse fuse free breaker earth leakage breakers wires conduit connectors and wire terminals have been properly selected according to the electrical data given in this Technical Catalog of the unit and ensure that the components comply with national and local codes 2 Use shielded wires 20 75mm_2 for
90. HITACHI Inspire the Next SET FREE SERIES A a FSNM E Service manual Outdoor Units RAS 8 12 FSNM E Service Manual HITACHI Inspire the Next Contents Model codes and descriptions Units installation Piping installation Electrical wiring Control system Available optional functions Test run Troubleshooting Spare parts Servicing Main parts Field work instruction SMGB0059 rev 0 04 2009 i a a ON OT FP O Na O HITACHI Inspire the Next 1 1 1 2 1 3 3 1 3 2 3 3 3 4 6 1 6 2 6 3 6 4 Model codes and descriptions Units installation General installation notes Transportation and handling 1 2 1 Hanging method 1 2 2 Center of gravity Outdoor units installation 1 3 1 Before installation 1 3 2 Installation location 1 3 3 Service space 1 3 4 Foundations Piping installation Piping work considerations 2 1 1 Copper pipes and sizes 2 1 2 Three principles on refrigerant piping work 2 1 3 Suspension of refrigerant piping 2 1 4 Tightening torque 2 1 5 Brazing work Electrical wiring General check Electrical wiring for the outdoor unit 3 2 1 Electrical wiring connection for outdoor unit 3 2 2 Setting the DIP switches for the outdoor unit Common wiring 3 3 1 Electrical wiring between the indoor unit and the outdoor unit Wire size Control system Device control system 4 1 1 RAS 8 10FSNM E refrigerant cycl
91. Inlet Air Thermistor 12 Sensor on Outlet Air Thermistor Ne as Incorrect Wiring Disconnecting Wiring 13 Indoor Unit Freeze Protection Thermistor 14 Gas Piping Thermistor 16 i Remote thermistor Thermistor A F P 17 Built in thermistor at remote control switch 19 Fan motor Tripping of Protection Device for Fan Motor Failure of Fan Motor 21 High Pressure Sensor 22 Outdoor Air Thermistor 23 SENSON On Discharge Gas Thermistor on Com Incorrect Wiring Disconnecting Wirin Outdoor Unit 9 P 9 9 9 24 Evaporating Thermistor 29 Low Pressure Sensor 72 SMGB0059 rev 0 04 2009 Troubleshooting Service Manual HITACHI Inspire the Next Code No Category Content of Abnormality Leading Cause 31 Incorrect Setting of Outdoor and Indoor Unit Incorrect Setting of Capacity Code 35 Incorrect Setting in Indoor Unit No Existence of the same Indoor Unit No in the same System Refrigerant Cycle F PeT Failure of Indoor Unit PCB Incorrect wiring 38 Abnormality of Protective Circuit in Outdoor Unit Connection to PCB in Indoor Unit 39 n a 43 Pressure Ratio Decrease Protection Activating Failure of Compressor Inverter Arey Overload to Indoor in Cooling High Temperature of 44 l Low Pressure Increase Protection Activating Outdoor Air In Heating Expansion Valve Open Lock Protection Overload Operation Excessive Refrigerant Cloggin 45 device High Pressure Increase P
92. K connection check the refrigerant cycle setting on the outdoor unit PCB1 and the indoor unit PCB Check whether the connections of the electric wiring and the refrigerant piping between the indoor unit and the outdoor unit are wrong Phenomenon Cause Action Check item Turn OFF Main Switch Shortage of refrigerant Closed stop valve Check the volume of charged refrigerant or check for leakage Check the stop valve Repair the leakage and correctly charge Open the stop valve Abnormal low or high pressure Excessively low suction pressure sensor in vacuum Check the connector for PCB1 Replace the pressure sensor if faulty Incorrect connection between the indoor unit and the outdoor unit Check the electrical system and Correctly connect between the the ref cycle indoor unit and the outdoor unit Locked Ex valve Check the connector for PCB Repair or replace the connector of PCB or the ex valve Closed Ex valve by disconnecting Td thermistor Check Td thermistors for compressors and measure Td thermistor resistance Repair or replace Td thermistor Faulty outdoor fan motor Measure the coil resistance and the insulation resistance Replace the outdoor fan motor if faulty Check for the conduction after the temperature of the outdoor fan motor is decreased Replace the outdoor fan motor Measure the resistance by means of the tester Re
93. M4 Screw for PCB2 M3 CN2 CN206 SMGB0059 rev 0 04 2009 156 aa HITACHI Inspire the Next Service Manual A Danger Do not touch the electrical parts when LED201 Red on the PCB2 is ON to avoid an electrical shock Remove the service cover according to the item Removing service cover 2 Open the power plate according to the item Opening electrical box Power plate Check to ensure the LED201 Red of the inverter PCB PCB2 is OFF when opening power plate Disconnect all the wires connected with the capacitor CB CB1 CB2 The wire has the polar characters Identify the wire mark band and the indication on the capacitor when wire connecting Remove two 2 screws fixing the capacitor and remove the capacitor Disconnect all the wires connecting with the magnetic contactor CMC1 Remove two 2 screws fixing the magnetic contactor and remove the magnetic contactor Remove four 4 screws fixing the reactor and remove the reactor DCL Disconnect all the wires connected with the noise filter NF 1 Remove the noise filter by clamping the top of the holder 6 portions with a pincher In case of 220V as shown in the figure NOTES Identify terminal numbers with the mark band numbers when reassembling to avoid incorrect wiring For the DSW setting after replacing PCB refer to Rotary switch and dip switch setting Long nose pliers Noise filter I Holder Enlarged view
94. N2E RPI 8 0FSN2E RPI 10 0FSN2E RPI Meaning of model codification Code 7E420000 7E420001 7E420002 7E420003 7E420004 7E420005 7E420007 7E420008 7E420009 7E420010 7E420011 FSN 2 E INDOOR UNITS Duct Wall Unit Code Unit RPK 1 0FSNH2M RPIM 0 8FSN2E 7E430000 RPK 1 5FSNH2M RPIM 1 0FSN2E 7E430001 RPK 1 0FSN2M RPIM 1 5FSN2E 7E430002 RPK 1 5FSN2M RPK 2 0FSN2M RPK 2 5FSN2M RPK 3 0FSN2M RPK 4 0FSN2M RPIM RPK 1 RPF 2 0 FS N 2 Unit Type Indoor Unit RCI M RCD RPC RPI RPK RPF I Compressor power HP 1 0 6 0 H Link Set Free System Free R410 A refrigerant Series E Made in Europe Made in Malaysia SMGB0059 rev 0 04 2009 Code 60277942 60277942 60277941 60277942 60277943 60277944 60277945 60277946 Floor Enclosure Unit Code RPF 1 0FSN2E 7E450001 RPF 1 5FSN2E 7E450002 RPF 2 0FSN2E 7E450003 RPF 2 5FSN2E 7E450004 ee RPF Model codes and decriptions Service Manual Floor Concealed Enclosure Unit RPFI 1 0FSN2E RPFI 1 5FSN2E RPFI 2 0FSN2E RPFI 2 5FSN2E Code 7E460001 7E460002 7E460003 7E460004 RPFI Model codes and decriptions H ITACHI Inspire the Next Service Manual Meaning of model codification Compressor power HP 8 10 12 R410 A refrigerant SMGB00859 rev 0 04 2009 yii HITACHI Inspire the Next Complementary systems Name KPI 502E1E KPI 802E1E KPI 1002E1E KPI 1502E1E KPI 2002E1
95. No 0 Indoor unit ba Remote control switch cable shielded twist b i 1 pair cable Lf X LLA 1N 3N 220 240V 50Hz Remote control switch cable shielded twist pair cable PZ iE Remote control A a switch PC ART Remote control switch PC ART TB Terminal board PCB Printed circuit board Field wiring Field supplied No 0 system indoor units No 1 system indoor units Optional accessory 26 SMGB0059 rev 0 04 2009 Electrical wiriing HITACHI Inspire the Next Service Manual 3 4 wire size E Electrical wiring connection Field minimum wire sizes for power source Indoor units Maximum Power Source Cable Size Transmitting Cable Size Model Power Source i i i Current A EN60 335 1 MLFC EN60 335 1 Shielded ma Pair All indoor units 5 0 0 75 mm 1 230V 50Hz 0 75 mm 0 75mm 0 5mm RPI 8 0 10 0 FSN2E 10 0 1 5 mm Outdoor units Maximum Power Source Cable Size Transmitting Cable Size Model Power Source i i i Current A EN60 335 10 MLFC ENG 335 10 gt VOCS Twist Pair RAS 8FSN2 14 0 2 5 mm 2 0 mm RAS 10FSN2 3 380 415V 50Hz 18 0 4 0 mm 3 5 mm 0 75mm 0 75mm RAS 12FSN2 23 0 4 0 mm 3 5 mm Refer the notes for selection of the power source cable size in next page NOTES 1 Follow local codes and regulations when selecting field wires
96. OB Ape ENEEKANE Replace PCB1 if faulty operation Faulty PCB Disconnected Wires tor the Check the connections Repair the wiring connection Ex valve control Fault Measure the resistance of Replace the thermistor if faulty thermistor Faulty discharge gas Incore Check the mounting state Correctly mount the thermistor mounting thermistor Remove looseness Replace Incorrect Check the connections the connector or repair the connection connections SMGB0059 rev 0 04 2009 87 HITACHI Inspire the Next Troubleshooting Service Manual Alarm code Description Abnormal operation of thermistor for the indoor unit air inlet temperature air inlet thermistor E The RUN LED flickers and ALARM is displayed on the remote control switch E The unit number the alarm code and the unit code are alternately displayed on the set temperature section The unit number and the alarm code are displayed on the display of the outdoor unit PCB1 This alarm code is displayed when the thermistor is short circuited less than 0 24 kQ or cut greater than 840 kQ during the cooling process or the heating process The system is automatically restarted when the fault is removed Is THM1 connected to intake No of PCB gt Connect it Yes PCB1 Control PCB in Outdoor Unit PCB Indoor unit PCB Is the resistance of THM1 Ne i betw
97. PCN12 PCN7 PCN6 on the control PCB PCB1 of the electrical box 4 Remove the reversing valve coil and solenoid valve coils by removing one 1 screw fixing each coil ja Upper cover gt lt Electrical box Reversing a da Rear cover valve coil i gt SVF SVA rae na AG z Fare oj PCN12 SVF Oe ae TE z raan E oF pe J da dis die dio Gia dis E PCN7 SVA in ape oll e es oF g Ea a SEREEE i le PCN6 Jg Creer Creer HW a la 5 Reversing valve ki RSW o lo eee r F w a t 8 m z a wn E an ap I el en m a f Fi TOt an p z af ras z ne CP a 88 TEES E cope O R138 Enlarged view fo PCB1 SMGB0059 rev 0 04 2009 149 Servicing HITACHI Inspire the Next Service Manual 9 1 12 Removing electronic expansion valve coil 1 Remove the service cover according to the item Removing service cover 2 Open the power plate according to the item Opening electrical box Power plate Check to ensure the LED201 Red on the inverter PCB PCB2 is OFF G NOTE Do NOT touch the electrical components when the LED201 Red on the inverter PCB PCB2 is ON to avoid electrical shock 3 Remove the CN5A connector
98. Products Europe S A Ronda Shimizu 1 Polig Ind Can Torrella 08233 Vacarisses Barcelona Espa a ISO 9001 Certified by AENOR Spain ISO 14001 Certified by AENOR Spain Hitachi Appliances Inc Shimizu shi Shizuoka ken Japan ISO 9001 Certified by JQA Japan ISO 14001 Certified by JQA Japan Hitachi Air Conditioning Products M Sdn Bnd Lot No 10 Jalan Kemajan Bangi Industrial Estate 43650 Bandar Baru Bangi Selangor Darul Ehsan Malaysia Certification ISO 9001 Malaysia Certification ISO 14001 Malaysia HITACHI Inspire the Next SMGBO0059 rev 0 04 2009 Printed in Spain
99. RUN LED flickers and ALARM is displayed on the remote control switch E The unit number the alarm code and the unit code are alternately displayed on the set temperature section The unit number and the alarm code are displayed on the display of the outdoor unit PCB1 This alarm is displayed when the abnormal operation is maintained for 30 seconds after the normal transmission between the outdoor unit PCB1 and PCB2 and also abnormality is maintained for 30 seconds after the micro computer is automatically reset The alarm is displayed when the abnormal transmission is maintained for 30 seconds from the starting of the outdoor unit Alarm code 04 is indicated when transmission between inverter and fan controller is abnormal PCB1 Control PCB in Outdoor Unit Yes Is LED2 Green on PCB1 Disconnect CN6 of PCB1 PCB2 Inverrter PCB flickering No Is LED2 Green on PCB1 Yes Check PCB2 and the flickering wiring between PCB1 and PCB2r Check the wiring between PCB1 ft No and PCB2 Faulty PCB1 i Outdoor unit PCB1 display indication m us iti i Check PCB2 Ll 4 Abnormal transmiting of inverter Phenomenon Cause Check item Acton Turn OFF the main switch B Between control PCB1 PCB2 Check the continuity of wires Disconnected wires insufficient f and fan controller Check for looseness of th
100. Room volume m C Refrigerant concentration lt 0 44 kg m for the R410A Use this value only for reference because this value is not fixed yet According to the KHK standards you should arrange the facility as follows so that the refrigerant concentration will be bellow 0 3 kg m 1 Provide a shutterless opening that will allow the fresh air to circulate into the room 2 Provide a doorless opening with a size of 0 15 or more to the floor area 3 Provide a ventilator which must be linked with a gas leak detector with a ventilating capacity of 0 5m min or more per Japanese Refrigeration Ton compressor displacement m h 8 5 of the air conditioning system which uses the refrigerant 4 Pay a special attention to the place such as a basement and others where the refrigerant may stay because the refrigerant is heavier than the air O U model Ton O U model Ton O U model Ton O U model Ton RAS 5FSN 2 27 RAS 32FSN1 14 12 RAS 16FXNE 5 81 RAS 18 20FSN2 8 21 RAS 8 12FSN1E 4 11 RAS 36FSN 13 83 RAS 20FXNE 7 58 RAS 22 24FSN2 9 32 RAS 14 16FSN1 6 57 RAS 42FSN 16 26 RAS 24FXNE 10 15 RAS 26 28FSN2 10 43 RAS 18 20FSN1 7 11 RAS 8FXNE 3 76 RAS 30FXNE 10 12 RAS 30 36FSN2 12 48 RAS 24FSN1 10 83 RAS 10FXNE 4 04 RAS 8 12FSN2 4 11 RAS38 42FSN2 15 64 RAS 28FSN1 12 97 RAS 12FXNE 4 12 RAS
101. SW1 SEG2 device has tripped or checking items 5 DSW5 Setting of transmitting 32 SMGB0059 rev 0 04 2009 Available optional functions Service Manual 5 Contents 5 Available optional functions HITACHI Inspire the Next Available optional functions 5 1 Outdoor units 5 1 1 Setting of external input and output functions 5 1 2 Description of external input signals 5 1 3 Description of external output signals 5 1 4 Optional functions SMGB0059 rev 0 04 2009 33 HITACHI Inspire the Next 5 1 Outdoor units Available optional functions Service Manual On the outdoor unit printed circuit board there are three input terminals to receive external signals and two output terminals to send signals outwards These signals are available by setting as shown below Control Function No SEG1 1 Input Fixing Heating Operation Mode Output Operation Signal Fixing Cooling Opeation Mode Alarm Signal Demand Stoppage Snow Sensor Outdoor fan ON OFF Compressor ON Signal Defrosting Signal Forced Stoppage Demand Current Control 60 Demand Current Control 70 Demand Current Control 80 O MI NID a BRI wo hry Demand Current Control 100 Each input terminal and output terminal setting as shown below Input Output Terminal Indication Connector Setting Function SEG2 Pin No Control
102. Service Manual Control subject Cooling process Heating process Defrost operation 2 Connection according to piping length 3 Discharge Pre Pd for piping length setting 3 Pd 2 1 0MPa 2 Connection according to piping length 3 Pd for piping length setting 3 Pd 2 1 0MPa Purpose Contents Purpose Contents Contents Inverter frequency of 1 Total operation 1 8Hz I U HP 1 Total operation 1 8Hz I U HP All compressors are the compressor capacity of the 2 10 Hz l U HP capacity of the 2 10 Hz l U HP operated indoor unit setting DSW6 indoor unit setting DSW6 Opening degree of expansion valve for the outdoor heat Capacity control 2 Changeover of total indoor unit Fully open unused heat exchanger fully close Discharge gas super heat TdSH control TdO Tc 30 lt 90 Fully open 2 For controlling the temperature difference between the gas pipe and the liquid pipe of the indoor heat exchanger 3 For balancing the temperature differences between the gas pipe and the liquid pipe of each indoor unit 2 Temperature difference between the gas pipe and the liquid pipe of each indoor unit 4 deg 2 For balancing the temp difference between air outlet and air inlet of I U exchanger capacity Opening degree of 1 For controlling 1 Tdo Tc 30 lt 95 1 For controlling Air outlet temp air Opening degree is expansion valve for temp of temp dif
103. Service Manual O hg 10 SEG2 SEG1 SEG2 SEG1 Control of the rr rm Not Available Not prepared Dg va Not Available indoor unit fan dur rr mt pt l I bt ing Thermo OFF in PSW2 heating mode PSW2 Psw1 PSW1 SET SET Available Available PSW3 PSW3 Long piping setting L yva Not Available Cancelation of moe rm Not Available r r el outdoor ambient i wn pt temperature limit of PW PSW2 heating Pswi f SEF PSW1 SET z Available Available PSW3 j PSW3 Cancelation of rer m7 Not Available Low noise setting A v Not Available outdoor ambient Lu im Ltt Lt temperature limit of m cooling PSW2 PaVa PSW1 7 PSW1 SET SET Available Available i PSW3 PSW3 Change of defrost va Not Available Fixing on demand 1 va Not Available condicion tenn et function im g et PSW2 PSW2 PSW1 PSW1 SET SET Available Available PSW3 PSW3 I Slo defrost setting yva Not Available Wave function setting 7 Not Avai
104. This alarm is displayed when the following conditions occur three times within one hour 1 The temperature of the thermistor on the top of the compressor is maintained higher than 132 C for 10 minutes 2 The temperature of the thermistor on the top of the compressor is maintained higher than 140 C for 5 seconds lt Is the thermistor on top of compressor normal 1 l Yes Is the thermistor installed correctly on the compressor No P PCB1 Faulty thermistor No i Yes Is it at cooling or heating mode when the alarm has occurred Heating Install it correctly Cooling Cooling process gt No AA Is the compressor discharge gas temperature over 132 C m Is the opening of all the operating indoor unit ex valve 100 Ne Remove the sudden changes of the indoor load short path etc or the short path of air between outdoor units Yes 1 Refer to Characteristics of thermistor fo Alarm code 23 2 PCB1 Connector No is shown in the below Expansion valve MV1 Connector number CN5A v Heating process gt No Is the T discharge gas temperature over 132 C ies Outdoor unit printed circuit board Refer to Characteristics of thermistor Thermistor mark Pot THM9 Is the opening of the outdoor u
105. Troubleshooting Service Manual Alarm code Description E Activation for protecting the system from excessively low suction pressure protection from the vacuum operation occurs two or more times in one hour E The RUN LED flickers and ALARM is displayed on the remote control switch E The unit number the alarm code and the unit code are alternately displayed on the set temperature section The unit number and the alarm code are displayed on the display of the outdoor unit PCB1 This alarm code is displayed when a suction pressure is lower than 0 09 MPa for over 12 minutes and the alarm Is the amount of refrigerant correct No Is the outdoor unit stop valve gt Yes gt Correctly charge the refrigerant open Yes Yes Is the refrigerant leaking ii No Is the suction pressure sensor No gt Open the stop valve Repair the leaks Replace the suction pressure normal l Yes Are the electronic ex valves sensor if faulty Check the connection of the connectors and the circuit board lt lt lt lt fully closed and locked gt Yes Check the outdoor electronic expansion valve during the cooling process and the indoor electronic expansion valve during the heating process No gt Replace the electronic ex valves if faulty Note In the case of H LIN
106. able installation as shown in the figure Recommended Metal Plate Size Field Supplied Material Hot Rolled Mild Steel Plate SPHC Plate Thickness 4 5T 10 SMGB0059 rev 0 04 2009 Units installation Service Manual Fixing plate Field supplied Both sides of the unit fixing can be possible When vibration measures are necessary add vibration proof rubber Field Supplied Air inlet Drain hole B524 66 127 73 Drain hole 2 26 Drain boss attaching position Incorrect Base width of outdoor unit gt Outdoor unit is unstable 100 mm Frame Frame width 60 mm Field supplied 1 Correct 7 Base width of outdoor unit 1 00 mm Outdoor unit is stable Metal plate le Metal plate 100 mm or more 560 Piping installation Service Manual 2 Piping installation Contents 2 Piping installation HITACHI Inspire the Next 2 1 Piping work considerations 2 1 1 Copper pipes and sizes 2 1 2 Three principles on refrigerant piping work 2 1 3 Suspension of refrigerant piping 2 1 4 Tightening torque 2 1 5 Brazing work SMGB0059 rev 0 04 2009 11 HITACHI Piping installation Inspire the Next Service Manual 2 1 Piping work considerations 1 Prepare locally supplied copper pipes 2 Select the piping size with the correct thickness and correct mater
107. ables when attaching the service cover to avoid electric shock or fire A caution Check the foundation to be flat leveled and strongly enough Install the unit in a restricted area not accessible by the general public Aluminium fins have very sharp edges Pay attention to the fins in order to avoid injury Do not install the indoor units in a flammable environment to avoid a fire or an explosion Check to ensure that the ceiling slab is strong enough If not strong enough the indoor unit may fall down on you Do not install the indoor units outdoor unit remote control switch and cable within approximately 3 meters from strong electromagnetic wave radiators such as medical equipment Do not install the indoor units in a machinery shop or kitchen where vapor from oil or mist flows to the indoor units The oil will deposit on the heat exchanger thereby reducing the indoor unit performance and may deform In the worst case the oil damages the plastic parts of the indoor unit To avoid any corrosive action to the heat exchangers do not install the indoor units in an acid or alkaline environment When lifting or moving the indoor unit use appropriate slings to avoid damage and be careful not to damage the insulation material on units surface This appliances are not intended for use by people including children with reduced physical sensory or mental capabilities or lack of experience and knowledge unless they have been gi
108. age on the terminals for transmission 1 and 2 G Check to ensure that each wire L1 L2 L3 and N R S and T is correctly connected at the power source If incorrectly connected the unit will not operate and the remote control switch will indicate the alarm code 05 In this case check and change the phase of the power source according to the attached seat on the reverse side of the service cover H Check to ensure that switch on the main power source has been ON for more than 12 hours to warm the compressor oil by the oil heater E FSN2 series outdoor units does not operate within 4 hours after power supply Stoppage Code d1 22 In case of operating within 4 hours release the protection control as follows 1 Supply power to the outdoor unit and indoor units 2 Wait for 30 seconds 3 Push PSW1 on PCB more than 3 seconds E Pay attention to the following items while the system is running A Do not touch any of the parts by hand at the discharge gas side since the compressor chamber and the pipes at the discharge side are heated higher than 90 C B DO NOT PUSH THE BUTTON OF THE MAGNETIC SWITCH ES It will cause a serious accident E Do not touch any electrical components for at least 3 minutes after turning OFF the main switch E Check that the refrigerant piping setting and electrical wiring setting are for the same system by operating the indoor unit one by 50 SMGB0059 rev 0 04 2009 Test run HITAC
109. al E Input 3 Snow sensor Control function No 4 In the case that the input terminals of the snow sensor on the outdoor unit PCB1 are short circuited during compressor stoppage all the outdoor fan motors are operated at the full speed However if the compressor is called for compressor operation the fan operation is changed to the normal operation If the input terminal is opened the fan s is stopped This function protects the outdoor units from a condition covered with snow Setting Example Snow Sensor at Input 3 between 1 and 2 pins of CN2 Outdoor unit SS3 Snow sensor switch 3P Connector PCB1 1 NZ 18 SS3 2 A Power oj 3 source X1 X1 Control circuit Wiring diagram example of snow sensor E Input 3 Forced stoppage Control function No 5 The compressor is stopped and the indoor fan motor is stopped when the forced stoppage input terminals on the outdoor unit PCB1 is short circuited during running However the remote control switch display remains at the same mode with D the stoppage code No 10 In this case if the input terminals are opened operation is resumed Setting Example Forced Stoppage at Input 3 between 1 and 2 pins of CN2 3P Connector Outdoor unit SS3 Forced stoppage switch PCB1 N2 18 1 a SS3 Power P oO i l source oj 3 X1 X1 Control circuit Wiring diagram example of forced stoppage SMGB0059 rev 0 04 2009 37 Available optional
110. ck clogging of exchanger the outdoor unit heat Remove the clogging exchanger Obstacles at inlet or the outlet of outdoor unit heat Remove the obstacles Is the service area for the outdoor unit sufficient Secure the service area Correct fan speed Replace the fan motor to the outdoor unit heat exchanger Excessively high air temp outdoor unit Short circuited air to the Remove the cause of the short circuited air the outdoor unit Any other heat load near Remove the heat source Excessively charged refrigerant Check Expansion valve opening Correctly charge the refrigerant Non condensate gas in cycle Check each temp and each pressure Charge the refrigerant after the vacuum pumping Clogging of the discharge piping Check for clogging Remove the clogging Failure or malfunction of the expansion valve Check for clogging Remove the clogging Check the connection cord and the connector Replace the connector Is there an operation sound from the coil Replace the coil Is the thermistor on the compressor normal Replace the thermistor Is the thermistor installed correctly on the compressor Correctly install the thermistor Malfunction or internal leakage of the 4 way valve Check the temp difference at the inlet and the outlet of the 4 way valve Replace the 4 way valve Excessively low suction
111. d local regulations Use security glasses and gloves for cutting or welding works 12 SMGB0059 rev 0 04 2009 Piping installation Service Manual E Piping Connection HITACHI Inspire the Next When connecting liquid piping for units with piping longer than 15 meters apply a piping size of 9 53 mm 3 8 inches Fix the connecting pipe as shown in the following figure using the insulation attached to the Indoor Unit Fix this part with Insulate this part with the the attached cord attaching flare nut to the connecting pipe in the multi kit package Use the flare nut of the indoor unit attached insulation band or with tape _ Field supplied i refrigerant piping MELA LLL Fh 4 Insulation attached to Brazing Field supplied insulation indoor unit Make flares after Ionn A system with no moisture or oil contamination will give maximum performance and lifecycle compared to a poorly prepared system Take particular care to ensure that all copper piping is clean and dry internally To ensure this blow oxygen free nitrogen through the pipes A caution source of future leakages When inserting a pipe through any hole protect the end with a cap Do not put pipes on the ground directly without a cap or vinyl tape at the end of the pipe Ifthe piping installation
112. direct radiation from high temperature heat source Do not install the outdoor unit where dust or other contamination could block the outdoor heat exchanger Install the outdoor unit in a space with limited access to general public Do not install the outdoor unit in a space where a seasonal wind directly blows to the outdoor heat exchanger or a wind from a building space directly blows to the outdoor fan Incase of installation in the open spaces unavoidably where there is no buildings or surrounding structures adopt the wind guard set or install near the wall to avoid facing the wind directly Ensure that the service space should be secured Using wind guard Wind guard set optional Model WSP 335A 2 pcs Strong wind NOTE If the extreme strong wind blows directly against the air discharge portion the fan may rotate reversely and be damaged If the unit is installed on the roof or the place forced directly against strong wind such as storm fix the unit securely with wire ropes as shown in the figure A CAUTION Aluminum fins have very sharp edges Pay attention to the fins to avoid any injury 6 SMGB0059 rev 0 04 2009 Direction of Strong Wind Xa Direction of Air Discharge o000 0 A wall to guard againts the wind Air intake side Face the air discharge side to the wall Secure the adequare service space Wire rope Sno
113. during the cooling process If the liquid stop valve is fully open it is difficult to charge the additional refrigerant Do not charge the refrigerant from the gas stop valve 172 SMGB0059 rev 0 04 2009 Field work instruction HITACHI Inspire the Next Service Manual 11 3 Insufficient cooling performance when a long piping is applied E Question and answer for the field work Example 2 Insufficient cooling performance when a long piping is applied Phenomenon Sufficient cooling was not available for an indoor unit that was located at the farthest position Cause If the location of an outdoor unit is 20 meters lower than the location of the indoor units resetting of the DIP switch DSW3 is required However no setting was performed Therefore the largest discharge pressure was not increased This resulted in an insufficient cooling performance for the indoor unit Indoor units Insufficient cooling Outdoor unit Check DSW3 Countermeasure The setting of the DSW3 was changed Remarks Pay a special attention to the size of the liquid pipe if the lift between the indoor units and the outdoor units is higher than 20 meters Refer to Piping Work in TC for details 11 4 Abnormally high operation sound in the ceiling type indoor unit E Question and answer for the field work Example 3 Abnormally high operation sound in the ceiling type i
114. e Replacing wires repairing contacting or incorrect tightening screws and incorrect Power source wiring for the connection screws Check the si connection f f wiring outdoor unit connection No Disconnected wires to PCB Check the connections Repair the wiring connections Faulty PCB PCB1 and PCB2 Faulty PCB Replace PCB if faulty Check the continuity Check for looseness of connection screws Incorrect wiring Check the connection Nos Correctly connect the wires Disconnected wires Incorrect wiring insufficient contacting Replacing wires repairing tightening screws Position of Surge Absorber SA When the unit is applied the excessive surge current due to HE o 2 ee EA O lighting or other causes it is indicated this alarm code 04 or Surge A oroar nE 0 0 0 DN the inverter stoppage code ITC 11 and the unit can not be operated In this case check to ensure the surge absorber SA E O on the noise filter NF1 If the inside of the surge absorber is AG SS St ewe normal turn OFF the power once and wait for PCB2 s LED OFF Ee and turn ON again ai 5 SB Qo a A a 380 415V SMGB0059 rev 0 04 2009 81 Troubleshooting HITACHI Inspire the Next Service Manual Alarm code Description i i 2 Abnormality of
115. e electrical system Check the ref cycle and the electrical system Repair the wiring Overcharged refrigerant Measure the pressure Refer to Test Run of SM Correctly charge the refrigerant Faulty Ex valve Check expansion valve refer to procedure of checking other main parts Replace the ex valve if faulty Decrease of the discharge gas superheat Fault Replace PCB1 and check the operation Replace PCB if faulty Faulty PCB Disconnected wires for the Ex valve control Check the connections Repair the wiring connection Fault Check thermistor Replace the thermistor if faulty Faulty discharge gas thermistor Incorrect mounting Check the mounting state Refer to Alarm code 07 Correctly mount the thermistor Incorrect connection Check the connections Remove looseness Replace the connector or repair the connections SMGB0059 rev 0 04 2009 85 HITACHI Inspire the Next Troubleshooting Service Manual Alarm code Description a pnt pnt chamber Excessively high discharge gas temperature at the top of the compressor E The RUN LED flickers and ALARM is displayed on the remote control switch E The unit number the alarm code and the unit code are alternately displayed on the set temperature section The unit number and the alarm code are displayed on the display of the outdoor unit PCB1
116. e alternately displayed on the set temperature section The unit number and the alarm code are displayed on the display of the outdoor unit PCB1 This alarm code is displayed when the thermistor is short circuited less than 0 24 KQ or cut greater than 840 KQ during the cooling process or the heating process The system is automatically restarted when the fault is removed PCB1 Control PCB in Outdoor Unit PCB Indoor unit PCB No Freeze protection thermistor THM3 Is THM3 connected to intake of PCB Connect it Yes Is the resistance of THM3 between 0 24kQ and 840kQ Faulty thermistor Refer to the thermistor resistance in Alarm 11 In case of 4 way cassette Faulty PCB Action Phenomenon Cause Check item Turn OFF the main switch Fault Check the resistance Replace the thermistor if faulty Faulty freeze protection thermistor Incorrect connection Check the wiring to PCB Connect wiring correctly Replace PCB and Faulty PCB check the operation Replace PCB if faulty 90 SMGB0059 rev 0 04 2009 Troubleshooting HITACHI Inspire the Next Service Manual Alarm code Description Abnormal operation of the thermistor for the indoor unit heat exchanger gas st refrigerant pipe temperature gas piping thermistor E The RUN LED flickers and ALARM is displayed on the remote control switch E The uni
117. e changin speed dependes on the outer setting Output 10 sec Activation recovery SMGB0059 rev 0 04 2009 Transmit error 30 sec Protection activation enn HITACHI Inspire the Next Service Manual Excessive High or Low Voltage for Inverter a Level of Detection When the voltage of direct current is greater than 750 V abnormalities are detected When the voltage of direct current is smaller than 350 V abnormalities are detected b Function When abnormalities are detected the inverter compressor is stopped and transmit the signal code of stoppage cause to PCB1 c Cancellation of Protection Function Transmission for signal code of stoppage cause is cancelled when a stopping order is given or main power source is cut off Abnormality of Current Sensor a Level of Detection When current of the inverter compressor decreases lower than 1 5A during the inverter compressor frequency between 15Hz and 18Hz an abnormality is detected b Function When abnormalities are detected the inverter compressor is stopped and transmit the signal code of stoppage cause to PCB1 c Cancellation of Protection Function Transmission for signal code of stoppage cause is cancelled when a stopping order is issued or main power source is cut off Overcurrent Protection for Inverter a Level of Detection When the current detected by current sensor reaches 150 of the rated current overcurre
118. e check joint of the high pressure side and the low pressure side of the outdoor unit 4 Turn on the main switch of the outdoor unit 5 Set the exclusion of the compressor by setting the DSW5 1 ON Compressor No 1 52C1 Inverter DSW so that a broken compressor will not work compressor You can set the exclusion of the compressor by DSW5 2 ON Compressor No 2 52C2 setting the DSW5 1 DSW5 6 of the PCB1 DSW5 3 ON Compressor No 3 52C3 and the others 6 Pre Pump Down by means of the Cooling Process After closing the gas stop valve the decrease of Ps is Start the test run of the cooling process fast To guarantee the reliability of the compressor make DSW4 1 ON sure that the decrease does not reach PS lt 0 1Mpa The test run should run for approximately 20 When you perform the enforced stoppage minutes until the test run reaches PS gt 0 3Mpa Td gt 75 C as a rough target Display of Ps in seven seconds of the outdoor PCB Close the gas stop valve quickly Then perform the enforced stoppage DSW4 4 ON when Ps lt 0 2Mpa Set the DSW4 1 to OFF in order to cancel the test run of the cooling Set the DSW4 4 to OFF in order to cancel the enforced stoppage 7 The compressor replacing mode is performed This operation is performed for up to a maximum of ten The DSW4 6 on the outdoor unit PCB ON The minutes cooling is run If the inverter compressor is excluded the operation starts af
119. e check valve may cause an incorrect increase at the stoppage during approximately brazing due to the gas pressure at the brazing of the five minutes Also make sure that Pd gt Ps discharge piping If the compressor replacing mode is performed again 0 03 MPa or set the DSW4 4 to OFF and keep the DSW4 4 at the Ps smaller OFF side during ten minutes Then start according to the p procedure No 6 2 minutes Time 11 Collect the refrigerant by means of the refrigerant The discharge of the refrigerant in the atmosphere collection is strictly forbidden Make sure that the refrigerant is Perform either A or B depending on the process collected by the collector 10 Keep a note of the quantity of the collected refrigerant A The leak rate at the process 10 is within the specification Collect the refrigerant only at the low pressure side B The leak rate at the process 10 is greater than the specification Collect all the refrigerant of the outdoor unit side by means of the machine 12 After collecting the refrigerant remove the change Make sure that there is no pressure increase of the low hose collector side of the low pressure side so that pressure sides after collecting the refrigerant the low pressure side of the refrigerant cycle willbe L _Make sure that the refrigerant cycle is the atmosphere the atmosphere pressure pressure Otherwise problems such as the blowing of gas and the suction of the cutti
120. e connections Is the coil resistance of the No fan motor normal gt Replace the motor Yes Check the indoor temperature If the indoor temperature is unusual take a suitable action to reduce the indoor temperature Action Turn OFF the main switch Cause Check item Activation of the internal thermostat for the indoor unit fan motor Measure the coil resistance and the insulation resistance Faulty indoor unit fan motor Replace the motor if faulty Check the continuity after the fan motor temperature decreases to room temp Replace the fan motor if Fauli there is no continuity Correct looseness Replace the connectors Measure the resistance Faulty internal thermostat by means of the tester Insufficient contacting Incorrect connection Check the connections Repair the connections 94 SMGB0059 rev 0 04 2009 Troubleshooting HITACHI Inspire the Next Service Manual Alarm code Description Abnormal operation of the high pressure sensor for the outdoor unit The RUN LED flickers and ALARM is displayed on the remote control switch E The unit number the alarm code and the unit code are alternately displayed on the set temperature section The unit number and the alarm code are displayed on the display of the outdoor unit PCB1 This alarm code is displayed when the high pressure sensor voltage decreases lower than 0
121. e control Outdoor Units PCB 4 2 1 _RAS 8 12FSNM E Available optional functions Outdoor units 5 1 1 Setting of external input and output functions 5 1 2 Description of external input signals 5 1 3 Description of external output signals 5 1 4 Optional functions Test run Checking procedure before the test run Test run procedure from the outdoor unit side Check list Judgement system for refrigerant amount Troubleshooting Initial troubleshooting 7 1 1 Emergency operation 7 1 2 Failure of the power supply to the indoor unit and the remote control switch 7 1 3 Abnormal transmission between the remote control switch and the indoor unit 7 1 4 Abnormal operation of the devices SMGB0059 rev 0 04 2009 Service Manual ONoOa a AA A N gt lt ee ee ee ee E a NOON N n Co Oo N NN pa N po ND N oo 29 30 30 32 32 33 34 34 39 41 49 50 52 53 56 59 60 61 62 64 Service Manual 7 2 10 10 1 10 1 10 2 10 3 10 4 10 5 11 11 2 11 3 11 4 11 5 11 6 Troubleshooting procedure 7 2 1 Alarm code indication of remote control switch 7 2 2 Troubleshooting by alarm code 7 2 3 Troubleshooting in check mode 7 2 4 Troubleshooting by means of the 7 segment display 7 2 5 Running current of the compressor 7 2 6 Protection control code on the 7 segment display 7 2 7 Activating condition of the protection control code
122. eck item Check the setting condition of thermistor of remote control switch by means of the optional setting Setting and control 00 Control by means of the indoor thermistor for the suction air 01 Control by means of the thermostat of the remote control switch 02 Control by means of the average value of the indoor thermistor for the suction air and the thermostat of the remote control switch Action Turn OFF the main switch If the thermostat of the remote control switch is not used set at 00 1 Refer to section Self checking of PCB using remote control switch 2 Refer to section Troubleshooting in check mode by remote control switch 3 Even if the remote control switches are normal the compressor does not operate under the following conditions Indoor temp is lower than 21 C or outdoor temp Is lower than 5 C during the cooling process DB Indoor temp is higher than 27 C DB or outdoor temp is higher than 15 C WB during the heating process When acooling or heating process signal is given to the outdoor unit and a different mode as heating or cooling process signal is given to the indoor units When an emergency stop signal is given to outdoor unit SMGB0059 rev 0 04 2009 65 HITACHI Inspire the Next Abnormal operation of the devices Cont Troubleshooting Service Manual Phenomenon change Indoor fan speed does not Failure of
123. ed on the remote control switch E The unit number the alarm code and the unit code are alternately displayed on the set temperature section The unit number and the alarm code are displayed on the display of the outdoor unit PCB1 This alarm code is displayed when the thermistor is short circuited less than 0 9 KQ for one second or cut greater than 5946 kQ during the operation If you find an abnormal operation of the thermistor check all the thermistors as shown below No Is discharge gas thermistor THM9 gt on PCB1 i Yes Is resistance of discharge gas thermistor THM9 same with No characteristic in the figure Yes Connect the thermistors Faulty thermistor Thermistor mark Peat THM9 Indication on the display of the outdoor unit PCB1 Faulty PCB1 Z Faulty Td1 Thermistor characteristics Resistance of thermistor kQ 200 100 14 2 i 8 32 0 25 50 100120 150 Air temperature C Action Phenomenon Cause Check item Turn OFF Main Switch Fault Check resistance Faulty thermistor for the discharge gas Incorrect connection Check wiring to PCB1 Replace thermistor if faulty Repair wiring and connections Faulty PCB1 Replace PCB1 and check operation Replace PCB1 if faulty Incorrect setting of DSW2 on PCB1 Check the setting of DSW2 on PCB1 Correctly s
124. eds 63A use MLFC cables and do not connect cables in series Install a multi pole main switch with a space of 3 5 mm or more between each phase Use shielded wires for transmission wires between the indoor and the outdoor units and connect the shielded part to the earth screw in the electrical box of the indoor unit as shown below Shield part Transmission wires Power Supply Wires Earth screw E Select the Main Switches in accordance with the following table Indoor units Maximum Running Current ELB Model Power Source A CB A no poles AimA All indoor units 5 0 6 1 230V 50Hz 2 40 30 RPI 8 0 10 0 FSN2E 10 0 16 Outdoor units Maximum Running Current ELB Model Power Source A CB A no poles A mA RAS 8FSNM 14 0 20 4 20 30 RAS 10FSNM 3 380 415V 50Hz 18 0 30 4 30 30 RAS 12FSNM 23 0 30 4 30 30 ELB Earthleakage Breaker CB Circuit Breaker SMGB0059 rev 0 04 2009 28 Control system HITACHI Inspire the Next Service Manual 4 Control system This chapter presents the control system flowcharts for the Set FREE FSNM E Outdoor Units series Contents 4 Control system 29 4 1 Device control system 30 4 1 1 RAS 8 10FSNM E refrigerant cycle control 30 4 2 Outdoor Units PCB 32 4 2 1 RAS 8 12FSNM E 32 SMGB0059 rev 0 04 2009 29 HITACHI Inspire the Next 4 1 Device control system Control system
125. een 0 24kQ and 840kQ lt Faulty thermistor Indoor unir air inlet thermistor THM1 Yes N Incase of 4 way N cassette Faulty PCB Action Phenomenon Cause Check item Turn OFF the main switch Fault Check the resistance Replace the thermistor if faulty Faulty air inlet thermistor Repair the wiring and the Incorrect connection Check the connection n connections Faulty PCB Replace POB and check the Replace PCB if faulty operation 90 82 O 70 NOTE Bg 61 This data is applicable to the following T thermistors ermistor 50 er racieiance a Ne 1 Indoor unit discharge air temperature KQ 0 27 2 Indoor unit liquid refrigerant 6 20 5 temperature io e510 gles 3 Indoor unit air inlet temperature o 25 4 Outdoor temperature 15 10 5 0 5 10 15 20 25 30 35 40 45 50 55 60 5 Outdoor unit evaporating temperature Air temperature C 6 Indoor unit gas piping Thermistor characteristics 88 SMGB0059 rev 0 04 2009 Troubleshooting HITACHI Inspire the Next Service Manual Alarm code Description lt 1 Abnormal operation of the thermistor for the indoor discharge air ga temperature air outlet thermistor The RUN LED flickers and ALARM is displayed on the remote control switch E The unit number the alarm code and the unit code are alternately displayed on the set temperature section The unit numbe
126. en connecting the motor wire check to ensure that the colors of the connectors on the PCB3 and PCB5 are matched with wires Firmly fix the air outlet grille to the shroud Rubber bush Partition plate Cord clamp or plastic tie Install DC fan motor to this position facing down the trap 1 Remove the service cover according to the item 2 1 Removing Service Cover 2 Remove the upper cover according to the item 2 3 Removing Upper Cover 3 Remove six 6 fixing screws for electrical box 4 Lift the electrical box and remove it O NOTES The wiring disconnecting works are required as follows when removing the electrical box 1 a A MN Remove reversing valve coil according to the item Removing Reversing Valve Coil and Solenoid Valve Coil Remove electronic expansion valve coil according to the item Removing Electronic Expansion Valve Coil Remove solenoid valve coil according to the item Removing Reversing Valve Coil and Solenoid Valve Coil Disconnect the faston terminal of the high pressure switch Disconnect the connectors on the PCB1 as follows THM7 Thermistor for Ambient Temperature THM8 Thermistor for Heating Evaporation Temperature THM9 Discharge Gas Thermistor PCN5 Oil Heater CN4 High Pressure Switch CN9 Low Pressure Sensor 6 Disconnect the connectors on the PCB3 and PCB5 as follows 142 SMGB0059 rev 0 04 2009 Servicing HITACHI Ins
127. equency Maximum Frequency Conditions HP Hz Hz 8 15 60 When night shift is set 1 ni 1 10 60 2 Outdoor fan ni 1 Below 70 12 60 SMGB0059 rev 0 04 2009 43 Available optional H ITACH l functions Inspire the Next Service Manual E Cancellation of outdoor ambient temperature limit of heating Press PSW1 and select the setting condition 1 at the cancellation of outdoor ambient temp limit of heating Then this function can be set ru wor The heating operation is continued under a high outdoor temperature Operation in heating mode The factory set limitation of the range Area of operation of permissible outdoor temperature in stoppage the heating process which is shown in the right figure is cancelled 27 25 Suction air tem perature C 0 17 19 29 Outdoor Temp C E Note The operation may be OFF due to high outdoor temperature protection control since protection control is not cancelled E Cancellation of outdoor ambient temperature limit of cooling Press PSW1 and select the setting condition 1 at the cancellation of outdoor ambient temp limit of cooling EL Then this function can be set The cooling operation is continued under a low temperature Operation in cooling mode The factory set limitation of the range of permissible outdoor temperature in the heating process wh
128. er atthe power source Failure of indoor unit fan motor Remove the cause of the short circuit and replace the fuse Check for any uncovered part of the wires Remove the cause of the short circuit and replace the fuse Measure the insulation resistance Measure resistance between wires and insulation resistance Replace AC chopper for indoor unit fan fan motor and fuse Failure of AC chopper for indoor fan Replace AC chopper for indoor unit fan and fuse Short circuit supplied between the wires Remove the cause of the short circuit and replace the fuse Check for any uncovered part of the wires Short circuit of the control circuit to earth Blown out fuse at the control Remove the cause of the short circuit and replace the fuse Measure the insulation resistance circuit Failure of indoor unit fan motor Measure resistance between wires and insulation resistance Replace AC chopper for indoor unit fan fan motor and fuse Failure of AC chopper for indoor fan Failure of the transformer at the indoor unit side Replace AC chopper for indoor unit fan and fuse Measure the voltage at the Replace the transformer secondary side Disconnected cable of the remote control switch Replace the cable or repair the Connect the cable cable Insufficient connection or incorrect connection of the indoor Insufficient contacting at the unit POB connectors of the remote control
129. erant leakage at the piping connection 4 Cabinet Stain and Lubrication Check for any stain and any lubrication Remove the stain and the lubrication Fixing Screw Check for any loosened screw or any lost screw Fix the loosened screws and the lost screws Insulation Material Check for any peeled thermal insulator on the cabinet Repair the thermal insulator 5 Electrical equipment Activation Check for an abnormal activation of the magnetic contactor the auxiliary relay the PCB and others Line condition Pay attention to the working voltage the working amperage and the working phase balance Check for any faulty contact that is caused by the loosened terminal connections the oxidized contacts the foreign matter and other items Check the electrical insulation resistance 6 Control device and protection device Setting Do not readjust the setting in the field unless the setting is maintained at a point that is different from the point that is listed in the section 5 5 Protection and Safety Control of this Service Manual E For the indoor unit 1 Air filter Cleaning Check for any accumulated dirt and any accumulated dust Remove the dirt and the dust 2 Drain pan drain up mechanism and drain pipe Drain line Check and clean the condensate drain pipe at least twice a year Drain up mechanism Check the activation of the drain up mechanism 3 Float switch Activation Check the activation of the
130. eration 98 SMGB0059 rev 0 04 2009 Troubleshooting Service Manual HITACHI Inspire the Next Alarm code Description Lf Abnormal operation of the low pressure sensor for the outdoor unit E The RUN LED flickers and ALARM is displayed on the remote control switch E The unit number the alarm code and the unit code are alternately displayed on the set temperature section The unit number and the alarm code are displayed on the display of the outdoor unit PCB This alarm code is displayed when the low pressure sensor voltage decreases lower than 0 1 V or increases higher than 4 9V during the operation Is the connection CN9 of the outdoor unit PCB1 bad Yes Connect it correctly be outdoor unit PCB1 Is 12 VDC applied across 1 and 3 of the connector CN9 of the outdoor unit PCB1 Is the voltage under 0 1 VDC or over 4 9 VDC across 2 and 3 of the connector CN9 of the Faulty PCB1 No Faulty PCB1 Yes Repl the check joint Clogged check joint ican a No Abnormal operation of low pressure sensor Action Phenomenon Cause Check item Turn OFF Main Switch Fault Check that the output voltage is Replace the pressure sensor if correct faulty Faulty low pressure sensor Incorrect connection Check the connections Repair the wiring and the connections Faulty PCB1
131. erformed up to second time of abnormality occurrence Conditions This alarm is indicated when the temperature of the internal thermostat for transistor module is higher than 100 C Yes Good Restart the operation Check the thermistor Does it trip soon Replace the PCB2 1 No Faulty Replace the thermistor Yes Is the heat exchanger of the outdoor unit clogged gt Remove the clogging No Replace the PCB2 or thermistor 1 1 Refer to section Procedure of checking other main parts for the replacing procedure and the checking procedure for the PCB2 SMGB0059 rev 0 04 2009 111 H ITACH i Troubleshooting Inspire the Next Service Manual Alarm code Description 2 2 Inverter failure E The RUN LED flickers and ALARM is displayed on the remote control switch E The unit number the alarm code and the unit code are alternately displayed on the set temperature section The unit number and the alarm code are displayed on the display of the outdoor unit PCB1 This alarm is indicated when the following phenomenon occurs 3 times in 30 minutes including 3 Retry operation is performed up to the occurrence of 2 times Actual frequency from PCB2 is less than 10Hz after inverter frequency output from PCB1 Conditions This alarm is indicated when PCB2 is not performed normally PCB1 Control PCB in Outdoor Unit
132. erter Repair the faulty part Compressor is not operating Check the compressor Replace the comp if faulty Valve stoppage at medium position of 4 way valve Measure the suction pipe temp of the 4 way valve Replace the 4 way valve if faulty Abnormal operation of the high pressure sensor or the low pressure sensor Excessively low air inlet temperature of the indoor unit Check the connector for PCB1 the power source and the pressure indication Check the indoor unit and the outdoor unit air temp thermistor Replace the sensor if faulty Replace the thermistor if faulty Leakage of the solenoid valve outdoor unit Check the solenoid valve SMGB0059 rev 0 04 2009 Replace SVA if leaking 103 HITACHI Inspire the Next Troubleshooting Service Manual Alarm code Description Lew Activation for protecting the system from excessively low suction pressure E The RUN LED flickers and ALARM is displayed on the remote control switch E The unit number the alarm code and the unit code are alternately displayed on the set temperature section The unit number and the alarm code are displayed on the display of the outdoor unit PCB1 Incase that compressor is operated under the condition that is higher than 1 5MPa of suction pressure Ps for 1 minute all compressors are stopped and retry operation is started after 3 minutes However the alarm code is
133. ervice Manual 7 1 Initial troubleshooting Checking by means of the 7 segment display E Simple checking procedure by means of the 7 segment display 1 Turn on all the indoor units which are connected to the outdoor unit 2 Turn on the outdoor unit 3 Auto addressing starts Outdoor unit printed circuit board PCB 1 During the auto addressing you can check the following items by means of the 7 segment display of the outdoor unit Disconnection of the power supply to the Indoor Unit Duplication of the Indoor Unit number Normal case The 7 segment display of the outdoor unit is not indicated Abnormal case If there is something wrong the 7 segment display of the outdoor unit displays the following indications Cause Indication Remarks a The indoor units are not supplied rm continues to flash after 30 seconds with power pt l b Disconnection of the operating line m7 continues to flash after 30 seconds between the outdoor units and the pt t indoor units c Duplicated settings of the indoor unit number on the rotary switch RSW Refer to the section Troubleshooting by means of the Alarm Code for the description of the alarm code 35 60 SMGB0059 rev 0 04 2009 Troubleshooting Service Manual HITACHI Inspire the Next Method of collecting refrigerant In case that compressor does not operate Perform only when collecting refrigerant of outdoor unit is required Pe
134. essure is different depending on the ambient temperature X s a protection prt m Discharge gas Temperature at the top of compressor is high gt temperature increase Frequency decrease protection Maximum temperature is different depending on fein ry Reversing valve When switching AP Pd Ps switching control AP lt 1 0MPa Frequency increase AP gt 1 3MPa Frequency decrease imi Oil return control Frequency less than a is maintained for more 7 00 a than1 hour Frequency 2 a Cooling operation 75 Heating operation 84 x q x High pressure Discharge pressure of compressor decrease gt decrease protection Frequency increase gt w Si 1 I x Demand current control Compressor run current 2 Demand setting value as Demand current setting value Upper limit of temperature of discharge gas Running current imit Frequency decrease total running current is set to 80 70 60 control at normal operation using input on PCB1 ee Discharge gas Temperature of discharge gas is low Td1 lt Pd SUPERHEAT decrease saturation temperature 15 C Frequency protection increase Frequency is different depending on x x a Low pressure increase Low pressure 2 1 3MPa Frequency increase protection 1 Lr Pat 4 a Pressure ratio decrease Compression ratio When it activates three times in 30 minutes
135. et DSW2 on PCB1 SMGB0059 rev 0 04 2009 97 H ITACH i Troubleshooting Inspire the Next Service Manual Alarm code Description al Abnormal operation of the thermistor for the evaporating temperature during m the heating process outdoor unit The RUN LED flickers and ALARM is displayed on the remote control switch E The unit number the alarm code and the unit code are alternately displayed on the set temperature section The unit number and the alarm code are displayed on the display of the outdoor unit PCB If you find an abnormal operation of the thermistor check all the thermistors as shown below This alarm is indicated when the thermistor is shortcircuited less than 0 9kQ or cut greater than 5 946kQ during running Is thermistor THM8 connected to connector THM8 Te1 of PCB1 No Thermistor mark Connect it Te1 THM8 Is the resistance of the thermistor between 0 2 KQ and 500 kQ Yes Faulty PCB1 Faulty thermistor Indication on the display of the outdoor unit PCB1 Z Faulty Te1 z Action Phenomenon Cause Check item Turn OFF the main switch Faulty thermistor for the Fault Check the resistance Replace the thermistor if faulty evaporating temperature during heating Incorrect Connection Check the wiring to PCB1 Repair the wiring ang me connections Faulty PCB1 Replace POR and check ihe Replace PCB1 if faulty op
136. et all the DIP switches of DSW1 to OFF after completing the test run Dip switch seting Operation Remarks Test run 1 Setting operation mode The indoor unit automatically Make sure that the indoor units start to operate Cooling Set DSW1 2 OFF starts to operate when the in accord with the test run of the outdoor unit test run of the outdoor unit is If you start the test run from the outdoor unit ON set and you stop the test run from the remote poe You can perform the ON OFF control switch the test run function of the 1234 operation from the remote remote control switch is cancelled However Tie control switch or the DSW1 1 the test run function of the outdoor unit is not Heating SET DSW1 2 ON of the outdoor unit cancelled Check to ensure that the DSW1 1 of Continuous operation during the outdoor unit PCB is turned OFF ON 2 hours is performed without In case that more than one indoor units are halt the Thermo OFF condition connected with one remote control switch 1234 perform the test run operation at each Starting the test run refrigerant system one by one Then make Set DSW1 1 at ON The sure to turn the power source OFF for the operation starts after 20 s indoor units at other refrigerant system not to In case of heating process leave operate test run DSW1 2 at ON Outdoor unit ON MEHE i l 1234 1 T Testa nis Power OFF The setting of DSW1 is not required for the test run from the remote control switch Man
137. evenly 7 Rubber plug L MN My 0 Packless valve High pressure hose 0 03 to 0 05 MPa 0 3 to 0 5 Kg cm2 G Reducer valve open this valve only when the gas is needed ZB x Nitrogen gas flow 0 05m h or smaller C6 A caution Use nitrogen gas for blowing during pipe brazing If oxygen acetylene or fluorocarbon gas is used it will cause an explosion or poisonous gas eoeooogec0o9o 8 During the brazing work a lot of oxidation film will be generated inside of the pipes if no oxygen free nitrogen gas is blown through the pipes This film will be flecked off after operation and will circulate in the refrigeration cycle resulting in clogged expansion valves etc This coud origin problems in the compressor Use a reducer valve when nitrogen gas blowing is performed during brazing The gas pressure should be maintained within 0 03 to 0 05 MPa If an excessively high pressure is applied to a pipe it could origin an explosion SMGB0059 rev 0 04 2009 17 Electrical wiriing HITACHI Inspire the Next Service Manual 3 Electrical wiring Contents 3 Electrical wiring 19 3 1 General check 20 3 2 Electrical wiring for the outdoor unit 21 3 2 1 Electrical wiring connection for outdoor unit 21 3 2 2 Setting the DIP switches for the outdoor unit 22 3 3 Common wiring 25 3 3 1 Electrical wiring between the indoor unit and the outdo
138. f m 26 compressor MC2 mic x 000 255 A for 14 to 48HP Estimated running current of m 7 27 compressor MC3 rm a a 000 255 A for 18 to 48HP Estimated running current of m L 28 compressor MC4 rt 000 255 A for 30 to 48HP Estimated running current of m r 29 compressor MC5 mt T bos 000 255 A for 38 to 48HP Fr yor ys Z bn b l Indoor unit expansion valve 30 opening 0 100 from 0 to 63 reo l ee Ln SMGBO0059 rev 0 04 2009 123 HITACHI Inspire the Next Troubleshooting Service Manual No Item Indication Data Values Units 7 re Z Indoor unit heat exchanger E EA a a liquid pipe temperature freeze 31 protection 7 62 127 C from 0 to 63 w J a Im l l Im al w w a g pa pt jt ot l bt Indoor unit heat exchanger gas 32 pipe temperature 5 62 127 C from 0 to 63 7 w iE us pa pt it Wf bt 7 re rm pt pt Ln pt Indoor unit air inlet 33 temperature 62 127 C from 0 to 63 Nad Z 7j a bt ml Im l 7 DO us m7 m R bt Indoor unit discharge air 34 temperature as 62 127 C from 0 to63 7 D 1 rm pt it ot al bt w oo ioe f Z1 No 0 Unit Ln ee R al Im 6 160 Indoor unit capacity setting _ _ 35 from 0 to 63 x1 8HP h No 63 Unit mie a a R o
139. fan motor Insufficient contacting Measure the voltage between the contacting parts Replace PCB for the outdoor unit Failure of the comp motor Measure the resistance between two wires Failure of the comp Check for an abnormal sound from the Comp Replace the compressor Failure of the magnetic switch for comp Failure of one of PCBs Insufficient contacting Disconnected wiring to PCB Check that the magnetic switch activates correctly or not Check the connections Replace the magnetic switch Correctly connect the wiring Failure of PCB Check PCB by means of the self check mode 1 Replace PCB if it failed The Comp does not stop or start even if the setting temperature on the LCD changes to 3 64 Failure of air inlet thermistor Failure of thermistor Disconnection of thermistor Abnormal operation of the remote control switch cord Check it by self checking 2 Replace or correctly connect the wires if Abnormal Operation exists Failure of the indoor unit PCB SMGB0059 rev 0 04 2009 Check PCB by means of the self check mode 1 Replace PCB if it failed Troubleshooting Service Manual Abnormal operation of the devices Cont HITACHI Inspire the Next Phenomenon The Comp does not stop or start even if the setting temperature on LCD changes to 3 Cause Incorrect optional setting Ch
140. ference inlet temp lt 24 C fixed indoor discharge gas between air outlet super heat and air inlet of I U TdSH Outdoor fan Fan controlling discharge pressure Pd 2 5 lt Pds lt 2 9MPa PWM control by DC motor constant speed fan motor Fan controlling outdoor air temp Outdor air temp PWM control by DC fan motor constant speed fan motor Stop Solenoid valve equalized pressure SVA 1 For equalizing the pressure of the inverter compressor during the stop In case of stopping inverter comp after operation For controlling inner pressure of stopag comp In case of stopping inverter comp after operation Solenoid valve for the oil return SVF For controlling temp oil circulation volume from the oil separator to each 1 Turn ON in comp operation 2 Turn OFF in comp stoppage For controlling temp oil circulation volume from the oil separator to each compresso Turn ON in comp operation 2 Turn OFF in comp stoppage Same as cooling heating operation compressor I U Indoor Unit Tc Te Condensing Temperature Evaporating Temperature Td Discharge Temperature TI Liquid Temperature Tg Gas Temperature Cap Capacity Temp Temperature comp Compresror 30 SMGB0059 rev 0 04 2009 Control system Service Manual The figure below shows the outline of the control system Example RAS 10FSNM E Indoor unit
141. fferent setting of the total indoor unit capacity in the same refrigerant cycle Countermeasure All the main switches for the indoor units were always ON 11 6 Not cooling well due to insufficient installation space for the outdoor unit E Question and answer for the field work Example 5 Not Cooling Well due to Insufficient Installation Space for Outdoor Unit Phenomenon Cooling operation was well performed through the intermediate season However the cooling operation was not well available when the outdoor temperature was higher than 35 C Cause As the outdoor units were installed without a sufficient installation space the hot discharge air from other outdoor units was circulated In this case though the outdoor temperature was 35 C the actual suction air temperature was nearly 50 C and Protection System from Excessively High Suction Pressure was activated the frequency of the compressor was decreased and the cooling capacity was also decreased accordingly As the outdoor units in line were installed back to back with a distance of 600 mm between each outdoor unit s back the hot discharged air from other outdoor units was circulated Min 300 mm Fence OS ee mm awe Countermeasure To protect the unit from a short circuit fences were mounted at the discharge air side as shown below Field work instruction HITACHI Inspire the Next Service Manual
142. g turn OFF the No 1 switch of the dip switch DSW1 on PCB2 4 Use the silicon grease provided as accessory Service Parts No P22760 Position of Surge Absorber SA 380 415V When the unit is applied the excessive surge current due to te Eo Mae OH lighting or other causes it is indicated this alarm code 04 or Surge gpoorbat Ol 1 0 0 Er the inverter stoppage code ITC 11 and the unit can not be o operated In this case check to ensure the surge absorber SA e A s on the noise filter NF1 If the inside of the surge absorber is BE A normal turn OFF the power once and wait for PCB2 s LED OFF and turn ON again j k a B oo o o 8 s 110 SMGB0059 rev 0 04 2009 Troubleshooting HITACHI Inspire the Next Service Manual Alarm code Description 2 _f Increase in the inverter fin temperature E The RUN LED flickers and ALARM is displayed on the remote control switch E The unit number the alarm code and the unit code are alternately displayed on the set temperature section The unit number and the alarm code are displayed on the display of the outdoor unit PCB Incase that the abnormality of alarm code 51 or 54 occurs three times within 30 seconds the alarm code of abnormality occurred for the third time is indicated Retry operation is p
143. g the cooling process the compressor will stop Resistance values of the thermistor are shown below Thermistor Characteristics 80 70 60 Thermistor 50 Resistance 46 Ka 40 z 30 OT 30 10 61 20 5 16 125 3 6 2 5 1 5 10 5 0 5 10 15 20 25 30 35 40 45 50 55 60 Ambient Temperature C 166 SMGB0059 rev 0 04 2009 Main parts Service Manual E Thermistor for the defrost operation THM10 THM11 and THM15 The resistance values of this thermistor are the same as the resistance values of the thermistor for the outdoor ambient temperature HITACHI Inspire the Next E Thermistor for the room temperature control thermistor for the inlet air temperature of the indoor unit THM1 The thermistor for the inlet air temperature THM1 controls the room temperature The remote control switch displays the selected temperatures by means of figures Set the room temperature so that the room temperature does not become too cool or too hot It is recommended to set the room temperature in the following ranges Economical cooling mode 27 C to 29 C Economical heating mode 18 C to 20 C The resistance values of the thermistor are shown below Thermistor Characteristics A CAUTION The thermo off valve of the thermistor for the inlet air 70 temperature of
144. gment display changes to an alarm code when the abnormal operation occurs Also the same alarm code is displayed on the remote control switch indicated instead of Li mark SMGBO0059 rev 0 04 2009 129 HITACHI Inspire the Next Troubleshooting Service Manual To monitor the conditions such as the temperature change and others the control of the frequency and other controls are performed by the protection control in order to prevent the abnormal operations The activating conditions of the protection control are shown in the table below O Note Shadowed items are applicable only to FSN2 series Code Protection control Activating condition Remarks Z F Pressure ratio control Compression ratio 2 9 Frequency decrease Pd 0 1 Ps 0 06 lt 2 2 Frequency increase Ii High pressure increase Pd 2 3 6 Mpa 36kgf cm G Frequency Ps Suction pressure of compressor Mpa Pd Discharge pressure of compressor Mpa increase protection protection decrease prt Inverter current Inverter output current 2 23 5A 380 415V protection Frequency decrease Ire Inverter fin temp Inverter fin temp 2 89 C Frequency decrease 914 Fan motor controller fin Fan motor controller fin temperature 100 C temperature increase the frequency 4 lt Low pressure decrease Low pressure is excessively low Frequency protection decrease Minimum pr
145. gt Faulty PCB2 electromagnetic switches a operation 20 Hz Replace it CMC 1 turn ON Compressor stops when No m frequency increases Approx 20 Hz to 60 Hz Is connection correctly between No PCB2 and capacitors CB CB1 eu c t tl and CB2 DCL or CMC 1 Cee COMECE Be extremely carefull because of the i high voltage Yes Faulty Is the DC voltage over 460V gt Cned oa CB m Replace the capacitors Capacitors have high voltage No Be extremely carefull 1 Normal y gt Faulty PCB2 Replace it 1 If the capacitor has a high voltage perform the high voltage discharge procedure 2 Checking procedures of the diode module are displayed in item Procedure for checking other main parts SMGB0059 Check de wiring transistor module and the capacitors In the case the wiring is correct replace transistor module rev 0 04 2009 83 HITACHI Inspire the Next Troubleshooting Service Manual Alarm code Description ror ht Decrease of discharge gas superheat displayed E The RUN LED flickers and ALARM is displayed on the remote control switch E The unit number the alarm code and the unit code are alternately displayed on the set temperature section The unit number and the alarm code are displayed on the display of the outdoor unit PCB Ifthe discharge gas superheat is below 10 C at the top of the compressor for 30 minutes the retry operat
146. gure on the next page 5 Remove the oil heater Direction to remove the cover Upper cover Sound proof Rear cover X A par Oil heater Valve stay Rear pipe cover Oil heater 144 SMGB0059 rev 0 04 2009 meres HITACHI Inspire the Next Service Manual Thermistor holder Td Thermistor Thermistor fixing plate Holder for Td t Thermistor Indication of terminal number _ r wires Terminal box cover Fix it with screw Details for compressor terminals Remove the suction pipe and discharge pipe from the compressor Isolate the wires and electrical components to protect from the burner flame at brazing Remove two 2 nuts fixing the compressor and remove the compressor from the unit by lifting in the condition of slightly inclining forward When brazing the replaced compressor quickly perform the brazing while the compressor side piping is cooled with wet cloth in order to avoid the brazing material from entering the compressor If the brazing material enters the compressor it will lead to compressor failure Reassemble the parts in the reverse order of removing procedures Tighten the screws U V and W for compressor wires with 2 5Nem Fix the lead wire firmly Attach the oil heater firmly to the compressor and fix it with spring as shown in the figure SMGB0059 rev 0 04 2009 445 HITA
147. h pressure during A low pressure sensor detects the suction pressure during the heating process The PID control with the operation the cooling process The PID control with the operation capacity of the indoor units controls the compressor capacity of the indoor units controls the compressor frequencies This way the high pressure is controlled frequencies This way the suction pressure is controlled within an appropriate range The output of the high within an appropriate range pressure sensor during the heating process performs the If the suction pressure becomes excessively low the protective control and the control of the gas bypass valve cooling action may be insufficient and the parts in the refrigerant cycle may be damaged Therefore if the output of the low pressure sensor indicates vacuum and the valve remains in the same position for 12 minutes or longer the compressor will stop in order to avoid damage Heating process Cooling process E l E E E l o PID control for compressor frequencies with the operation capacity of the indoor unit PID control for compressor frequencies with the operation capacity of the High pressure E indoor unit Low pressure control control Gas bypass valve check for y Vacuum preventive control protective control 4 5 4 5 S S Q oO a a o oO F 2 5 2 5 gt gt Q Q 3 3 0 5 0 5 03 0 2 5 5
148. harge Gas Temperature b2 air inlet temperature that is displayed on the remote control switch by means of the check mode However this is applicable only when b2 Air Inlet Temperature b1 setting temperature is higher than three degrees as the PCB the wiring the coil the valve Excessive pipe resistance Failure of the thermistor for the discharge air temperature No Check item Standard Causes Result 1 Is oE outdoor unit expansion valves Total of oE Low excessive refrigerant opening abnormally low or high when total frequency of High insufficient refrigerant TdSH is 15 to 45 degrees compressor x 0 2 to 0 6 2 Is Pd 1 6 to 3 5 Low leakage of the SVA Pd is high when the indoor temperature solenoid valve is high High excessive gas pipe resistance 3 Is H1 compressor frequency Low excessive refrigerant abnormally low or high The lower High insufficient refrigerant the room temperature and the outdoor excessive pipe resistance temperature the higher the above value 4 Is Ps 0 2 tof 1 1 Low short circuit of the indoor Only under the condition that the unit electrical expansion valve SVA is Low High failure of the OFF following components outdoor unit fan motor or outdoor ambient thermistor 5 Is the temperature difference among Failure of components such NOTE 1 The symbol with an underline indicates a check item The mark indicates the checking data
149. harge pressure high Check pressure and refrigeration No Smaller than activation current Check the diode module 2 Abnormal cycle all Check for clogging of the heat exchanger Check the fan motor Normal Check the inverter circuit board PCB2 connection 3 Abnormal gt Replace the diode module Normal gt Connect it correctly Transistor module IPM is faulty Replace it 1 Regarding the setting value of activation current refer to the item Specifications of inverter 2 Regarding replacing or the checking diode module refer to the item Procedure of checking other main parts 3 Regarding replacing or the checking method for inverter parts refer to the item Procedure of checking other main parts SMGBO0059 rev 0 04 2009 107 HITACHI Inspire the Next Troubleshooting Service Manual Alarm code Desc ription eid it Activation of inverter overcurrent protection device 2 E The RUN LED flickers and ALARM is displayed on the remote control switch E The unit number the alarm code and the unit code are alternately displayed on the set temperature section The unit number and the alarm code are displayed on the display of the outdoor unit PCB1 The alarm code is indicated when instantaneous overcurrent trip occurs at six times within 30 minutes
150. he alarm code is indicated on the display of the outdoor unit PCB1 This alarm code is indicated when the following condition occurs thre times in 30 minutes Indoor fan rotates less than 70 rpm for 5 seconds during operation When the cause is checked by means of this flow chart confirm that fan speed setting is Hi Indication of alarm Check the connectors Indoor unit PCB Set air flow volume Hi before starting this check code 19 PCN7 PCN11A PCN11B PCN15 Ahigh voltage is applied to electrical parts Never contact with them when checking to avoild electric shock Yes Is 220V applied No between R and S of h Check power supply TB1 Is LED4 on Insuffcient voltage for PCB OFF Faulty PCB microcomputer Replace PCB Is LEDS on Yes Insuffcient voltage for fan PCB OFF Faulty PCB motor DC280 gt Replace PCB No 1 Is DC power Is the voltage between Vcc15V and VDC of Faulty PCB we Use a tester gt Replace PCB Refer to the figure above for the check point supply for PCB correctly 1 2 Is the voltage between VccO5V and GND1 of PCB 5V 4 Faulty PCB Is the voltage between Vcc12V and GND1 of gt PCB 13 3V 10 Is DC power supply for PCB correctly 2 Replace PCB Is fan motor speed control command to fan motor co
151. he airflow optional part and open both right and left sides Note Mount the airflow optional part and open both right and left sides gt 350 Note Mount the airflow optional part and open both right and left sides E Obstacles in right and left Upper side is open Obstacles in above Single installation Multiple installation discharge flow is not short circuited NOTE If L is higher than H mount the units on a base so that H is greater or L A equal to L H Unit Height 1650mm Base Concrete Height Ds LOSH 600 or more 0 5H lt LSH 1400 or more In this situation ensure that the base is closed and does not allow the airflow to short circuit In each case install the outdoor unit so that the SMGB0059 rev 0 04 2009 8 Units installation HITACHI Inspire the Next Service Manual E Multi row and multiple installations Keep a distance of more than 100mm between other units and L A B do not put obstacles on the right and left sides Dimension B is as shown beside 0 lt L lt 0 5H 600 or more 300 or more 0 5H lt L lt H 1400 or more 350 or more E NOTE If L is larger than H mount the units on a base o that H is greater or equal to L In this situation ensure that the base is closed and does not allow the airflow to short circuit Air flow di
152. he display of the outdoor unit PCB1 This alarm code is displayed when the contact between 1 and 2 of CN14 is not closed over 120 seconds during the cooling process the heating process or the fan operation Is DC12V applied between 2 of CN14 and GND CN14 is not mounted in RPK type No PCB1 PCB Outdoor unit printed circuit board Indoor unit printed circuit board Activation of the safety device such as float Yes Faulty PCB switch FS or incorrect wiring Example of RCD RPI and RPC Types OOOTLS THM THM2 THM3 THM4 THM CN1925 CNS CN ONE Y QO Phenomenon Cause Action Eneckitem Turn OFF the main switch High Drain Level Clogging of the drainage Remove the clogged Check the drain pan foreign particles Activation of the float Fault Sheer me continuity Replace the float switch if when the drain level is low faulty switch Faulty float switch Faulty contacting Fix the looseness and Replace the connector Measure the resistance by means of the tester Faulty connection Check the connections Repair the connection Faulty indoor unit PCB Check PCB by self checking Replace PCB if faulty Outdoor unit PCB display indication Indor unit Alarm code number for failure 74 SMGB0059 rev 0 04 2009 Troubleshooting Service Manual HITACHI Inspire the Next Ale
153. he product as close to installation location as practical before unpacking CAUTION A Do not put any material on the product When hanging the unit ensure a balance of the unit check safety and lift up smoothly For transportation Do not remove any packing materials Hang the unit without removing the packaging with ropes through each square hole and apply the splints or corrugated paper for unit protection A DANGER Do not tie ropes at the wooden base E When Using Handles Wire rope KY BN WY Hh Ky q When manually lifting the unit using the handles pay attention to the following points 1 Do not remove the wooden base from outdoor unit 2 To prevent the unit from overturning pay attention to the center of gravity as shown in the below figure 3 Two or more personnel should be used to move the unit Model Unit gross weight kg RAS 8FSNM E 179 RAS 10FSNM E RAS 12FSNM E 182 The figure shows the location of the center of gravity 4 SMGB0059 rev 0 04 2009 Center of gravity 620 Handle Wooden base Over 60 V ZE ee Q 0 7 to 1 0m Do not remove the plastic band or the corugated paper frame Pass the wire ropes through each lifting hole in the wooden base as shown Fall angle of this product Approx 20 Units instal
154. he setting temperature valve 7 Is there any excessive different among __ It is normal if SH is within 3 Expansion valve locked in fully indoor units at SH TG TL of the heat deg lower than other units open position The refrigerant exchanger of the indoor units and is iE cycle number does not match lower than 7 Mismatched between wiring It is applicable when intake air temp is and piping 3 deg higher than setting temp 8 Is there any indoor unit with SH TG It is normal if SH is within Expansion valve locked in TL excessively lower than the value 3 deg higher than other slightly open position or of other units under the condition of IE units closed expansion valve The indoor unit expansion valve 100 refrigerant cycle number does not match Mismatched between wiring and piping 9 Is the difference between the discharge air temperature and the inlet air temperature more than 7 deg The temperature difference between I U means the following b3 Discharge Air Temp b2 Intake Air Temp indicated on the remote control switch by check mode 54 SMGB0059 rev 0 04 2009 Test run Service Manual b Heating process if the outdoor temperature is higher than 0 C HITACHI Inspire the Next the indoor units more than 10 degrees when iE indoor unit expansion valve is 100 The temperature difference among the indoor units means the following b3 Disc
155. hooting Service Manual HITACHI Inspire the Next Alarm code Description pt pce Excessively low or high voltage for the inverter The alarm code is displayed on the display of the outdoor unit PCB1 times retry is performed 06 indicates faulty fan controller E The RUN LED flickers and ALARM is displayed on the remote control switch E The unit number the alarm code and the unit code are alternately displayed on the set temperature section This alarm code is displayed when the voltage between terminal P and N of transistor module IPM is insufficient and the alarm has three occurrences in 30 minutes In the case that the occurrence is smaller than two PCB1 Outdoor unit printed circuit board Restart the operation PCB Indoor unit printed circuit board Is the power supply s voltage 10 of the No 7 n Check i wiring the nominal voltage cable capacity Is the voltage over 323V during the No operation 400V Is the voltage over 187V during the gt operation 230V 7 i Yes Does the voltage fall during Yes the operation because of the operation of other apparatus No gt Frequency can increase higher than 60 Hz Does LED201 on PCB2 How is the A Yi Compressor stops is ON after compressor s compressor Pae k aries
156. i valve opening it pn bt Outdoor unit 14 expansion valve mie i it i th at ml opening Estimated electric current indication 15 Compressor running Da me r current A w pn bt Returns to temperature indication 120 SMGB0059 rev 0 04 2009 Troubleshooting Service Manual This indicates the internal information for the remote control switch This does not have any specific meaning This is an indication for frequency of inverter The total value is indicated when two compressors are running Troubleshooting H ITACHI Inspire the Next Service Manual E Simple checking by 7 segment display 1 Turn ON all Indoor Inits connected to the Outdoor Unit During auto addressing the following items can be checked using the outdoor unit s on board 7 segment LED display 1 Disconnection of power supply to the indoor unit Turn ON the Outdoor Unit Auto addressing starts 2 Reverse connection of the operating line between the outdoor and indoor units Outdoor Unit Circuit Board PCB1 3 Duplication of indoor unit number E Checking method by 7 segment display Operating conditions and each part of refrigeration cycle can be checked by 7 segment disply and push switches PSW on the PCB1 in the Outdoor Unit During checking data do not touch the electric parts except for the indicated switches because 220 240V is applied to them Pay attention not to contact the tools
157. ial which can have sufficient pressure strength Use the table below to select the required pipe Nominal Diameter Thickness Copper type mm in mm 6 35 1 4 0 80 Roll 9 53 3 8 0 80 Roll 12 70 1 2 0 80 Roll 15 88 5 8 1 00 Roll 19 05 3 4 1 00 Pipe 22 23 7 8 1 00 Pipe 25 40 1 1 00 Pipe 28 60 11 8 1 00 Pipe 31 75 11 4 1 10 Pipe 34 93 1 3 8 1 25 Pipe 38 10 11 2 1 35 Pipe 41 28 1 5 8 1 20 Pipe 44 45 13 4 1 55 Pipe i Note Incase of using copper pipes for piping sections bigger than 19 05 mm 3 4 inches flaring work cannot be performed If necessary use a joint adapter 3 Select clean copper pipes Make sure there is not dust and moisture inside Blow the inside of the pipes with oxygen free nitrogen to remove any dust and foreign materials before connecting the pipes 4 After connecting the refrigerant piping seal the open space between Knockout hole and refrigerant pipes by using insulation material as shown below Insulation material f 4 y Field supplied refrigeration pipe Unit side g Insulation material Insulation material A caution Do not use a saw and a grindstone or other tools which cause copper powder When cutting pipes secure the part for brazing in accordance with both national an
158. ich is shown in 207 Area of operation the right figure is cancelled stoppage Suction air tem 10 perature C 8 0 Outdoor Temp C Note The operation may be OFF due to low outdoor temperature protection control since protection control is not cancelled 44 SMGB0059 rev 0 04 2009 Available optional functions H ITACHI Inspire the Next Service Manual E Change of defrost condition Press PSW1 and select the setting condition 1 at the change of defrost condition hi Setting condition Standard Specifications Cold area specification When change of defrost condition is NOT set When change of defrost condition is set Defrosting operation stop area Temperature conditions Defrosting operation stop area under defrosting Outdoor evaporating Outdoor evaporating temperature C temperature C Pipe Pipe operation A5 10 Outdoor temperature C P Outdoor tennperature C 10 Defrosting operation 10 Defrosting operation start area start area E SLo defrost setting Press PSW1 and select the setting condition 1 at the slow defrost setting Pot Indoor fan operation is stopped during the defrost operation However this function can be operated the indoor fan at low speed during the defrosting operation E Long piping setting Press PSW1 and select the setting condition 1 at the long piping setting Ut
159. ine with current sensor Phase V CTV If connected incorrectly malfunction or electrical component damage will occur 4 When mounting PCB and the sheet metal part for PCB pay attention not to clamp the electrical wiring together 5 Screws bushes and collars are used for fixing inverter PCB Check to ensure that the bushes and collars are used for PCB remounting If not used it may cause malfunction 6 In case of replacing control PCB set all the dip switches as the same position before replacing If not malfunction may occur 7 Do not apply strong force to the electric components and PCBs to avoid damage Remove the service cover according to the item Removing service cover 2 Open the power plate by rotating 90 degrees to the left according to the item Opening electrical box Power plate Check to ensure that LED201 Red of the PCB2 is OFF E Removing PCB2 Disconnect the wirings of connectors C CN2 CN206 and PCN301 on the PCB2 Disconnect the wirings of U and V on the transistor module After removing three 3 M3 screws remove the bushes and the collars from the PCB2 When remounting attach those bushes and collars E Removing Diode Module Disconnect all the wirings connected to the diode module as shown below Disconnect the wirings of terminal U V W on the diode module Remove two 2 M5 fixing screws on the diode module Remove the diode module from the electrical box
160. ine for comp insulate the wiring terminal with vinyl tape 8 Turn ON the main switch of O U This process is before removing and mounting electrical box 9 Set DSW4 4 to ON side O U PCB1 10 Perform the vacuuming from the check joint at low and high pressure side 11 Turn OFF the main switch of O U 12 Set DSW1 4 back to the original setting Refer to Process No 9 13 Check that the power line for comp and wiring are connected correctly 14 Recharge the collected refrigerant Process No 4 from the check joint at high pressure side For the remained quantity Open the liquid and gas stop valve completely and set DSW4 1 to ON side O U PCB1 Then recharge it from the liquid stop valve check joint during cooling operation 15 Check the liquid and gas stop valves are open completely O U Outdoor Unit LU Indoor Unit 7 Seg 7 Segment Comp Compressor SMGB0059 rev 0 04 2009 61 HITACHI Inspire the Next E The LED and the LCD are not indicated E Not operated Troubleshooting Service Manual If the fuses are blown out or a breaker is activated investigate the cause of the overcurrent and take the necessary action Phenomenon Cause Power failure or power is not ON Action ener ier Turn OFF the main switch Measure the voltage by means of the voltmeter Supply the power Short circuit supplied between the wires Short circuit of the wires to earth Blown out fuse or activation of the break
161. ion Model AIC ABN H Heat Pump F Inverter Connected number of Indoor Units F Multi E Cooling Only E Others L KPI Sa Category Content of Abnormality Leading Cause 01 Indoor Unit Activation of Protection Device Ei of Fan Motor Drain Discharge Clogging PCB 02 Outdoor Unit Activation of Protection Device Activation of B SH pipe clogging excessive refrigerant inert gas mixing 03 Abnormality between Indoor or Outdoor and Incorrect Wiring Failure of PCB Tripping of Fuse Outdoor or Indoor Power Supply OFF Transmission Abnormality between Inverter PCB and Outdoor PCB Transmission Paure Loone Connector If only ani controller is failed indications are as follows 04 Abnormality between Fan Controller and Outdoor PCB Number 1 Fan Controller Failure F1 04 Number 2 Fan Controller Failure F2 04 05 Supply phase Abnormality of Power Source Wiring Reverse Phase Incorrect Wiring Outdoor Voltage Drop Insufficient Power Capacity If voltage drop cause by fan controller is detected 06 Voltage Abnormal Inverter Voltage indications are as follows No 1 Fan Controller Failure F1 06 No 2 Fan Controller Failure F2 06 07 Decrease in Discharge Gas Superheat apie Refrigerant Charge Expansion Valve Open Cycle f 08 Increase in Discharge Gas Temperature Insufficient Refrigerant Ref Leakage Clogging or Expansion Valve Close Lock 09 n a 11
162. ion is performed However if the alarm occurs twice in addition to the first occurrence within two hours this alarm code is Is the thermistor on top of compressor normal 1 Yes Is the thermistor installed correctly on the compressor Yes Is it at cooling or heating mode when the alarm has occurred Refer to Characteristics of see position of the thermistor in the next page No gt Faulty thermistor thermistor No gt Install it correctly Heating Cooling Cooling process gt v v Heating process gt v unit PCB1 Check the high pressure and the compressor discharge gas temperature Calculate the superheat value in the outdoor Check the discharge pressure and the compressor discharge gas temperature Calculate the superheat value in the outdoor Is the superheat value under 10 C gt Are the refrigerant piping and the electric wiring matching No Match the refrigerant piping and the electric wiring under 10 C Yes unit PCB1 Is the superheat value gt Is the opening of the outdoor unit heat exchanger s expansion valve under 8 gt yes es Is the connector on the indoor unit PCB for the ex valve connected properly Plug the connector properly Are the connectors
163. ipment must comply with the local codes and the international codes Make sure that the power source voltage is correct An incorrect wiring may cause a breakdown of the transformer PSC 5HR or the units Especially DO NOT connect the power source to the terminal board for transmission DO NOT install the H LINK II wires along the power supply wire other signal wires and others If you install the H LINK II wires along those wires there may be a malfunction due to the electrical noise If you need to install the H LINK II wires near those wires provide a distance of 15cm or more Or alternatively insert the wires into the steel pipe and ground one end of the pipe SMGB0059 rev 0 04 2009 25 H ITACH i Electrical wiring Inspire the Next Service Manual Electrical wiring connection Modeles ae IARSNNIE Max 1 Outdoor Unit Power Supply Line The Power source for outdoor units must be made individually If not fire may occur in the worst case No 0 system outdoor unit No 1 system outdoor unit TB1 TB2 TB1 O 010 i L1 L2 L3 N 910 910 M 1 2 L1 L2 L3 N ojojo l KE e GEGEE e UJ hh L X X EE L RA A R Operating line shielded twisted pair cable ELB DC5V non pole transmission H LINK II system Distribution box or pull box Distribution box or pull box FUSE Main switch 3N 380 415V 50Hz m o o o TB1
164. k instruction HITACHI Inspire the Next Service Manual Outdoor Unit Model Serial No RAS Serial No RAS Serial No Accumulated operation time of comp 1 c UJ1 Accumulated operation time of comp 2 c UJ2 Accumulated operation time of comp 3 c UJ3 Accumulated operation time of comp 4 c UJ4 Accumulated operation time of comp 5 c UJ5 Outdoor alarm code AC Inverter stoppage cause code iTC Fan motor controller stoppage cause code FTC1 Fan motor controller stoppage cause code FTC2 AC Alarm code ITC Inv FTC Fan stop AC Alarm code ITC Inv FTC Fan stop Failure history 01 15 stoppage page stoppage page Total Indoor unit capacity x 1 8HP GP Total Indoor unit quantity AA Refrigerant system address GA RVR 4 way valve SVA F Solenoid valve CH Cranckcase heater DCFan Direct control fan Fant Constant speed fan 180 SMGB0059 rev 0 04 2009 Field work instruction Service Manual HITACHI Inspire the Next No Procedure Remarks 1__ Turn off the main switch of the outdoor unit 2 Remove the covers the thermistor the crankcase Make sure that the terminal part of the detached power heater the power wirings and other items according supply wires is not exposed by the winding insulation tape to the chapter Removing the Parts of the Oudoor and other items Unit 3 Attach the manifold to th
165. l current sensor When activating three times in 30 minutes 48 51 and 53 alarm is indicated 1 a Fan motor controller trip retry Automatic stoppage of fan controller Electronic thermal activation or Micro computer reset 4 a aS Daad Insufficient voltage excessive voltage retry Insufficient excessive voltage at the inverter circuit or CB connector part When it activates three times in 30 minutes the alarm code 06 is displayed a MA fe a High pressure decrease retry Pd lt 1 00MPa for 1 hour No alarm i 04 FIE tl AC fan motor protection device retry Activation of internal thermostat of outdoor AC fan motor When it activates three times in 30 minutes the alarm code 09 is displayed Ps Suction pressure of compressor Pd Discharge pressure of compressor SMGB0059 rev 0 04 2009 131 Spare parts Service Manual 8 Spare parts Contents 8 Spare parts HITACHI Inspire the Next 132 8 1 RAS 8 12FSNM E Structural and cycle parts 133 8 2 RAS 8 12FSNM E Electrical parts 135 SMGB0059 rev 0 04 2009 133 Spare parts HITACHI Inspire the Next Service Manual I pa cle Structural and cy SMGB0059 rev 0 04 2009 134 Spare parts
166. lable vi R R pt PSW2 PSW2 Sr PSW1 i PSW1 SET Available Available PSW3 PSW3 I Cancellation of out L ya Not Available Cold draft protec Not Available door hot start limit mw pt tion 1 h i PSW2 PSW2 SET PSW1 j Psw1 SET Available Available PSW3 I PSW3 Priority cooling ml yva Not Available Cold draft protec md r Not Available capacity mode mg pt tion 2 ar Z Ll PSW2 PSW2 SET PSW1 t PSW1 SET Available Available PSW3 I PSW3 A eee L ve rm Not Available Not prepared md y Not Available capacity mode rut el Z 1 Lt PSW2 PSW2 SEF PSW1 f PSW1 SET Available Available PSW3 I PSW3 Not prepared cr v Not Available Not prepared r va Not Available lln pt I hal PSW2 PSW2 ser TJ PSW1 ji PSw1 SET Available Available PSW3 I 0 I 0 SMGB0059 rev 0 04 2009 41 HITACHI Inspire the Next E Circulator function at heating thermo OFF Press RSW1 and select the setting condition 1 at the circulator function at heating thermo OFF Available optional functions Service Manual CMs In case that the fan speed is changed to LOW at heating Thermo OFF there is a case that the room air temperature is too high at heating Thermo OFF In this case the circulator function at heating thermo OFF is recommended and its function explains below The indoor fan operates for 2 minutes and stops for 6 minutes as a cycle when the activation conditions are satisfied
167. lation HITACHI Inspire the Next Service Manual 1 3 Outdoor units installation A WARNING Install the outdoor unit with sufficient clearance around it for operation and maintenance as shown in the next figures Install the outdoor unit where good ventilation is available Do not install the outdoor unit where is a high level of oil mist salty air or sulphurous atmosphere Install the outdoor unit as far as practical being at least 3 meters from electromagnetic wave radiator such as medical equipment Keep clearance between the units of more than 50 mm and avoid obstacles that may hamper air intake when installing more than one units together Install the outdoor unit in the shade or not exposed to direct sunshine or direct radiation from high temperature heat source A CAUTION Check to ensure that the foundation is flat level and sufficiently strong Install the unit in a restricted area not accessible by the general public Aluminum fins have very sharp edges Pay attention to the fins to avoid injury A CAUTION Pay attention to the followings to run through the cables under the unit using conduit for piping and wiring works The pipe cover is required to remove before performing piping and wiring works 1 Attach the pipe cover to avoid entering rats or other small animals into the unit 2 Completely seal the conduit inlet with sealing materials 3
168. ld be remained at OFF position 22 SMGB0059 rev 0 04 2009 Electrical wiriing HITACHI Inspire the Next Service Manual DSW2 Optional function setting Setting is required when optional functions are required ON Setting before shipment pee 123456 ON FEE 123456 Function setting ON External input output selection pee eee 123456 DSWS3 Capacity setting No setting is required RAS 8FSNM E ON AWA 1234 RAS 10FSNM E ON na a a 1234 RAS 12FSNM E ON AAA 1234 DSW4 and RSW1 Refrigerant cycle number setting Setting is required Setting for the tenth digit first digit Seting for the units digit last digit Set by inserting slotted screwdriver into the grove DSW5 End terminal resistance No setting is required Setting before shipment ON SMGB0059 rev 0 04 2009 23 H ITACH i Electrical wiring Inspire the Next Service Manual DSW 6 Height difference Setting is required Setting before shipment ON I 123 The indoor unit is located higher than ON outdoor unit 20 to 30 m Aud 123 Fine tuning of heating capacity ON EAE 123 JP1 6 Jumper cable Power supply JP1 JP2 JP3 JP4 JP5 JP6 380 415V 50Hz O O X X O O O with jumper cable X without jumper cable Setting for transmitting It is required to set the refrigerant cycle numbers and e
169. lty PCB a correctly 4 Replace PCB ig Is fan motor speed control y command to fan e Faulty PCB gt motor correctly 5 5 Disconnect CN550 on PCB when performing If 2V or over are applied between CN550 5 to CN550 3 on PCB for 10 sec Approx after No starting operation the PCB is normal Note The voltage may not be conducted squen tially after 10 sec to perform the above operation Faulty fan motor Replace it SMGB0059 rev 0 04 2009 93 HITACHI Inspire the Next Troubleshooting Service Manual Alarm code Description 7 Activation of the protection device for the indoor fan motor except RCI and RPK 130 C E The RUN LED flickers and ALARM is displayed on the remote control switch E The unit number the alarm code and the unit code are alternately displayed on the set temperature section The unit number and the alarm code are displayed on the display of the outdoor unit PCB This alarm code is displayed when the temperature of the internal thermostat for the indoor fan motor is higher than Does the indoor fan run Yes Phenomenon Yes inui No No Is the continuity present at Is the fan motor the internal thermostat of the gt hot Replace the motor indoor fan motor i Yes No Is the connection bad at the Repair the wiring and gt connector th
170. ly high discharge pressure E The RUN LED flickers and ALARM is displayed on the remote control switch E The unit number the alarm code and the unit code are alternately displayed on the set temperature section The unit number and the alarm code are displayed on the display of the outdoor unit PCB1 Incase that compressor is operated under the condition that is higher than 3 8MPa of suction pressure Pd for 1 minute all compressors are stopped and retry operation is started after 3 minutes However the alarm code is indicated when same phenomenon is occurred at two times within the next 30 minutes PCB1 Control PCB in Outdoor Unit PCB Indoor Unit PCB Yes Is there a leakage of SVA gt Replace SVA if faulty No Is the outdoor unit stop valve Yes closed gt Open the stop valve No No Check the connection of the ae 2 rae Is the high pressure sensor OK amp circuit board connector Replace the high pressure sensor if faulty Yes Are the ex valves fully closed Yes Check the circuit board and and locked connection of the circuit board Check the outdoor electronic expansion valve connector Replace the electronic t during the cooling process and the indoor expansion valves if faulty l No electronic expansion valve during the heating process Are the electric wiring and the Yes refrigerant piping between the
171. m cece Description j i Activation of the safety device in the outdoor unit E The RUN LED flickers and ALARM is displayed on the remote control switch E The unit number the alarm code and the unit code are alternately displayed on the set temperature section The unit number and the alarm code are indicated on the display of the outdoor unit PCB1 This alarm is indicated when one of safety devices is activated during compressor running Is the connbector PCN8 connected to the PCB1 correctly Is there conduction of PCN8 during operation stoppage Does CMC1 ON when starting Does CMC1 turn ON for more than 3 seconds y Yes PCB1 Outdoor unit printed circuit board gt Connect PCN8 correctly No No Are the faston tubs No of high pressure SW PSH connected correctly Yes No Connect tha faston tubs correctly Is the voltage between PCN9 1 to 3 on PCB1 220V or 240V when operation starting No Yes Faulty high pressure Normal PCB1 v Is the coil of CMC1 Yes SW PSH Is the protective device still Faulty PCB1 operating Is the a contact Yes of CMC1 ON Faulty PCB1 breaking Check activation of the following safety devices Remove the cause after checking High Pressure Switch PS
172. mer Primary side 220 V or 240 V Secondary side o D G 2 le gt ke c fo x gt O Check the wiring connection on the PCB Thermistor connectors Connector of the remote control cable Connector of the transformer Each connector in a high voltage circuit Check the connectors according to the Electrical Wiring diagram 11 2 Burnt out compressor due to an insufficient refrigerant charge E Question and answer for the field work Example 1 Burnt out compressor due to an insufficient refrigerant charge Phenomenon After commissioning the alarm code 08 sometimes occurred and the compressors were burnt out after operating for two months Cause Countermeasure The refrigerant piping work was performed during the summer season The additional refrigerant was not sufficiently charged from the discharge gas side This insufficient refrigerant charge resulted in the overheating of the discharge gas and the oil deterioration which was finally due to the separated operation despite the alarm code 08 1 The compressor was replaced with a new compressor 2 The correct refrigerant amount was charged according to the refrigerant piping length and the connected indoor units Remarks Additional refrigerant charge Open the liquid stop valves slightly when you charge the additional refrigerant from the check joint of the liquid stop valves the discharge gas side
173. move and reassemble the reversing valve by cooling with wet cloth Reassemble the parts in the reverse order of removing procedures When SVF solenoid valve is removed fix it according to the item Removing solenoid valve Brazing Reversing valve Brazing RZ URS v Screw Reversing valve ga Cover by wet cloth Brazing Compressor SMGBO0059 rev 0 04 2009 151 HITACHI cee Inspire the Next Seneatianiel Service Manua 1 Remove the service cover and rear cover according to the item Removing service cover and the item Removing the lower part of service cover and rear cover 2 Collect the refrigerant from the check joint according to the item Removing compressor 3 Remove the coil according to the item Removing electronic expansion valve coil 4 Remove the brazing as shown in the figure below Electronic Expansion Valve EVO 2 brazing parts Perform the brazing to remove and reassemble the electronic expansion valve by cooling with wet cloth Protect the connecting wires and pipe insulation from brazing work 5 Reassemble the parts in the reverse order of removing procedures Electronic expansion valve EVO Brazing part 152 SMGB0059 rev 0 04 2009 meres HITACHI Inspire the Next Service Manual Remove the service cover and rear cover according to the item Removing service cover and the item Removing
174. move looseness and replace the connector Internal Thermostat for Outdoor Fault Fan is Activated in Heating Faulty int i process auty intema Incorrect thermostat contact Incorrect connection 106 SMGB0059 rev 0 04 2009 Check the connection Connect correctly Troubleshooting Service Manual HITACHI Inspire the Next Alarm code Description _f H Activation of inverter overcurrent protection device 1 E The RUN LED flickers and ALARM is displayed on the remote control switch E The unit number the alarm code and the unit code are alternately displayed on the set temperature section The unit number and the alarm code are displayed on the display of the outdoor unit PCB1 The alarm code is indicated when inverter electronic thermal protection is activated at six times within 30 minutes Retry operation is performed up to five times Conditions of Activation Inverter current with 105 of the rated current runs for 30 seconds continuously or Inverter current runs intermittently and the accumulated time reaches up to 3 minutes in 10 minutes Is the cause of stoppage FE of troubleshooting by 7 segments display 2 or 4 gn PCB1 Control PCB in Outdoor Unit PCB2 Inverter PCB y Restart operation Is the compressor current larger than activation current 1 Yes gt Refer to next page m Is disc
175. mperature Increase a Level of Detection SMGBO0059 rev 0 04 2009 163 HITACHI ee Inspire the Next Service Manual When the temperature of internal thermistor exceeds more than 100 C an abnormality is detected b Function When abnormalities are detected the inverter compressor is stopped and the signal code of stoppage cause is transmitted to PCB1 c Cancellation of Protection Function Transmission for signal code of stoppage cause is canceled when a stopping order is issued or main power source is cut off 6 Earth Detection a Level of Detection When the starting current of the compressor reaches 80 of the overcurrent protection value an abnormality is detected b Function When abnormalities are detected the inverter compressor is stopped and the signal code of stoppage cause is transmitted to PCB1 c Cancellation of Protection Function Transmission for signal code of stoppage cause is canceled when a stopping order is issued or main power source is cut off 1 4 Overload C a Level of Detection When the output current exceeds 105 of the maximum output current an abnormality is detected b Function An overload signal is issued when output current exceeds 105 of the maximum output current and the frequency decreases For 10 seconds after the output current decreases lower than 88 of the rated current the operation is performed with the compressor frequency limited to the upper level
176. nd terminal resistance for this H LINK or H LINKII system Setting of Refrigerant Cycle No In the same refrigerant cycle set the same refrigerant cycle number for the outdoor unit and the indoor units as shown below As for setting indoor unit refrigerant cycle number set the RSW2 and DSW5 on the indoor unit PCB Setting switch ten digit unit digit PET 123456 Outdoor unit DSW4 Indoor unit H LINK II DSW5 Example in case of setting refrigerant cycle ON number 25 pea 123456 DSW and RSW setting before shipment is 0 Maximum in setting refrigerant cycle number is 63 24 SMGB0059 rev 0 04 2009 Electrical wiriing HITACHI Inspire the Next Service Manual 3 3 Common wiring A CAUTION Use the shielded twisted pair cable or the shielded pair cable for the transmission cables between the indoor unit and the outdoor unit Connect the shielded part to the earth screw in the electrical box of the indoor unit as shown below Also use these cables for the operation wiring between one indoor unit and another indoor unit H LINK connection Shielded part Transmission cables Power supply cables o 000 Earth screw gjlglele OOJO Connect the electrical cables between the indoor unit and the outdoor unit as shown in the wiring diagram Make sure that the terminals for the power
177. ndoor unit Phenomenon The operation sound at the HIGH speed was abnormally high Cause The indoor units were installed without the ducts Since there scarcely was any external static pressure an abnormally big air volume was supplied This resulted in a higher air speed through the heat exchanger Damper Indoor unit 4 1 x A Filter At gt gt gt Countermeasure In order to reduce the airflow rate a plate that is used as a damper at the discharge gas side 1 1 was added Remarks Note that the running current is increased when no external pressure is given to the indoor unit This results in an overheating SMGBO0059 rev 0 04 2009 173 Field work instruction HITACHI Inspire the Next Service Manual 11 5 Alarm Code 31 E Question and answer for the field work Example 4 Alarm code 31 Phenomenon Alarm code 31 sometimes occurred and the system stopped Cause The combination of the indoor units and the outdoor unit was the following ON Power source y Fon oy OFF FON FON Son This system was used in a tenant building One of tenant s customers turned off the main switch for the indoor unit while other indoor units are running This results in a di
178. ng material may occur when you are removing the compressors 13 Turn OFF the main switch of the outdoor unit 14 Perform the replacement of the compressor and the Make sure that you follow the instructions change of the refrigerant oil according to the section Replacing the Compressor 15 Perform the vacuum from the check joint of the low If you collect the refrigerant only on the low pressure side pressure side Ain 11 You cannot perform the vacuum of the refrigerant from the check joint of the high pressure side 16 Open the liquid stop valve and the gas stop valve completely when you finish the vacuum 17 Make sure that the power is turned OFF and attach the following items the power supply wire the thermistor the crankcase heater the 63H wiring the panel and the nut 18 Set the DSW back to the original setting Make sure that all the wirings to the compressor are connected correctly 19 Recharge the refrigerant that is collected in the If the replacement of the compressor takes more than two process by the stop valve of the liquid side during the hours an additional change of the refrigerant is necessary cooling at the TEST RUN mode Additional Change Replacing Time 2 hours x 0 5kg 182 SMGB0059 rev 0 04 2009 f AENOR k CE Eg Empresa f ill REGISTERED MALAYSIA MS ISO9NIL Etana een SIRIM MS 180 14031 Hitachi Air Conditioning
179. nit ex valve 100 o Remove the sudden changes of load like short path of an outgoing air to the air intake of the outdoor unit or the cause of frequent thermo ON OFF Are the connectors of the outdoor unit heat exchanger s properly Plug the connectors properly Nee See connector numbers in the next page x Is the refrigerant correctly charged electric expansion valve connected an Ni Is the gas leaking No Charge the correct refrigerant volume Refer to TC Check the exp valve SMGB0059 rev 0 04 2009 86 ve Repair the leaks of gas Correctly charge the refrigerant Troubleshooting Service Manual E Characteristics of thermistor Thermistor characteristics HITACHI Inspire the Next Resistance of thermistor kQ 200 100 0 25 50 100120 150 Air temperature C Action Phenomenon Cause Check item Turn OFF the main switch Excessively high discharge gas temperature at top of compressor Ref cycle is different from the electrical system Check the ref cycle and the electrical system Repair the wiring Undercharged refrigerant Check pressures Correctly charge the refrigerant Faulty Ex valve Check expansion valve refer to procedure of checking other main parts Replace the ex valve if faulty Fault RePised E
180. nk Connection is performed Set the terminal resistance to ON when CN2 is removed Set the terminal resistance to OFF when CN2 is reconnected SMGB0059 rev 0 04 2009 79 HITACHI Inspire the Next Troubleshooting Service Manual Phenomenon Cause Check item Action Turn OFF the main switch Power failure or no power supply Measure the voltage by means of the tester Supply the power Blown out fuse for the power source or activation of the outdoor unit breaker Short circuit between wires Check the insulation material for breaks Remove the short circuit and replace the fuse Short circuited wire to ground Measure the insulation resistance Remove the short circuit to ground and replace the fuse Faulty comp motor Measure the resistance between the wires and the insulation resistance Replace the comp and the fuse Faulty outdoor unit fan motor Measure the resistance between the wires and the insulation resistance Replace the outdoor unit fan motor and the fuse Blown out fuse for control circuit or activation of outdoor unit breaker Short circuit between wires Check the insulation material for breaks Remove the short circuit and replace the fuse Short circuit of the control circuit to ground Measure the insulation resistance Remove the short circuit and replace the fuse Faulty solenoid coil for the magnetic switch for the comp mot
181. not be activated n Cold draft protection 1 Press PSW1 and select the setting condition 1 at the cold draft protection 1 Fh so the cold draft protection can be set When the minimum Indoor unit discharge air temperature falls down to 12 C and below at cooling operation outdoor fan stops and compressor frequency forcibly decreases to prevent a drop in discharge air temperature E Cold draft protection 2 Press PSW1 and select the setting condition 1 at the cold draft protection 2 Fic so this function can be set When Indoor unit minimum discharge air temperature falls down to 10 C and below at cooling operation the compressor stops In this case stoppage code number 28 is given SMGB0059 rev 0 04 2009 47 Test run HITACHI Inspire the Next Service Manual 6 Test run Contents 6 Test run 49 6 1 Checking procedure before the test run 50 6 2 Test run procedure from the outdoor unit side 52 6 3 Check list 53 6 4 Judgement system for refrigerant amount 56 SMGB0059 rev 0 04 2009 49 HITACHI Test run Inspire the Next Service Manual 6 1 Checking procedure before the test run Test run should be performed according to the Table 6 2 And use the Table 6 1 for recording test run A WARNING E Do not operate the system until all the check points have been cleared A Check to ensure that the refrigerant piping and transmission between outdoor unit and indoor
182. nt is detected Instantaneous Overcurrent When the current detected by current sensor exceeds 105 of the rated current continuously for 30 seconds or for 3 5 minutes in total during a 10 minutes period overcurrent is detected Electric Thermal Relay b Function When abnormalities are detected the inverter compressor is stopped and transmit the signal code of stoppage cause to PCB1 c Cancellation of Protection Function Transmission for signal code of stoppage cause is canceled by stopping order is issued or main power source is cut off Protection of transistor module and IPM a Level of Detection When some of the output terminals between U and V V and W W and U of transistor module or IPM are short circuited an abnormality is detected When the running current of transistor module or IPM reaches Maximum Rated Current x 105 an abnormality is detected When an internal temperature is measured by internal thermistor of transistor module or IPM an abnormality is detected When the control voltage of transistor module or IPM decreases an abnormality is detected b Function When abnormalities are detected the inverter compressor is stopped and the signal code of stoppage cause is 1 O transmitted to PCB1 c Cancellation of Protection Function Transmission for signal code of stoppage cause is canceled when a stopping order is issued or main power source is cut off Fin Te
183. nual Abnormal operation of the devices Cont HITACHI Inspire the Next Phenomenon Cause Check item Action Turn OFF the main switch Cooling or heating process with an abnormal sound Foreign particles inside of the fan casing Visually inspect it Remove the foreign particles Indoor unit fan runner is hitting the casing Visually inspect it Adjust the position of the fan runner Outdoor unit propeller fan is hitting the shroud Visually inspect it Adjust the position of the propeller fan Faulty Installation Check that each part is tightly fixed Tightly fix each part Liquid ref compression Check expansion valve opening Ensure superheat Abnormal sound from the compressor Wear or breakage of the internal comp parts Abnormal Sound from the Inside of the Compressor Replace the compressor No heating by the oil heater Check the Resistance Oil Heater Fuse Replace the oil heater or the fuse Humming sound from the magnetic conductor Check the surface of the contacts Replace the magnetic switch Abnormal vibration of the cabinets Check each fixing screw Tightly fix each screw Outdoor fan does not operate when the compressor operates Obstacle at the outdoor fan Check the obstacles Remove the obstacles Watching condition for the heating process Wait for the switching of the 4 Way Valve 1 3 minutes
184. of P Enlarged view of Q Capacitor Diode module Resistor co O O eNe o NFA CS2 cst IPM CB2 Noise filter 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Transistor module Capacitor PCB2 Inverter PCB Current sensor SMGB0059 rev 0 04 2009 157 Servicing HITACHI Inspire the Next Service Manual 158 SMGB0059 rev 0 04 2009 Main parts Service Manual 10 Main parts HITACHI Inspire the Next Contents 10 Main parts 157 10 1 Inverter 158 10 1 1 Specifications of inverter 158 10 1 Inverter 158 10 1 1 Specifications of inverter 158 10 1 2 Inverter time chart 160 10 1 3 Protective Function 161 10 1 4 Overload Control 162 10 2 Thermistor 163 10 2 1 Position of thermistor 163 10 2 2 Resistance value of the thermistor 163 10 3 Electronic expansion valve 166 10 3 1 Electronic expansion valve for the outdoor unit 166 10 4 Pressure sensor 167 10 5 Scroll compressor 168 10 5 1 Reliable mechanism for low vibrating and low sound 168 10 5 2 Principle of compression 168 SMGB0059 rev 0 04 2009 159 10 HITACHI Inspire the Next 1
185. of the next indoor Indoor unit aa Outdoor unit H Link 1 II Symbol Name Symbol Name MC1 DC Motor for Inverter Compressor SVA Solenoid Valve MOF1 DC Motor for Outdoor Fan SVF Solenoid Valve MOF2 AC Motor for Outdoor Fan RVR Reversing Valve MIF Motor for Indoor Fan PSH High Pressure Switch MS Motor for Auto Louver Ps Suction Gas Pressure Sensor MV Electronic Expansion Valve for Indoor Unit Pd Discharge Gas Pressure Sensor MV1 Electronic Expansion Valve for Outdoor Unit CTu v Current Sensor CMC1 Magnetic Contactor for Compressor CH Crankcase Heater SMGB0059 rev 0 04 2009 31 HITACHI Inspire the Next 4 2 Outdoor Units PCB Control system Service Manual E PCB drawing LED INDICATION soz ss n F LED1 Power Source for PCB1 Normal 0 im Aime alll x 14 Red Condition Activated Abnormal 4 LI O ag Li E Condition Deactivated h This LED2 indicates the fii aff transmission state between Hue a T k js
186. or Measure the resistance of coil Replace the magnetic switch and the fuse Failure of the outdoor unit fan motor Measure the resistance between the wires and the insulation resistance Replace the outdoor unit fan motor and fuse PCB1 power circuit failure Measure PCB1 output voltage 2 Replace PCB1 Disconnected wires insufficient contacting or incorrect connection Between outdoor unit and indoor unit Power source wiring for the outdoor unit Check the continuity of the wires Check for looseness of the connection screws Check the terminal Nos Replacing wires repairing and tightening the screws and the correct wiring Faulty PCB outdoor unit indoor unit Disconnected wires to PCB Check the connections Correctly connect the wires Faulty PCB Replace PCB if faulty Incorrect wiring Disconnected wire insufficient contacting Check the continuity and the looseness of connection screws Replacing wires repairing and tightening the screws Incorrect wiring Check the terminal Nos Correctly connect the wires 2 VCC12 GND2 12VDC VCC05 GND1 5VDC VCC12 GND1 12VDC VCC15 GND1 15VDC VCC24 GND1 24VDC VCC12T GND1 12VDC SMGB0059 rev 0 04 2009 80 Troubleshooting HITACHI Inspire the Next Service Manual Alarm code Description mt _f Abnormal transmission between Inverter and the Outdoor Unit PCB1 2 E The
187. or unit 25 3 4 Wire size 27 SMGB0059 rev 0 04 2009 19 Electrical wiring HITACHI Inspire the Next Service Manual 3 1 General check A DANGER Before installing the electrical wiring or before performing a periodical check turn OFF the main switch to the indoor unit and the outdoor unit For safety reasons be sure that the indoor fan and the outdoor fan have stopped Prevent the wires from touching the refrigerant pipes the plate or cutting edges and the electrical components inside the unit to prevent them getting damaged In worst cases a fire may occur Tightly secure the wires with the cord clamp inside the indoor unit NOTE Incase of performing a test run operation take especially care because some security features are disabled the units will operate during 2 hours without Thermo OFF and the 3 minute guard for compressor protection will not be effective during the test Fix rubber bushes with an adhesive on the panel when the conduit pipes to the outdoor unit are not used In forced stopped compressor mode the compressor operation is OFF 1 Make sure that the field selected electrical components main switches circuit breakers wires conduit connectors and wire terminals have been properly selected according to the electrical specifications in this service manual Make sure that the electrical components comply with the National Electrical Code NEC 2
188. or units The signal will be sent even when the alarm occurs from one 1 indoor unit Setting Example Alarm Signal at Output 2 between 1 and 3 pins of CN7 Auxiliary relay 3P Connector housing Outdoor unit PCB1 CN7 Connector Wiring diagram example of alarm signal SMGB0059 rev 0 04 2009 39 Available optional H ITACH l functions Inspire the Next Service Manual E Output 2 Compressor ON signal Control function No 3 Auxiliary relay contacting RYa is closed during the compressor operation Setting Example Compressor ON Signal at Output 2 between 1 and 3 pins of CN7 Auxiliary relay 3P Connector housing ee Outdoor unit PCB1 CN7 Connector Wiring diagram example of compressor ON signal E Output 2 Defrosting signal Control function No 4 Auxiliary relay contacting RYa is closed during the defrosting Setting Example Defrosting Stoppage at Output 2 between 1 and 3 pins of CN7 Auxiliary relay 3P Connector housing Outdoor unit PCB1 CN7 Connector Wiring diagram example of defrosting signal Table 5 2 Specifications of required main parts Parts Specifications High Power Relay LY2F DC12V made Auxiliary Relay by OMRON y Do not use the relay with diode built in Refer to the table 5 1 for the connector parts 40 SMGB0059 rev 0 04 2009 Available optional functions H ITACHI Inspire the Next
189. otection Transistor module or IPM 1 Short Circuit Trip of Arm 2 Instantaneous Overcurrent Trip 3 Instantaneous Overcurrent Trip 4 Electronic Thermal Trip Condition is maintained longer than 30 seconds or accumulated longer than 3 minutes during 10 minutes sampling time Transistor module or IPM has four protection function for self protection 1 Some of the output terminals between U and V V and W W and U has a short circuit 2 Running current reaches the maximum rated current 3 Abnormal temperature is measured by internal thermistor 4 Control voltage decreases abnormally Overload Control Overload control as a current greater than Rated Current X105 Overload control release at a current smaller than Rated Current X 88 Fin Temperature Increase The unit is stopped when the IPM temperature is higher than 100 C Earth Detection The unit is stopped when the compressor is earthing O Note Characteristics are fluctuated by the current minimize control SMGB0059 rev 0 04 2009 161 HITACHI Inspire the Next Main Circuit Power Source Frequency Instruction Output Voltage Soft Start Stop Frequency Failure Signal Activation of Protection Device Overload Signal Charged Indication LED2 on PCB2 Frequency LOW Frequency HIGH All bit 1 All bit 1 Operation ras Main parts Service Manual 162 gt Th
190. ove the service cover according to the item Removing service cover 2 Disconnect all the wires connected with the relay PCB PCB3 PCBS 3 Clamp the hook of the four 4 holders by long nose pliers and remove by sliding toward front side Enlarged view of P Holder Ponzo C 1 Long nose pliers PCB5 I ___ Control PCB PCB1 Relay PCB PCB3 PCB5 Holder 154 SMGB0059 rev 0 04 2009 aa HITACHI Inspire the Next Service Manual A Danger Do not touch the electrical parts when LED201 Red on the PCB2 is ON to avoid an electrical shock O Notes 1 When replacing the transistor module IPM and diode module DM on heat radiation fin slightly apply the heat conducting silicon grease Manufacturer Shin Etsu Chemical Co Ltd Product No G 746 over the fin contact surface Use the silicon grease provided as accessory Service Parts No P22760 2 Identify the terminal Nos with the mark band Nos when reassembling If connected incorrectly malfunction or electrical component damage will occur 3 Correctly insert two wires of U and V phases for the power cable of inverter compressor into the current sensor CTU and CTV on PCB2 Connect Phase U power cable with the current sensor Phase U CTU and Phase V power l
191. ow 6 gt 7 gt 8 gt 9 Control Function No Demand Control Adopting self demand function which drastically decreases power consumption has largely improved energy saving Excesive power supply consumption exceeding the power setting range is restricted q Power setting Selectable from 100 80 70 and 60 of the rated power consumption for cooling operation Power consumption Morning Daytime Nigth Operating hours 46 SMGB0059 rev 0 04 2009 Available optional functions HITACHI Inspire the Next Service Manual E Wave function setting Press PSW1 and select the setting condition 1 so that the wave function setting LIE While this function is activated the maximum limit of running current is changed from 60 to 100 as shown in the figure Wave function cannot be available when the setting condition 1 at the fixing of demand function dE is selected and the demand current control from the external input signal is set Electricity consumption 100 Electricity consumption 60 to 100 20min 10min 20min 10min 20min 10min 20min a Wave function can be activated when demand function is selected at one of the input terminal indications and lt 3 0 The minimum limit of running current control is according to the set value of the demand function If demand function is not set at the input terminal indication this function can
192. per cover Pj F and remove the upper cover upward ae Upper cover 140 SMGB0059 rev 0 04 2009 Ron meres HITACHI Inspire the Next Service Manual 2moving the lower part of service cover and rear cove Remove the service cover according to the item Removing service cover Remove five 5 screws fixing the lower part of service cover and remove the lower part of service cover by pulling towards front side Remove the upper cover according to the item Removing upper cover Remove fourteen 14 screws fixing the rear cover and remove the rear cover by pulling towards rear side Air inlet grille electrical box valve stay Electrical box Aire inlet grille Fixing portion for Air outlet grille Rear cover outdoor temperature Valve stay themistor Screws for air inlet grille 5x Rear cover Lower part of service cover 5 Removing outdoor fan motor Remove the service cover according to the item Removing service cover Remove the air outlet grille according to the item Removing air outlet grille Remove the upper cover according to the item Removing upper cover Remove the propeller fan by removing the cap nuts and washers fixing the propeller fan onto the motor shaft If it is difficult to remove the fan use puller Remove the DC fan motor connector from the PCB5 PCN203 white and CN
193. pire the Next Service Manual PCB5 PCN203 CN201 for DC Fan Motor PCB3 PCN404 for AC Fan Motor 7 Disconnect the compressor wires from the compressor terminal box 8 Reassemble the electrical box in the reverse order of removing procedures Screw Deda Lt aeeti hati by n Screw Screw Portion plate Elecrical box When mounting the lectrical box hook these portions to the portion plate as shown 2 portions Front side SMGB0059 rev 0 04 2009 143 HITACHI re Inspire the Next l Senca Manal Service Manua 1 Remove the service cover and the lower part of the service cover according to the item Removing service cover and the item Removing the lower part of service cover and rear cover In case that the outdoor unit is installed to the wall closely remove the outdoor unit from the wall 2 Collect the refrigerant from the check joint Collect the refrigerant from the liquid stop valve gas stop valve and check joint at piping 3 Open the soundproof cover wrapping around the compressor and remove the terminal box cover at the compressor Disconnect the compressor wires in the terminal box and remove the soundproof cover NOTE Check to ensure each terminal Nos and indications If wires are connected in incorrect order at reassembling it will lead to compressor failure 4 Remove the holder for Td thermistor and the thermistor on the top of the compressor according to the fi
194. pressure Failure of bypass solenoide valve Checking for leakage of solenoid valve Replace solenoid valve Malfunction or internal leakage of the 4 way valve Check the Temp Difference between the Inlet and the Outlet of 4 Way Valve Replace the 4 way valve Discharge temp of the indoor unit is unstable valve of the indoor unit in Check the expansion the same system Replace the failed expansion valve of the indoor unit 68 SMGB0059 rev 0 04 2009 Troubleshooting Service Manual HITACHI Inspire the Next Abnormal operation of the devices Cont Action Phenomenon Cause Check item Turn OFF the main switch Indoor heat load is greater than the heating capacity Calculate the heat load daar ia Correctly charge the eu leakage a refrigerant after the insufficient refrigerant Measure superheat charge gas leakage check and repairing Excessively small Measure the field Use thespeci ed pipes diameter or long piping supplied piping P pip Check for clogging Remove the clogging Check thie connection Replace the connector cord and the connector Failure or malfunction of Is there an operation Replace th coll the expansion valve sound from the coil p Is the thermistor on the Replace th thermistor compressor normal p Is the thermistor installed Correctly install the correctly on compressor thermistor Insufficient heating Check the temp F process Clogging of I U O U
195. protecting the system from the low compression ratio E The RUN LED flickers and ALARM is displayed on the remote control switch E The unit number the alarm code and the unit code are alternately displayed on the set temperature section The unit number and the alarm code are displayed on the display of the outdoor unit PCB1 This alarm code is displayed when a compression ratio Pd 0 1 Ps 0 06 is calculated from a discharge pressure Pd MPa and a suction pressure Ps MPa and the condition which is lower than 1 8 occurs three or more than three times in one hour lt Does the inverter op erate gt No if Yes Check the inverter Does the compressor operate No Check the compressor and the power cable Yes Is the four way valve spindle No mounted at the middle position Replace the four way valve if faulty Yes Are the high pressure sensor No Replace the high pressure and the low pressure sensor OK gt sensor or the low pressure sensor if faulty l Yes Is there a leak in the solenoid Yes valve for the hot gas bypass gt Replace SVA if faulty SVA No Check whether the inlet air gt temperature is too low at the indoor units or the outdoor units Phenomenon Cause Check item Acton Turn OFF Main Switch Excessively low compression ratio Inverter is not functioning Check the inv
196. r and the alarm code are displayed on the display of the outdoor unit PCB1 This alarm code is displayed when the thermistor is short circuited less than 0 24 KQ or cut greater than 840 kQ during the cooling process or the heating process The system is automatically restarted when the fault is removed PCB1 Control PCB in Outdoor Unit PCB Indoor unit PCB Is THM2 connected to intake No of PCB Connect it Yes Is the resistance of THM2 between 0 24kQ and 840kQ Faulty thermistor y Indoor unir air inlet 1 thermistor THM2 In case of 4 way NI cassette Faulty PCB Refer to alarm code 11 for thermistor resistance 7 Action Phenomenon Cause Check item ctio Turn OFF the main switch Fault Check the resistance Replace the thermistor if faulty Faulty air outlet thermistor Repair the wiring and Incorrect connection Check the connection connections Replace PCB and Faulty PCB check the operation Replace PCB if faulty SMGB0059 rev 0 04 2009 89 Troubleshooting HITACHI Inspire the Next Service Manual Alarm code Description 1 Abnormal operation of the thermistor for the indoor unit heat exchanger l liquid refrigerant pipe temperature freeze protection thermistor The RUN LED flickers and ALARM is displayed on the remote control switch E The unit number the alarm code and the unit code ar
197. re of two compressors is indicated p p Thermo temp of the Le 7 gt pies on a iae 11 remote control switch sama ee If the temperature is higher than 126 C i275 Troubleshooting HITACHI Inspire the Next Service Manual Indication of micro computer input output PCB Part name Heating thermo ON Relay x a Alarm 12 Micro computer input LL Cooling thermo ON H2 Relay for drain pump MD and or output in indoor unit Im I en R dew heater EHW a E O t 52H Relay for electric heater CEH t 52H Y211 Relay for 4 way valve i i Y52C1 Ri Micro computer input rou _ ery TOP COMPrESSOr 13 output in outdoor unit LZ Y52C2 Y211 NS2C1 Y20A Relay for Selonoid Valve SVA2 EN tr Y20B Relay for Selonoid Valve SVA1 1 Y20A Y20F Relay for Selonoid Valve SVF Nam Outdoor Relay for Outdoor Fan Y212 utdoor fan Ean YCH Relay for Cranckcase heater Indication of unit stoppage cause og Operation OFF Power OFF yva of Thermo OFF Note 1 14 Cause of stoppage mrt ht 1 2 Aam Note 2 g3 Freeze protection overheating protection l gs Instantaneous power failure at outdoor unit reset Note 3 rai Instantaneous power failure at indoor unit reset Note 4 aq Stoppage of cooling process due to low outdoor temperature stoppage of heating process due to high outdoor temperature o Compressor quan
198. rection g Base of outdoor unit Secure the outdoor unit with the anchor bolts Fix the outdoor unit to the anchor bolts by special washer of factory supplied accessory Max 21 mm When installing the outdoor unit fix the unit by anchor bolts Refer to figure regarding the location of fixing holes When the mark dimension is secured piping work from bottom side is easy without interference of 4 16x23 5 hole foundation for anchor bolt Example of fixing outdoor unit by anchor bolts Max 21 mm after cut A Cut this portion when this type of anchor bolt is used A If not it is difficult to remove MESANE COVEN Concrete Anchor bolt SMGB0059 rev 0 04 2009 9 HITACHI Inspire the Next 4 Fix the outdoor unit firmly so that declining making noise and falling down by strong wind or earthquake is avoided When installing the unit on a roof or a veranda drain water sometimes turns to ice in a cold morning Therefore avoid draining in an area where people often use because it is slippery Incase of the drain piping is necessary for the outdoor unit use the drain kit DBS 26 Optional Parts The whole of the base of the outdoor unit should be installed on a foundation When using vibration proof mat it should also be positioned the same way When installing the outdoor unit on a field supplied frame use metal plates to adjust the frame width for st
199. rform the replacing compressor and oil return circuit if necessary ae Procedure Remarks 1 Turn OFF the main switch of O U 2 Connect manifold to the check joint at low and high Not the check joint of liquid gas stop valves pressure sides of O U 3 Close the liquid and gas stop valve completely To improve the performance of vacuuming 4 Collecting refrigerant in O U The discharge of the refrigerant in the atmosphere is Collect the refrigerant from check joint at high and low strictly forbidden Make sure that the refrigerant is collected pressure sides using the collector by the collector Measure the quantity of the collected refrigerant 5 Remove charge hose at the low and high pressure sides Make sure that there is no pressure increase of the low check joint so that the low pressure side of the refrigerant pressure side after collecting the refrigerant cycle will be the atmosphere pressure Disconnect the Make sure that the refrigerant cycle is the atmosphere charge hose at charge port of return oil circuit pressure Otherwise problems such as the blowing of gas and the suction of the cutting material may occur when removing the comp 6 Perform replacing comp return oil circuit and electrical Removing electrical box may be required parts 7 With the electrical box mounted check the wrings by contacting except the power line for comp For the power l
200. rmance when a long piping is applied 171 11 4 Abnormally high operation sound in the ceiling type indoor unit 171 11 5 Alarm Code 31 172 11 6 Not cooling well due to insufficient installation space for the outdoor unit 172 11 7 Guideline for selecting the drain pipe for the indoor unit 173 11 8 Caution with the refrigerant leakage 174 11 8 1 Maximum permissible concentration of the HCFC Gas 174 11 8 2 Calculation of the refrigerant concentration 174 11 8 3 Countermeasure for the refrigerant leakage according to the KHK standard 174 11 9 Maintenance work 175 11 10 Service and maintenance record 176 11 11 Service and maintenance record by means of the 7 segment display 177 11 11 1 Data Sheet for Checking by 7 Segment Display 177 11 11 2 Pump down method for replacing the compressor 179 SMGBO0059 rev 0 04 2009 171 HITACHI Inspire the Next 11 1 Field work instruction Service Manual Checking the power source and the wiring connection Check the following items in the case of abnormal operation No Check item fuse cut out 1 Is the breaker of the Procedure Check the secondary voltage of the breaker and the fuse by means of a tester 2 Is the secondary 3 Is the wiring loosened or incorrectly connected power source on the transformer correct Disconnect the secondary side of the transformer and check the voltage by means of a tester Indoor unit transfor
201. rocedure Room temperature 20 C 30 C DB Outdoor temperature 15 C DB or more Room temperature 20 C 30 C DB Outdoor temperature 0 C 15 C DB Cooling Heating Checking procedures for cooling Process 1 Convert iE indoor unit expansion valve opening with the following table Indoor Unit HP Conversion 0 8 to 6 HP iE 8 and 10 HP iE x 2 0 2 Sum up the converted values of iE 3 Calculate the total frequency H1 Inverter frequency Judgement If total of converted iE Total frequency lt 0 7 Insufficient refrigerant If total of converted iE Total frequency gt 1 6 Excessive refrigerant 56 SMGB0059 rev 0 04 2009 Test run Service Manual Checking procedures for heating Process 1 Detect oE total outdoor unit expansion valve opening 2 Calculate the total frequency H1 Inverter frequency Judgement If total oE Total frequency lt 0 8 x Target value Insufficient refrigerant If total oE Total frequency gt 1 2 x Target value Excessive refrigerant Refer to the following table to use the target value in heating 0 55 0 50 0 45 0 40 Target value 0 35 0 30 Examples Cooling process 10 Outdoor air temp C HITACHI Inspire the Next Indoor units 2HP 2HP 2HP 2HP 2HP iE from the checking data 32 38 30 20 18 3
202. rotection Activating P i 9 gging of Heat Exchanger 47 Low Pressure Decrease Protection Activating Insufficient refrigerant 48 Activation of inverter overcurrent protection device Overload operation compressor failure 51 Sensor Abnormal Current Sensor Current sensor failure gt Driver IC Error Signal Detection Protection for inverter Error signal Detection Overcurrent Low Voltage Short Circuit Inverter Abnormal Inverter Fin Thermistor Abnormal Outdoor 54 Increase in Inverter Fin Temperature Fan Outdoor fan Disconnecting Wiring or Incorrect Wiring between 57 motor Abnormality of fan motor Control PCB PCB1 and Fan Relay PCB PCB3 PCB5 Failure of Fan Motor EE Compressor Compressor protection alarm Failure of compressor Outdor unit b1 number Incorrect outdoor unit number setting Over 64 No is set for address of refriogerant cycle setting Indoor unit b5 n mb r Incorrect indoor unit number setting More than 17 non corresponding to H LINKII units are setting connected to one system SMGB0059 rev 0 04 2009 73 HITACHI Inspire the Next Troubleshooting Service Manual Alarm code Description Activation of the safety device in the indoor unit The RUN LED flickers and ALARM is displayed on the remote control switch E The unit number the alarm code and the unit code are alternately displayed on the set temperature section The unit number and the alarm code are displayed on t
203. rrectly 3 No 3 Does fan motor Faulty fan motor Replace fan motor rotate Yes No Is pulse signal to Yes 4 PCB correctly 4 Faulty PCB c Replace PCB Faulty PCB ii No Replace it Faulty fan motor PCB Indoor Unit PCB Replace it 3 Disconnect PCN15 on PCB when performing If 1V or over is applied between PCN15 5 and VDC on PCB for 10 sec Approx after starting operation the fan motor is normal Note Even when the operation is stopped 0 3 to 0 4V may be applied The voltage may not be conducted sequentially after 10 sec to perform the above operation H 4 With PCN15 on PCB connected if a few volts are applied between VDC and PC4 2 terminal on PCB the PCB is normal Note Even when the operation is stopped 0 2V Approx may be applied RCI Model Electrical Box 92 SMGB0059 rev 0 04 2009 Troubleshooting H ITACHI Inspire the Next Service Manual Alarm code Description oa Activation of the protection device for the indoor fan motor RPK E The RUN LED flickers and ALARM is displayed on the remote control switch E The unit number the alarm code and the unit code are alternately displayed on the set temperature section The unit number and the alarm code are displayed on the display of the outdoor unit PCB This alarm code is indicated when the following conditions occur
204. rtions If applied leakage may occur Use two spanners here to squeeze the flare nut Piping installation HITACHI Inspire the Next Service Manual The most important work in the refrigerant piping installation work is the brazing of the pipes If it accidentally occurs a leakage due to a careless brazing process it will cause clogged capillary pipes or serious compressor failure In order to guarantee a proper brazing neck between different pipes surfaces accurate pipe dimensions after the expansion process see the table below It is important to control the clearance of the pipe fitting portion as shown below In the case that a cooper tube expansion jig is used following dimensions should be secured secs d1 Gap a ieee d1 Gap a 0 08 0 1 0 33 0 09 0 1 0 39 6 35 6 5 6 22 22 22 42 10 0 08 0 0 07 0 09 0 0 11 0 08 0 1 0 35 0 12 0 1 0 42 29 53 9 7 8 25 4 25 6 12 0 08 9 0 93 0 12 0 0 08 0 08 0 1 0 38 0 12 0 1 0 42 C Q12 7 212 9 8 28 58 28 78 12 i 0 08 0 0 19 0 12 0 0 08 a 0 09 01 0 41 0 12 0 1 0 47 215 88 16 1 8 31 75 32 0 12 0 09 0 0 13 0 12 0 0 13 0 09 0 1 0 44 0 12 0 1 0 52 219 05 219 3 10 238 1 238 3 14 0 09 0 0 16 0 12 0 0 18 A basic brazing method is shown below Pre heat the outer tube for better flowing of the filler metal Heat inner side tube
205. s the motor run gt This alarm is indicated due to detected overcurrent by the contrary wind This is normal Remove the foreign matter Connect it correctly This is normal This is normal No Alarm code is not indicated Yes Does the fan stop by the foreign gt matter No Check to remove the connectors as follows PCB1 CN6 CN12 CN14 PCB3 CN401 CN402 CN404 CN405 PCN401 PCN406 PCN407 PCB2 CN206 CN3 PCN301 PCN302 PCB5 CN201 CN202 PCN201 PCN203 j Faulty 4 Are the connectors abnormal gt gt Good Restart operation Da y Yes 4 Does the motor run gt gt No Replace the fan motor Restart operation Yes Does the motor run gt gt No Alarm code is not indicated a Replace the PCB1 or the fan controller In the case that the fan motor does not run even the PCB1 is replaced replace the PCB2 SMGB0059 rev 0 04 2009 113 HITACHI Inspire the Next Troubleshooting Service Manual Alarm code Description re jn a Compressor protection E This alarm code is displayed when one of the following alarms occurs three times within six hours If the outdoor unit operates continuously without removing the cause of the alarm the compressor may be seriously damaged A CAUTION Alarm Code Content of Abnormality
206. s three times in 30 minutes Indoor fan rotates less than 70rpm for 5 seconds during operation Set air flow volume Hi before starting this check Does the indoor 4 1 Turn OFF the power before checking the connectors Sek eee 1 If not PCB and the fan motor may be damaged fan run Indoor unit PCB CN550 CN500 Also the LED4 must be turned OFF before starting this check to avoid electric shock Is LED4 on PCB OFF Insuffcient voltage for Faulty PCB microcomputer Replace PCB 2 correctly 2 11 9 to 12 8V Use a tester Note Use the following check points writen Yes in Japanese on the PCB Refer to the figure HA 5V next to DSW5 12V 12V next to HA connector GND next to IC6 do not use 280V15V GND T 15V 5V pDSW5 Is DC power No Is the voltage between 5V and GND of PCB supply for PCB 4 75 to 5 25V gt Pply Faulty PCB Is the voltage between 12V and GND of PCB Replace PCB GND 280V 15V Is DC power 3 h caon Pp Is the voltage between CN550 1 and CN550 CN550 supply No 3 of PCB 280V 10 Use a tester 280V for PCB Faulty PCB correctly 3 PCB Indoor Unit PCB i gt 4 Is DC power Is the voltage between CN550 3 and CN550 4 of PCB 14 8V to 15 8V supply No Use a tester 15V for PCB Fau
207. ssor MC2 MC3 MC4 MC5 is detected by the current sensor CT2 CT5 Cause code of stoppage for the inverter content of check item o ma HITACHI Inspire the Next Code Cause Cause of stoppage for correspondign unit Automatic stoppage of the transistor module IPM Error a overcurrent decrease voltage increase temperature Remark Indication during retry a i I Alarm code Instantaneous overcurrent Abnormal inverter fin thermistor a a a lt at lt l Electronic thermal activation maS x 1 Inverter voltage decrease Insufficient Voltage a en Daad x lt m aad Voltage increase a Z gt Daad x lt J rr Abnormal transmission a gt Daad Abnormal current sensor a x 1 Instantaneous power failure detection a gt Daad Reset of micro computer for inverter a gt Daad Earth fault detection for compressor only starting a J J Daad Wy Pe a Abnormal power source phase a lt gt Daad me mr Inverter retry a S gt Daad J 0 x lt SMGB0059 rev 0 04 2009 127 Troubleshooting HITACHI Inspire the Next Service Manual Cause code of stoppage for Fan Controller content of check item
208. ssure sensor and low pressure sensor 146 9 1 10 Opening electrical box Power plate 146 9 1 11 Removing reversing valve coil and solenoid valve coil SVA SVF 147 9 1 12 Removing electronic expansion valve coil 148 9 1 13 Removing reversing valve 149 9 1 14 Removing electronic expansion valve 150 9 1 15 Removing solenoid valve 151 9 1 16 Remove the control PCB PCB1 152 9 1 17 Removing Relay PCB PCB3 PCB5 152 9 1 18 Removing inverter components 153 9 1 19 Removing other inverter components 155 SMGB0059 rev 0 04 2009 139 HITACHI cl Inspire the Next Service Manual 9 1 Outdoor Unit FSNM E Remove the main parts according to the following procedures To reassemble perform the procedures in reverse To prevent contamination of the refrigerant with water or foreign particles do not expose to the atmosphere for long periods If necessary seal pipe ends using caps or tape 9 1 1 Removing service cover Remove the five 5 fixing screws slide the service cover downward and remove Pay attention not to fall off the service cover Pay attention not to be injured by the edge of the cover Service cover 9 1 2 Removing air outlet grille Remove the eight 8 fixing screws of the shroud Air outlet grille B 9 1 3 Removing upper cover a Na 8 Remove eleven 11 screws fixing the up
209. t is applicable when the inlet air DSW for capacity of indoor temperature is three degrees higher units Incorrect setting than the setting temperature 2 Is the fan actually running when Fo Failure of the fan motor airflow rate of fan is other than 0 Failure of the PCB1 Failure of the condenser 3 Is the total of iE indoor expansion Total of iE Low excessive refrigerant valves opening abnormally low or high horsepower of the outdoor High insufficient refrigerant unit X 0 7 to 1 5 excessive pipe resistance 4 Is TL liquid pipe temperature of the It is normal when Failure of the TL thermistor heat exchanger of the indoor unit lower TL Ti lt 5 deg Fully closed expansion valve than Ti air inlet temperature of the Short circuit indoor unit 5 Is TG gas pipe temperature of the heat It is normal when Failure of the TG thermistor exchanger of the indoor unit lower than TG Ti lt 5 deg Fully closed expansion valve Ti air inlet temperature of the indoor or slightly open expansion unit valve Short circuit 6 Is there any excessive difference It is normal if the difference Failure of the TL TG among indoor units at SH IG TL among units is within 3 7 thermistor of the heat exchanger of the indoor deg lower than other units Fully open expansion valve units It is applicable when the inlet slightly open expansion valve air temperature is three degrees higher or fully closed expansion than t
210. t number the alarm code and the unit code are alternately displayed on the set temperature section The unit number and the alarm code are displayed on the display of the outdoor unit PCB1 This alarm code is displayed when the thermistor is short circuited less than 0 24 kQ or cut greater than 840 kQ during the cooling process or the heating process The system is automatically restarted when the fault is removed Freeze protection Is THM5 connected to intake ne thermistor THM3 of PCB Connect it Yes Is the resistance of THM5 between 0 24kQ and 840kQ Faulty thermistor Refer to the thermistor resistance in Alarm 11 In case of 4 way cassette Faulty PCB Action Phenomenon Cause Check item Turn OFF the main switch 7 Fault Check the resistance Replace the thermistor if faulty Faulty gas piping thermistor Incorrect connection Check the wiring to PCB Connect wiring correctly Replace PCB and check the Faulty PCB operation Replace PCB if faulty SMGB0059 rev 0 04 2009 91 Troubleshooting HITACHI Inspire the Next Service Manual Alarm code Description J Activation of the protection device for the indoor fan motor RCI E The RUN LED flickers and ALARM is displayed on the remote control switch E The unit number the alarm code and the unit code are alternately displayed on the set temperature section and t
211. t pat t sa 6 160 a It No 0 Unit pt toe bt 0 99 36 Indoor unit cause of stoppage _ _ from 0 to 63 a No 63 Unit jo a pa jaa t 0 99 Pressure ratio fall protection ya 0 not in operation 37 i degeneration control bn I LU 4 in operation High pressure rise protection 0 not in operation 38 p degeneration control bn af 4 in operation Inverter fin temperature losnotinop rati n 39 increase protection Z u i i 403i ps lam on in operation degeneration control SMGB0059 rev 0 04 2009 124 Troubleshooting HITACHI Inspire the Next Service Manual No lItem Indication Data Values Units 40 Discharge gas temp decrease NA rr ya 0 not in operation protection degeneration control al 1 14 in operation 41 Discharge gas temp increase _ Cc ya O not in operation protection degeneration control bm Al J 1 in operation 42 Current protection o v ya 0 notin operation degeneration control Im Iml 4 in operation Total accumulated hours of a a Da _ x10 times a compressor MC1 pf bt kh yO 9999 hours Total accumulated hours of m x10 times 44 compressor MC2 bel a a tf 4 Jo 9099 hours for 14 to 48HP Total accumulated hours of m x10 times 45 compressor MC3 if at J Z at 0 9999 hours for 18 to 48HP Total accumulated hours of l 7 x10 times
212. ter three minutes 8 The operation finishes when one of the following The operation may finished when any of the conditions 1 conditions occurs to 3 occurs 1 Ten minutes have passed and STP is displayed in seven segments 2 08 is displayed in seven segments 3 When Ps lt 0 1MPa is continued for one minute in ten minutes STP is displayed in seven seconds and the operation finishes 9 Close the liquid stop valve completely To avoid the spillage of all the refrigerant if the check valve is broken SMGBO0059 rev 0 04 2009 181 11 HITACHI Inspire the Next Field work instruction Service Manual No Procedure Remarks 10 Check for a leakage of the check valve on the When you stop the compressor for replacing discharge gas side You can check the leakage of the check valve DSW4 4 Enforced stoppage of the compressor by means of the Ps variation because the SVA opens so gt ON so that the compressor will not run that the discharge gas side of the inverter compressor although the running command is sent from the can connect to the low pressure side remote control switch oe 0 03 Mpa 2 minutes is within the permissible limits for Check that variation of Ps on the outdoor unit PCB the check valve on the discharge gas side is 17 seconds Make sure that the Ps increase is within 0 03 Mpa in two minutes after the Ps The leakage of th
213. the Discharge Air Temp Thermistor Cause Failure of the Thermistor Disconnected Wire of the Thermistor Check item Check the Thermistor by means of the self check mode 2 Action Turn OFF the main switch Replace or Correctly connect the wiring when it is abnormal Failure of the Remote Control Switch Failure of PCB for the indoor unit Check it by means of the self check mode 1 Replace if it failed Replace if PCB fails Failure of AC chpper for indoor unit Check the indoor unit stoppage when the remote control switch is swicthed OFF Replace if AC chpper is failed No defrost operation mode is available during the heating process or the defrost operation continues Failure of thermistor for outdoor evaporating temp during heating Failure of thermistor Disconnected wire of thermistor Replace or correctly connect when it is abnormal Failure of 4 way valve Disconnected 4 way valve coil Measure the resistance of coil Incorrect activation of 4 way valve Enforced power supply Replace the 4 way valve Disconnected control wires between indoor unit CH unit and outdoor unit Check the connectors Correctly connect the wiring Failure of the outdoor units of PCB Disconnected wiring to PCB Failure of PCB Check the connectors Check PCB by means of the self check mode 1 Correctly connect the wiring Replace PCB when
214. the alarm code and the unit code are alternately displayed on the set temperature section The unit number and the alarm code are displayed on the display of the outdoor unit PCB1 This alarm code is displayed when the thermistor is short circuited less than 0 2 kQ or cut greater than 500 kQ during the operation However this alarm occurs during the test run mode only In the case that the thermistor is abnormal during the operation the operation continues based on the assumption that the outdoor temperature is 35 C Cooling 6 C Heating Is the thermistor THM7 TA No connected to PCB1 Connect it Yes Is the resistance of THM7 No between 0 24 kQ and 500 kQ Faulty thermistor Yes Outdoor unit ambient thermistor Faulty PCB1 Action Phenomenon Cause Check item Turn OFF Main Switch Fault Check resistance Replace thermistor if faulty Faulty thermistor for the outdoor unit ambien Incorrect connection Check wiring to PCB1 Repair wiring and connections Replace PCB1 and check Faulty PCB1 operation Replace PCB1 if faulty 96 SMGB0059 rev 0 04 2009 Troubleshooting Service Manual HITACHI Inspire the Next Alarm code Description 1 Abnormal operation of thermistor for discharge gas temperature on the top of compressor chamber oot E The RUN LED flickers and ALARM is display
215. the clogging Check the connection cord and the connector Replace the connector Failure or malfunction of the expansion valve Is there an operation sound from the coil Is the thermistor on the compressor normal Replace the coil Replace the thermistor Is the thermistor installed correctly on compressor Correctly install the thermistor Clogged strainer in the indoor unit clogging at the low pressure piping Check the temp difference at the inlet and the outlet of the strainer Replace the strainer in the indoor unit Clogging at the low pressure piping Check the temp difference Remove the clogging Insufficient air flow to the indoor unit heat exchanger Check for clogged air filter Clean the air filter Check for an obstacle at the inlet or the outlet Remove the obstacles Excessively low air temp to the indoor unit heat exchanger Insufficient speed of the indoor unit fan motor Short circuited indoor unit air Replace the fan motor Remove the cause of the short circuited air SMGB0059 rev 0 04 2009 67 HITACHI Inspire the Next Abnormal operation of the devices Cont Troubleshooting Service Manual Phenomenon Cause Check item Action Turn OFF the main switch Insufficient cooling process Excessively high discharge pressure Insufficient air flow to the outdoor unit heat exchanger Che
216. the common pipe Slope of 1 25 1 100 gt 100 mm Common drain piping Common pipe must horizontal be downward Common drain piping vertical SMGBO0059 rev 0 04 2009 175 Field work instruction HITACHI Inspire the Next Service Manual 11 8 Caution with the refrigerant leakage The designers and the installers have the responsibility to follow the local codes and the local regulations that specify the safety requirements against the refrigerant leakage The refrigerant R410A which is charged in the SET FREE FSN system is an incombustible non toxic gas However if the leakage occurs and the gas fills a room the gas may cause suffocation The maximum permissible concentration of the HCFC gas and the R410A in the air is 0 44 kg m according to the refrigeration and air conditioning system standard KHK S 0010 by the KHK High Pressure Gas Protection Association Japan Therefore you must take some effective measures in order to lower the R410A concentration in the air below 0 44 kg m if there is a leakage 1 Calculate the total quantity of refrigerant R kg that is charged in the system that connects all the indoor units of the rooms that need air conditioning systems 2 Calculate the room volume V m of each room 3 Calculate the refrigerant concentration C kg m of the room according to the following equation R Total quantity of charged refrigerant kg V
217. the indoor unit is set 8 60 61 at a higher temperature than the amp temperature displayed on the remote 2 50 46 control switch by 4 C the maximum 40 5 inlet air temperature is 34 C The 5 suction air temperature during the i o 27 heating process has a tendency to E 30 as T become higher than the temperature Ei 12 5 49 5 of the occupied zone in order to 5 3 3 6 25 provide a more efficient heating 0 operation 15 10 5 0 5 10 15 20 25 30 35 40 45 50 55 60 Ambient Temperature C E Thermistor for the control of the discharge air temperature Thermistor for the discharge air temperature of the indoor unit THM2 The thermistor for the discharge air temperature THM2 prevents the cold blow during the heating process The resistance values of the thermistor are shown in Fig 10 4 E Thermistor for the liquid pipe temperature of the indoor heat exchanger When the temperature of the indoor heat exchanger decreases to 0 C or a lower temperature for 3 minutes the thermostat automatically turns off When the temperature of the indoor heat exchanger increases to 16 C or a higher temperature the thermostat turns on The purpose of this function is to prevent frosting on the indoor heat exchanger during the cooling process and the dry operation The resistance values of the thermistor are shown in the figure above E Thermistor for the gas pipe temperature of the indoor heat exchanger The thermistor for the gas pipe temperature senses
218. tion cycle the refrigeration oil should be of a synthetic type one In order to avoid oxidation pay much careful attention to basic piping work control to avoid infiltration of moisture or dust during the refrigerant piping work Three principles Cause of failure Presumable failure Preventive action Pipe protection 1 Pinching Icing inside tube at ex valve 2 Ei Water enoking Flushing Water infiltration due to insufficient l 1 Dry Keep good dryness Generation of hydration and protection at pipe ends oxidation of oil Dewing inside of pipes L Insuffic ing ti Insufficient vacuum pumping time Clogged Strainer etc insulation One gram of water turns into gas approx 1000 Irs failure and compressor failure at 1 Torr Therefore it takes long time to vacuum pump by a small vacuum pump Vacuum Drying Clogging of expansion valve Infiltration of dust or other through capillary tube and filter Pipe Protection the pipe ends 1 Mounting Caps 2 Clean Oxidation film during brazing a l 2 Taping No dust Inside of pipes without blowing nitrogen Oxidation of oil 3 Pinching Insufficient flushing by nitrogen Compressor failure after brazing l Flushing Insufficient cooling or heating compressor failure Refrigerant shortage Careful Basic Brazing Work F Basic Flaring Work Brazing failure w Performance decrease 3 No leakage l Failed flaring work and insufficient Oxidation of oil Basic
219. tion location 1 3 3 Service space 1 3 4 Foundations ONOa oO AR A N gt SMGB0059 rev 0 04 2009 1 Units installation HITACHI Inspire the Next Service Manual 1 1 General installation notes A warning Install the outdoor unit with sufficient clearance around it for operation and maintenance as shown in the next pages Install the outdoor unit where good ventilation is available Do not install the outdoor unit where exists a high level of oil mist salty air or sulphurous atmosphere Install the outdoor unit as far as practical being at least 3 meters from electromagnetic wave radiator such as medical equipment Keep clearance between units of more than 50 mm and avoid obstacles that could hamper air intake when installing more than one unit together Install the outdoor unit in the shade or not exposed to direct sunshine or direct radiation from high temperature heat source Do not install the outdoor unit in a place where a seasonal wind directly blows into the outdoor fan For cleaning use non inflammable and nontoxic cleaning liquid Use of inflammable agent may cause explosion or fire Work with sufficient ventilation for working in an enclosed space could cause oxygen deficiency Toxic gas may be produced when cleaning agent is heated to high temperature by e g being exposed to fire Cleaning liquid shall be collected after cleaning Pay attention not to clamp c
220. tity changeover stoppage HP 8 q Demand of 4 way valve changeover stoppage FX only g Demand enforced stoppage I Retry due to pressure ratio decrease ig Retry due to low pressure increase 3 uy 5 Retry due to high pressure increase Retry due to abnormal current of constant speed compressor HP gt 12 Retry due to abnormal high temperature of discharge gas excessive low suction pres sure 5 Retry due to decrease of discharge gas superheat rq Retry due to inverter tripping ig Retry due to voltage decrease that Expansion valve opening change protection eu Operation mode changeover of indoor unit Note 5 Enforced Thermo OFF Enforced Thermo OFF hot start control at crankcase heater preheating Retry due to high pressure decrease a od a Do de Cooling air discharge temperature control NOTE 1 Explanation of Terms Thermo ON A condition where an indoor unit is requesting the compressor to operate Thermo OFF A condition where an indoor unit is not requesting the compressor to operate 2 Even if stoppage is caused by Alarm 02 is not always displayed 3 Ifthe transmission between the inverter printed circuit board and the control printed circuit board is not performed during 30 seconds g the stoppage cause is d1 05 and the alarm code 04 may be Abnormal operation occurrence counter displayed
221. tomatically switched in every 1 second Hystory No 15 7 wl rE bios TEEN The oldest failure ru et tay FTC indication 58 Total capacity setting of indoor ld Pa ar 1 lo 9999 rE unit pn l Al be Total quantity of combined Pa Pa fa _ 59 indoor unit rm rm jar 64 units j of m lo 60 Address of refrigerant system i rm it 0 63 Return to Start sc E Reset for accumulated operation time of compressor 1 5 after maintenance cUJ1 cUJ5 Procedure Press PSW1 for 5 seconds while the accumulated operation time of compressor data is displayed Example of compressor 1 PSW2 t PSW3 cet i cUJ1 Accumulated operation time of compressor 1 will be indicated PSW2 1 PSW3 Ha Press PSW1 for 5 sec while the accumulated operation time is displayed l The indication will be changed to 0 The accumulated operation time of compressor 1 is 0 LULi 126 SMGB0059 rev 0 04 2009 Troubleshooting Service Manual E Inverter primary current The inverter primary current is estimated from the running current of the compressor MC1 displayed on the 7 segment display as chart 25 20 T E g 154 3 gt T 5 10 c o z l 380 415V Lower limit 5 10 15 20 Running current of compressor MC1 indicated on 7 segment E Displayed running current of the compressor MC2 MC3 MC4 MC5 The running current of the compre
222. ual Setting the compressor manually When DSW1 4 is ON during Do not turn ON and OFF the compressor compressor OFF Set DSW1 4 at ON the compressor operation the frequently OFF compressor stops operating Manual defrost Manual defrost operation starts Press the PSW1 for more than three seconds during the heating process The defrost operation starts after two minutes This function is available once the heating process has been running for five minutes Manual defrost operation finishes The defrost operation automatically finishes and the heating process starts The defrost operation is available regardless of the frosting conditions and the total time of the heating process The defrost operation is not performed when the temperature of the outdoor heat exchanger is higher than 10 C the high pressure is higher than 2 0 Mpa or under the Thermo OFF condition Do not repeat the defrost operation frequently When the PSW1 accepts the manual defrost operation the remaining time before starting the defrost operation is displayed at the 7 segment display on the PCB Remaining time every 4 seconds 52 SMGB0059 rev 0 04 2009 Test run Service Manual 6 3 Check list HITACHI Inspire the Next E Check list on test run Client Installer Date Outdoor unit model Outdoor unit serial No Checker Indoor unit model Indoor unit
223. ure Pipe diameter mm Size B R410A Tightening torque Nm B 6 35 17 20 29 53 22 40 gt 12 70 26 60 ig 215 88 29 80 I 19 05 36 100 Stop valve FSNM E Gas valve Liquid valve Tighten the cap with the torque at 30N m after this work Refrigerant pressure Do not apply O ring two spanners at rubber this portion If ioj al ied leakage Check joint Ppiled 9 Only the charging hose can be will occur connected Tighten the cap with the torque Y at 13N m Refrigerant piping Use two spanners here to squeeze flare nut O Note 1 This valve is a ball valve The stem is turned to arrow direction for valve open and close as below 2 Use adjustable wrench for the stem operation Turn the stem until contact to the pin 3 Attach the ring securely after the stem operation 4 Do not leave the stem at half opening position 16 SMGB0059 rev 0 04 2009 Charge port cap Tightening torque 26N M Liquid valve Check joint connectable only for charging hose Cap Tightening torque 37N m This cap is attached after work lt Ref pressure Spindle valve Counterclockwise Open Clockwise Close Closed before shipment Stop ring Refrigerant piping Hexagonal wrench O Ring rubber Size 4 mm To open close spindle valve Do not apply force by spanner at this po
224. ve heat is generated there Then oil heater is failed due to overheating When mounting the reassembled oil heater this point should be taken into account 7 If the oil heater lead wire is caught on the spring the lead wire may be cut due to vibration When reassembling attention should be paid to the lead wire 146 SMGB0059 rev 0 04 2009 ain HITACHI Inspire the Next Service Manual 9 1 8 Removing high pressure switch 1 Remove the service cover according to the item Removing Service Cover 2 Collect the refrigerant from the check joint according to the item Removing Compressor 3 Pull out the fasten terminals Remove the high pressure switch from the brazing part of the discharge pipe A CAUTION Check to ensure whether there are flammable things around or not when using a burner And remove the insulations before brazing work If not fire may occur ee Upper cover Electrical box Rear cover oO aR Brazing part ya Discharge pipe High pressure switch SMGB0059 rev 0 04 2009 147 HITACHI ii Inspire the Next l Senne an del Service Manua Qa10 irae r ah nrace r anenr and Iny nti ARA 9 1 5 Re ving high pressure sensor and lo yressure sensor 1 Remove the connector for the pressure sensor wiring from PCB1 NOTE Remove the connector firstly If not the wiring may be damaged 2 Remove the refrigerant piping for the high pressure sensor or low pressure
225. ven supervision and instruction concerning the use of the appliance by a person responsible for their safety Turn OFF all power switches before maintenance is performed Do not start the cleaning procedures before 5 minutes of the stop of the unit A warning Check and ensure that the accessories are packed with the indoor unit Do not install the indoor units outdoors If installed outdoors an electric hazard or electric leakage will occur Consider the air distribution from each indoor unit to the space of the room and select a suitable location so that uniform air temperature in the room can be obtained It is recommended that the indoor units be installed 2 3 to 3 meters from the floor level If the unit is installed higher than 3 meters it is also recommended to use a fan in order to obtain an uniform air temperature in the room Avoid obstacles which may hamper the air intake or the air discharge flow Children must be supervised to ensure that they do not play with the electrical appliances Before obtaining access to terminals all supply circuits bust be disconnected 2 SMGB0059 rev 0 04 2009 Units installation HITACHI Inspire the Next Service Manual A warning Pay attention to the following points when the indoor units are installed in a hospital or other places where there are electronic waves from medical equipment and similar Do not install the indoor units where electromagnetic wave
226. vice Manual Unit code list MODEL CODIFICATION 4 Way Cassette Unit RCI 1 0FSN2E RCI 1 5FSN2E RCI 2 0FSN2E RCI 2 5FSN2E RCI 3 0FSN2E RCI 4 0FSN2E RCI 5 0FSN2E RCI 6 0FSN2E Code 7E400001 7E400002 7E400003 7E400004 7E400005 7E400007 7E400008 7E400009 a Meaning of model codification Unit Type Indoor Unit RCI M RCD RCI RPC RPI RPK RPF I Compressor power HP 1 0 6 0 H Link Set Free System Free R410 A refrigerant Series E Made in Europe Made in Malaysia HITACHI Inspire the Next 0 Model codes and descriptions 4 Way Mini Cassette Unit RCIM 1 0FSN2 RCIM 1 5FSN2 RCIM 2 0FSN2 RCIM RPI 3 0 Code 60278011 60278013 60278014 FS N FSN 2 E INDOOR UNITS 2 Way Cassette Unit RCD 1 0FSN2 RCD 1 5FSN2 RCD 2 0FSN2 RCD 2 5FSN2 RCD 3 0FSN2 RCD 4 0FSN2 RCD 5 0FSN2 Code 60278029 60278030 60278031 60278032 60278033 60278034 60278035 RCD Please check by model name your air conditioner type its abbreviation and reference number in this service manual Ceiling Unit RPC 2 0FSNE RPC 2 5FSN2E RPC 3 0FSN2E RPC 4 0FSN2E RPC 5 0FSN2E RPC 6 0FSN2E Code 7E440003 7E440004 7E440005 7E440007 7E440008 7E440009 y RPC SMGB0059 rev 0 04 2009 v 0 HITACHI Inspire the Next Unit RPI 0 8FSN2E RPI 1 0FSN2E RPI 1 5FSN2E RPI 2 0FSN2E RPI 2 5FSN2E RPI 3 0FSN2E RPI 4 0FSN2E RPI 5 0FSN2E RPI 6 0FS
227. w protection hood option Units installation HITACHI Inspire the Next Service Manual Install the outdoor unit with a sufficient space around the outdoor unit for operation and maintenance as shown below E Obstacles on inlet side Upper side is open Single installation Multiple installation 1 Around sides Around sides are open are closed Front side Front side 5 j gt 100 Frontside gt 50 Frontside gt 100 Note Open both right and left sides Fit positions with front side Note Mount the airflow optional part and open both right and left sides Note Mount the airflow optional part and open both right and left sides gt 350 Obstacles in above Single installation Multiple installation lt 300 2 O A Note Open both right and left sides E N gt 350 Note Mount the airflow optional part and open both right and left sides Note Mount the airflow optional part and open both right and left sides SMGB0059 rev 0 04 2009 7 HITACHI Inspire the Next E Obstacles on discharge side Upper side is open Units installation Service Manual Single installation Front side Fit positions with unit front side Note Mount the airflow guide optional part and open right end or left end Multiple installation Note Mount t
228. xt 60291476 Image not available 60291105 60199286 Be 7E790214 7E299907 NEW 7E513300 v SMGB0059 rev 0 04 2009 7E513200 D ix 7E790211 7E790212 7E790213 i is 0 HITACHI Inspire the Next Name HARC BXE A HARC BXE B HC A64BNP CSNET WEB v3 TS001 WEB SCREEN PC A 110 HC A160SMS DBS 26 P N23WA P N23WAM P N23DWA P N46DWA Description Buildin g Management System Gateway to LONWORKS systems max 64 IU 8 parameters Building Management System Gateway to LONWORKS systems max 32 IU 16 parameters Building Management System Gateway to BAC Net system Control System 15 inch touch screen display Integration of teams into H LINK SMS alarm warning device Drain discharge connection Air panel for RCI FSN2E Air panel for RCIM FSN2E Air panel for RCD FSN2E Air panel for RCD FSN2E SMGB0059 rev 0 04 2009 Code 60290874 60290875 60291569 7E891938 7E891935 7E519000 7E519100 60299192 70530000 60197160 60291574 60291575 Figure Model codes and decriptions Service Manual Model codes and decriptions Service Manual Name B 23H4 F 23L4 K F 23L4 D F 46L4 D PDF 23C3 PDF 46C3 OACI 232 PD 75 PI 23LS5 TKCI 232 MW 102AN MW 162AN MW 242AN MW 302AN MH 84AN MH 108AN Description Adapter for deodorant filter Antibacteria filter Deodorant

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