Sanyo CHDXR09663* Service Manual

* Salt-Air Damage Resistant Specifications. ** 96 72 Class C ECO-i W-2WAY CHDX07263 CHDX09663 CHDXR07263 CHDXR09663 * * CHDX07263 CHDX09663 CHDXR07263 CHDXR09663 * * 85464849280000 SM830180-00 Indoor Units 9 Class UM XM Mini Semi-Concealed U X XHX3652 A T D F FM K 7 SERVICE MANUAL 12 15 18 24 19 36 48 54 4-Way Air Discharge Semi-Concealed 4-Way Air Discharge 1-Way Air Discharge Semi-Concealed Concealed Duct Type Slim Concealed Duct Type Concealed-Duct High Static Pressure Ceiling-Mounted Wall-Mounted Type Floor-Standing Type Concealed-Floor Standing Type UMHX0762 UHX0762 AHX0752 UHX0962 AHX0952 UMHX0962 KHX0752 KHX0952 FHX0762 FHX0962 FMHX0962 FMHX0762 KHX1252 UMHX1262 UHX1262 XHX1252 XMHX1252 AHX1252 UHX1562 UMHX1562 THX1252 UMHX1862 UHX1862 XHX1852 KHX1962 KHX1862 THX1852 FHX1862 FMHX1862 FHX1562 FMHX1562 FMHX1262 FHX1262 XHX2452 XMHX1852 UHX2462 UHX3662 UHX4862 UHX5462 DHX4852 DHX3652 THX2452 KHX2452 FHX2462 FMHX2462 ** Necessary to install the External Electronic Expansion Valve Kit (Optional:ATK-SVRK56BA). REFERENCE NO.

This air conditioning system meets strict safety and operat- ing standards. As the installer or service person, it is an important part of your job to install or service the system so it operates safely and efficiently. Carefully read this instruction booklet before beginning. Follow each installation or repair step exactly as shown. Observe all local, state, and national electrical codes. This symbol refers to a hazard or unsafe practice which can result in personal injury or product or property damage. In Case of Improper Installation When Wiring ELECTRICAL SHOCK CAN CAUS SEVERE PERSONAL INJURY OR DEATH. ONLY A QUALIFIED, EXPERIENCED ELECTRICIAN SHOULD ATTEMPT TO WIRE THIS SYSTEM. E • Do not supply power to the unit until all wiring and tubing are completed or reconnected and checked. • Highly dangerous electrical voltages are used in this sys- tem. Carefully refer to the wiring diagram and these instructions when wiring. Improper connections and inad- equate grounding can cause accidental injury or death. • When Installing… …In a Room Properly insulate any tubing run inside a room to preven “sweating” that can cause dripping and water damage to walls and floors. t …In Moist or Uneven Locations … …In a Snowy Area (for Heat Pump-type Systems) Install the outdoor unit on a raised platform that is higher than drifting snow. Provide snow vents. • • Keep all tubing runs as short as possible. • Use the flare method for connecting tubing. • Apply refrigerant lubricant to the matching surfaces of the flare and union tubes before connecting them, then tighten the nut with a torque wrench for a leak-free con- nection. • Check carefully for leaks before starting the test run. When Servicing • • Keep your fingers and clothing away from any moving parts. • • • Confirm after installation that no refrigerant gas is leak- ing. If the gas comes in contact with a burning stove, gas water heater, electric room heater or other heat source, it can cause the generation of poisonous gas. IMPORTANT! For safe installation and trouble-free operation, you must: Pay close attention to all warning and caution notices given in this manual. This symbol refers to a hazard or unsafe practice which can result in severe personal injury or death. WARNING CAUTION If Necessary, Get Help These instructions are all you need for most installation sites and maintenance conditions. If you require help for a special problem, contact our sales/service outlet or your certified dealer for additional instructions. The manufacturer shall in no way be responsible for improper installation or maintenance service, including fail- ure to follow the instructions in this document. SPECIAL PRECAUTIONS WARNING Ground the unit following local electrical codes. Connect all wiring tightly. Loose wiring may cause over- heating at connection points and a possible fire hazard. When Transporting Be careful when picking up and moving the indoor and outdoor units. Get a partner to help, and bend your knees when lifting to reduce strain on your back. Sharp edges or thin aluminum fins on the air conditioner can cut your fingers. Use a raised concrete pad or concrete blocks to provide a solid, level foundation for the outdoor unit. This prevents water damage and abnormal vibration. In an Area with High Winds Securely anchor the outdoor unit down with bolts and a metal frame. Provide a suitable air baffle. When Connecting Refrigerant Tubing Ventilate the room well, in the event that is refrigerant gas leaks during the installation. Be careful not to allow contact of the refrigerant gas with a flame as this will cause the generation of poisonous gas. Turn the power OFF at the main power box (mains) before opening the unit to check or repair electrical parts and wiring. Clean up the site after you finish, remembering to check that no metal scraps or bits of wiring have been left inside the unit being serviced. CAUTION Ventilate any enclosed areas when installing or testing the refrigeration system. Escaped refrigerant gas, on contact with fire or heat, can produce dangerously toxic gas. • • • • • i

The room in which the air conditioner is to be installed requires a design that in the event of refrig- erant gas leaking out, its density will not exceed a set limit. The refrigerant (R410A), which is used in the aircondition- er, is safe, without the toxicity or combustibility of ammonia, and is not restricted by laws imposed to protect the ozone layer. However, since it contains more than air, it poses the risk of suffocation if its density should rise excessively. Suf- focation from leakage of refrigerant is almost non-existent. With the recent increase in the number of high density buildings, however, the installation of multi air conditioner systems is on the increase because of the need for effec- tive use off loor space, individual control, energy conserva- tion by curtailing heat and carrying power, etc. Most importantly, the multi air conditioner system is able to replenish a large amount of refrigerant compared to conventional individual air conditioners. If a single unit of the multi air conditioner system is to be installed in a small room, select a suitable model and installation pro- cedure so that if the refrigerant accidentally leaks out, its density does not reach the limit (and in the event of an emergency, measures can be made before injury can occur). ASHRAE and the International Mechanical Code of the ICC as well as CSA provide guidance and define safe- guards related to the use of refrigerants, all of which define a Refrigerant Concentration Level (RCL) of 25 pounds per 1,000 cubic feet for R410A refrigerant. For additional guidance and precautions related to refrigerant safety, please refer to the following documents: International Mechanical Code 2009 (IMC-2009) (or more recently revised) ASHRAE 15 ASHRAE 34 ii

Section 1: CONTROL FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 2. Selecting Outdoor Unit for Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 3. Compressor Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 4. Special Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 5. Other Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 6. Operation of Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15 7. Outdoor Unit Electronic Thermostatic Expansion Valves [MOV1, MOV2 & MOV4] . . . . . 1-17 8. Outdoor Fan Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19 9. Demand Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20 10. Indoor Unit Control of the Electronic Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21 11. Rap Valve Kit Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23 12. Indoor Unit Refrigerant Oil Self Recovery Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24 13. Discharge Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25 14. Current Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26 15. Pressure Sensor Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27 16. Backup Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28 17. Service Maintenance Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30 18. Other Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32 Section 2: OUTDOOR UNIT REPAIR PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 1. Removing Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 2. Removing Electrical Component Box and Duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 3. Discharging Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 4. Backup Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 5. Recovering Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 6. Checking for Leakage After Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 7. Evacuating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 8. Charging Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 9. Pumping Out Refrigerant from Outdoor Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 10. Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 11. High and Low Pressure Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35 12. Replacing 4-way Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36 Section 3: OUTDOOR UNIT MAINTENANCE REMOTE CONTROLLER . . . . . . . . . . . . 3-1 1. Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 2. Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 3. Ordinary Display Controls and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 4. Monitoring Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 5. Outdoor Unit Alarm History Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 6. Mode Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Section 4: REMOTE CONTROLLER FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 1. Simple Settings Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 2. Detailed Settings Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 3. Remote Controller Servicing Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 iii

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

W-2WAY ECO-i SYSTEM Control Functions Contents 1. CONTROL FUNCTIONS 1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 2. Selecting Outdoor Unit for Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 3. Compressor Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 4. Special Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 5. Other Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 6. Operation of Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15 7. Outdoor Unit Electronic Thermostatic Expansion Valves [MOV1, MOV2 & MOV4] . . . 1-17 8. Outdoor Fan Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19 9. Demand Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20 10. Indoor Unit Control of the Electronic Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . 1-21 11. Rap Valve Kit Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23 12. Indoor Unit Refrigerant Oil Self Recovery Control . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24 13. Discharge Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25 14. Current Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26 15. Pressure Sensor Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27 16. Backup Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28 17. Service Maintenance Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30 18. Other Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32

1 1 1 1 1 1 1 1 At time of shipment At time of shipment System address No. of indoor units No. of outdoor units Unit No. On-site setting On-site setting Not necessary Not necessary Not necessary The W-2WAY ECO-i is a system that allows multiple outdoor units to be connected. The outdoor units all contain inverter compressors, and the system does not utilize the sub units that were used in earlier systems. The outdoor unit where the unit No. is set to “1” includes the CCU (command controller unit) functions that are used to control the entire system. As a result, the system will not operate if no outdoor unit has been set as unit No. “1.” Required settings for Test Run Outdoor unit No. 2 Unit No. 2 Unit No. 1 1 ~ 3 units 1 ~ 40 units System 1 ~ 30 This system can be expanded to connect a maximum of 3 outdoor units. (The max. system capacity shall be within 24 Ton.) The CCU functions are disabled at all units except the unit that is set as unit No. 1. Therefore no problems will result even if the system address, No. of indoor units, and No. of outdoor units settings are made at the other units. However, making these settings may be convenient for manual backup operation, as it eliminates the necessity of making the settings again if unit No. 1 fails. 1 - 2 1. Introduction W-2WAY ECO-i SYSTEM Control Functions

* For information concerning EEPROM settings, refer to the field application functions. (1) (2) Stopping individual outdoor units The last unit to stop operating is the outdoor unit that contains the inverter compressor with the shortest amount of operating time. In cooling mode, all inverter compressors in the outdoor units are designed to operate simultaneously Therefore, all the outdoor units will stop at a time when any one unit is stopped. In heating mode, the out door unit which has the inverter compressor with the shortest amount of operating time continues to run and rest of the other outdoor units may be stopped. . - (1) Delayed start of outdoor units in the same system If it is necessary to operate the compressors simultaneously at multiple outdoor units, each outdoor unit will start, beginning with unit No. 1, after a delay of a number of seconds equivalent to the outdoor unit address. The units do not start simultaneously. This is in order to reduce the load on the power receiving equipment. Starts after 1 second Starts after 2 seconds 2-1. Outdoor Unit Operating Rules 2-2. Delayed Start of Outdoor Units 2-3. Outdoor Unit Stop Rules Because in this system all outdoor units contain an inverter compressor, ordinarily there is no absolute order of priority for compressor operation. Therefore there is no order of priority for the outdoor units. However, it is possible to operate the outdoor units in sequence, beginning with unit No. 1, by using the outdoor unit maintenance remote controller to change the outdoor unit EEPROM settings. * For information concerning EEPROM settings, refer to the field application functions. address 1 address 2 Outdoor unit Outdoor unit At the time of factory shipment, delayed start for each system is not set to occur. Therefore when systems are linked and multiple systems are selected for start simultaneously by the central control device, all systems will begin operating simultaneously. For this reason, a function is included to delay the start time for each system address when systems are linked and multiple systems are selected for start by the central control device. In order to enable this delay time, it must be set in the EEPROM for each system. Those systems where this setting has been made will start after a delay according to their system addresses. Simultaneous stop of multiple outdoor units When all outdoor units, or multiple outdoor units, must stop, the units stop at the same time. However, depend- ing on the communications timing, a difference of approximately 10 seconds may occur. 1 - 3 W-2WAY ECO-i SYSTEM Control Functions 2. Selecting an Outdoor Unit for Operation

Constant speed 5 hp ––– Scroll 72 96 DC Inverter DC Inverter Capacity Rotary hp = horsepower * Immediately after installation, all compressors have an operating time of zero. In this case, the compressors start in the following sequence: Inverter compressor > Constant-speed compressor 1 > Constant-speed com- pressor 2. Examples of accumulated operating time: ODU=Outdoor Unit Compressor Selection Sequence in Cooling Mode: ODU 1 100 hrs. 150 hrs. 70 hrs. 160 hrs. 4th [CHDX07263, CHDX09663] INV Compressor 2 Compressor 1 Type 96 INV Compressor 1 Type 72 3-2. Compressor Selection Rules In cooling mode, all inverter compressors in the outdoor units are designed to operate simultaneously. All the inverter compressors will stop at a time when the outdoor is stopped accordingly. Constant-speed compressors run in order of the shortest amount of operating time. In heating mode, the inverter compressor with the shortest amount of operating time runs at first followed by the compressors in order of the shortest amount of operating time including inverter units. Suppose the following tentative system. All the inverter compressors are firstly selected simultaneously. ODU 2 Comp 1 Comp 2 ODU 1 ODU 2 Comp 1 Comp 2 1st 3rd 1st Compressor Selection Sequence in Heating Mode: First, the inverter compressor with the shortest amount of operating time is selected. And then, the remained other compressors are selected and start in the order of shortest amount of operating time. 3rd 4th 2nd Installed compressor Compressor 1 Compressor 2 1st ODU 1 ODU 2 Comp 1 Comp 2 1 - 4 3. Compressor Control W-2WAY ECO-i SYSTEM Control Functions

protection control. * If Quiet mode is selected, the inverter may stabilize at a frequency lower than those stated above. For information about Quiet mode, refer to the field application functions. * If the Power Demand Mode is selected, the inverter may stabilize at a frequency lower than those stated above. Refer to the Field Application Function for the detail. (1) The below mentioned Roadmap Control are performed according to the pressure sensor on the outdoor unit and the 2 temperature sensors attached to the indoor unit heat exchanger coil. , * With the roadmap control in heating mode, the pressure detected by the pressure sensor at high pressure side is converted to the saturation temperature. This converted saturation temperature is called the “High Pressure Saturated Temperature”. (2) (3) The evaporation temperature control and the temperature used to determine the area (A, AB, B, C) for the con- densation control shown in the figure on the next page, may vary depending on the relationships among factors including the difference between the room temperature setting and the air intake temperature (=air intake tem- perature difference) and the difference between the air discharge temperature setting and the air discharge temperature (=air discharge temperature difference). (4) Definitions of evaporation temperature and condensation temperature Lowest heat exchanger temperature (E1, E3) at any indoor unit * E3 temperature in heating mode is not used for the condensation temperature detection, because it may indi- cate the temperature of superheated gas. 3-3. Compressor Capacity Control The compressor operating conditions vary depending on the indoor unit operating conditions and the effects of indoor heat load, outdoor temperature and other factors. Unit No. 1 (CCU) calculates the required capacity accord- ing to these operating conditions, and allocates the capacity requirement among the outdoor units, according to the compressor start/stop rules. Fine adjustments to system capacity control are made by the inverter compressors. (Depending on the conditions, all inverter compressors may be operating for fine adjustment.) 3-4. Inverter Compressor Capacity Control The inverter compressor has a center limit value and upper limit value for the operating frequency. These limits are set for each outdoor unit capacity. 3-5. Forced Compressor Stop 3-6. Roadmap Control Once a compressor stops, it will not start for a period of 3 minutes (3-minute forced OFF). However, this does not apply when the compressor was forced to stop as the result of a control operation during the special controls (start control, defrost control, refrigerant oil recovery control, etc.) which are described later. This control is performed every 15 seconds. Evaporation temperature (Te): Condensation temperature (Tc): Highest temperature among the outdoor unit pressure sensor temperature and the heat exchanger temperatures (E1) at all indoor units where the heating thermostat is ON. Ordinarily, this is the outdoor unit pressure sensor temperature. (If multiple outdoor units are connected, this is the highest outdoor unit pressure sensor temperature. ) 1 - 5 W-2WAY ECO-i SYSTEM Control Functions 3. Compressor Control

temperatures for each area may vary as shown in the figure. (1) (2) Even within the same area, the compressor capacity varies depending on the refrigerant temperature. (3) (4) (5) (6) When the area changes to area C, area C is considered to be area B for control purposes for the first 6 min- utes, even if the horsepower is the minimum value within the range where capacity control is possible (opera- tion with inverter frequency of 25 Hz only). Subsequently if C area continues, the thermostat turns OFF. 3-6-1. Evaporation Temperature (Te) Control: Control of Indoor Units Operating in Cooling Mode 51.9 51.8 41.1 41.0 35.6 35.4 Horsepower decrease Horsepower increase prohibited Horsepower increase permitted Horsepower increase permitted Area A Area AB Area B Area C 60.8 53.6 51.8 45.5 41.0 35.6 Maximum requirement level [L] 0 15 30 For indoor units that are operating in Cooling Mode, if one unit is selected for a test run mode, the room temper- ature control by the set temperature cannot be performed. Areas B and C are assumed to be area A for control purposes, instead. By this reason, the compressor continues its operation regardless of the low evaporation temperature (This is used for additional charging of refrigerant, test run checking etc.) Vapor may be discharged if the test run continues for a long time. However, this does not indicate problems. If the thermostat turns OFF while Te is within area C, the next time the compressor starts it may restart from a lower capacity. For 6 minutes after the compressors start, area C is considered to be area B for control purposes. During special control, control of the compressor capacity according to Te is not performed. 1 - 6 3. Compressor Control W-2WAY ECO-i SYSTEM Control Functions

* Depending on the maximum requirement level of the indoor unit, the judgment temperatures for each area may vary as shown in the figure (example). (1) For indoor units which are operating in Heating mode, if one unit is selected for a test run, the air intake tem- perature difference is ignored, however Tc control is performed according to the figure above in order to pre- vent excessive load. (This is used for test run checks, etc.) (2) Even within the same area, the compressor capacity varies depending on the refrigerant temperature. (3) (4) (1) During operation when only a single outdoor unit is installed, the air discharge temperature level is determined (the highest value is used), and the compressor capacity is limited, by using the air discharge temperature of the operating compressor (as shown in the tables below). Air discharge temperature level: Highest level among the air discharge temperature levels of all compressors 2 1 0 3 4 5 221 219 217 Discharge temp. °F Horsepower limit Less than 208 Decrease by 2 horsepower Decrease by 1 horsepower Decrease by 0.5 horsepower No control The values shown in the table above are reduced to the values calculated by roadmap control. Condensation Temperature (Tc) Control: Control of Indoor Units Operating either in Cooling Mode or Heating Mode 3-6-2. 118.5 118.4 116.6 116.4 113.0 112.8 Horsepower decrease Area D Area C Area B Area AB Area A 118.4 116.6 30 15 0 98.6 100.4 109.4 107.6 If the condensation temperature (Tc) enters area D and the thermostat turns OFF, the next time the compressor starts it may restart from a lower capacity. Temperature PX is the coefficient value used to correct for any deviation with the high pressure or condensa- tion temperature. It may vary. (At the time of shipment it is 127°F.) Protection control consists of 2 types of protection: discharge temperature protection and current protection. The limit values from this protection control are incorporated into the output compressor capacity increase/decrease values that were calculated from control based on the temperature at the indoor unit heat exchanger coil (roadmap control). In some cases, the control shown below may stop the compressor, issue a warning, or reduce the compressor capacity. * Discharge Temperature Protection Air discharge temp. level 212 ~ Less than 217 208 ~ Less than 212 Permit horsepower increase (slowly) 3-6-3. Protection control Prohibit horsepower increase 1 - 7 W-2WAY ECO-i SYSTEM Control Functions 3. Compressor Control

(1) If trip counter =1, the horsepower increases at a speed that is 1/2 of ordinary roadmap control. (2) If trip counter =2, the horsepower increases at a speed that is 1/3 of ordinary roadmap control. (2) Current Protection Inverter compressor current control is composed of primary current control and secondary current control. Current protection control for the inverter compressor is performed by self-protection in the inverter circuit, and does not increase or decrease the compressor capacity. 16.5A 13.5A 13.0A 12.5A 12.0A 90Hz 80Hz - Primary current Secondary current Inverter compressors stop (HIC auto. protection) Inverter compressors stop (When 100ms is detected, current protection works.) Control Hz decrease in the inverter compressor Prohibit Hz increase in the inverter compressor Permit Hz increase in the inverter compressor 75.0A or (302°F) 16.0A~ 14.5A~ 13.5A~ 3-6-4. Roadmap Control after Trip The trip counter will be cleared if no trip occurs within 10 minutes after operation starts. 1 - 8 3. Compressor Control W-2WAY ECO-i SYSTEM Control Functions

* When the above operation is finished, normal operation starts at the horsepower determined by the indoor units where thermostats are ON. Control time 1. 2. 3. (1) Cooling control when the outdoor unit heat exchanger is acting as a condenser Indoor units * Control time When the oil level in an operating compressor is detected as 0 (zero), the compressor stops in 120 seconds. If this compressor repeats this operation 3 times and the oil level does not reach 2, system refrigerant oil recovery con- trol is started. * In addition to ordinary heating and cooling operation, this system also includes the following 3 types of special con- trols for control of the system as a whole. 4-way Valve Adjustment Control System refrigerant oil recovery control Defrost control 4-1. 4-way Valve Adjustment Control When the microcomputer is initialized immediately after power-ON, after warning output, and all outdoor units are kept stopped for a preset period (standard = 60 minutes) , the 4-way Valve Adjustment Control will be performed. This control is intended to changeover the 4-way valve of outdoor unit. When the unit has been stopped for long period, and if refrigerant has accumulated somewhere in the tubing, recovery of the refrigerant is performed. This control can also compensate for tubing thermal loss by radiation during heating start as well as for oil recovery. 4-2. System Refrigerant Oil Recovery Control 4-2-1. System refrigerant oil recovery cycle 4-2-2. Start of System Refrigerant Oil Recovery Control When the compressor has stopped because the oil level is 0, a count is added to the alarm counter. The counter for this compressor is not cleared unless the oil level for that compressor reaches 2, or else alarm output occurs. Outdoor units Electronic Thermostat Expansion Valve RAP valve kit Fan All outdoor units operate at the maximum horsepower. 60 seconds Outdoor units Electronic Thermostat Expansion Valve RAP valve kit Fan Valves at all indoor units operate at a fixed pulse according to the indoor unit capacity. Valve kits at all indoor units operate in Cooling mode (OFF status). Fan operates at the set fan speed or stops, depending on the indoor unit operation mode. Valve kits at all indoor units operate in heating mode (ON status). Fan operates at the set fan speed, stops or operates at a very low speed, depending on the indoor unit operation mode. Minimum 1 min - Maximum 10 min [until max (pressure sensor temp., E1) 95°F ] All outdoor units operate at the maximum horsepower. Valves at all indoor units operate at 250 pulses as a default. When the above operation is finished, normal operation starts at the horsepower determined by the indoor units where thermostats are ON. This control is performed using the cooling cycle during cooling operation and using the heating cycle during heat- ing operation. Indoor units 1 - 9 W-2WAY ECO-i SYSTEM Control Functions 4. Special Controls

Simplified flow of system refrigerant oil recovery control Refrigerant oil recovery control between systems shall be performed as the flow mentioned below. Cooling cycle 4-3-1. Defrost Methods Maximum 3 minutes (Stops once before and once after control.) All outdoor units operate at maximum horsepower. Outdoor units Electronic Thermostat Expansion Valve RAP valve kit Fan Indoor units Valves at all indoor units operate at a fixed pulse according to the indoor unit capacity. Valve kits at all indoor units operate in Cooling mode (OFF status.) Fan operates at the set fan speed, or stops depending on the operation mode of the indoor unit. Heating cycle Control time Outdoor units Maximum 3 minutes (Stops once before and once after control.) All outdoor units operate at maximum horsepower. Valves at all indoor units operate at 480 pulse. Valve kits at all indoor units operate in Heating mode (ON status.) Fan operates at the set fan speed, stops or operates at a very low speed. Expansion Valve Electronic Thermostat RAP valve kit Fan Indoor units 4-3. Defrost Control This system uses the following 2 defrosting systems. System employs Defrost control method Reverse cycle defrost Outdoor unit cycle defrost 1 outdoor unit in the refrigerant system 2 outdoor units in the refrigerant system 4-3-2. Constraint conditions Frost detection does not occur for 5 minutes after operation starts. Defrost does not begin again for 35 minutes of A/C operation after defrost was once completed. If all indoor units are stopped while defrost control is in effect, or if the outdoor unit is stopped due to protection control or another reason, then defrost control will not start for a minimum of 10 minutes after restart occurs. Normal operation 3-minute stop Refrigerant oil recovery control between systems (Max. 3 minutes) 3- minute stop Normal operation 1 - 10 4. Special Controls W-2WAY ECO-i SYSTEM Control Functions

operating. Condition 2: L1 line or below is detected for a total of 60 minutes when the compressor is operating. 4-3-4. Outdoor units where defrost occurs * Defrost control is also performed at outdoor units where the outdoor unit heat exchanger is not functioning as an evaporator (such as stopped outdoor units). • Defrost flow E: Evaporator operation C: Condenser operation E C: Switching from evaporator operation to condenser operation C E: Switching from condenser operation to evaporator operation –13 –9 14 L2 L1 26 –6.5 17 30 50 50 Heat exchange liquid temperature °F Defrosting operation end temperature (The end temperature is different from the above detection temperature.) E E E E E E E E E E C Stopped Stopped 4-3-3. Frost detection (A) Frost detection does not occur for 5 minutes after operation starts. (B) Frost is detected when either condition 1 or 2 below is met. External temperature °F The frost detection area is located under the thick lines Even if the total time has not reached 35 minutes, if there is 1 or more outdoor units that fulfills the defrost detec- tion conditions, all operating outdoor units perform defrost control at the same time. 4-3-5. Reverse Cycle Defrost If there is 1 outdoor unit and no thermal storage tank in a refrigerant system, a reverse cycle defrost will be carried out. Outdoor unit status Stopped indoor units Indoor units where fan is operating Cooling mode indoor units Heating mode indoor units Thermostat ON Thermostat OFF Thermostat ON Thermostat OFF Compressor Time Operating Operating Max. 10 min Defrost end judgment Defrost preparation Defrost in progress Defrost end 1 min C E E E C E C E C E C E C E E C C E E C E C E C E C E C E C 1 min 1 min E C 1 - 11 W-2WAY ECO-i SYSTEM Control Functions 4. Special Controls

E: Evaporator operation C: Condenser operation S: Shut off E C: Switching from evaporator operation to condenser operation C E: Switching from condenser operation to evaporator operation ON ON ON ON C C C C E C C S S S C C S S S S S C C C ON C OFF Switch (1) 4-3-6. Outdoor unit cycle defrost Outdoor unit cycle defrost is performed in systems where 2 outdoor units are connected to the refrigerant system. Description of outdoor unit cycle defrost With this defrost method, when 1 outdoor unit operates in defrost mode (heat exchanger operating as a con- denser), another outdoor unit operates as an evaporator in the same way as in ordinary heating mode. In this way, the other outdoor unit is heating the unit where defrost is occurring. When 1 outdoor unit completes defrost, the other outdoor unit performs defrost in the same way. Because the amount of time that the unit operates as an evaporator is very short, there is little danger of frost forming again quickly. Rather, because the heat source is very powerful, it is possible to shorten the defrost operating time. Defrost sequence Outdoor unit cycle defrost is always completed in 2 defrost operations. (A) When there are 2 outdoor units Defrost outdoor unit outdoor unit Evaporator outdoor unit outdoor unit Defrost First operation Second operation Outdoor unit(s) where defrost occurs first Outdoor compressor(s) where defrost occurs first Outdoor unit(s) where defrost follows later Outdoor compressor(s) where defrost follows later Stopped indoor unit(s) Indoor units where fan is operating Heating mode indoor units Thermostat ON Thermostat OFF Time Defrost preparation Defrost in progress Defrost in progress Defrost preparation E or S OFF OFF S Defrost end judgment 1 min Max. 6 min Max. 6 min Defrost end judgment OFF 1 min E E OFF S C E or S E C E C C E 1 min 1 - 12 4. Special Controls W-2WAY ECO-i SYSTEM Control Functions

Defrost ends when either of the below defrost end judgment conditions is met. Condition 1: The temperatures are 50°F or higher at all temperatures sensors installed on the outdoor unit heat exchanger coils. However, if there is any other outdoor unit where the defrost end condition has not been met, defrost control continues for all outdoor units, and system defrost control is not ended. Condition 2: The maximum defrost time listed in the table above has elapsed. 4-3-8. System defrost end When all outdoor units where defrost control is in effect have met the defrost end conditions, defrost control is ended for the system. 1 - 13 W-2WAY ECO-i SYSTEM Control Functions 4. Special Controls

However, if the oil level becomes 2, this control is stopped. * If the low oil level continues, that outdoor unit (oil-receiving outdoor unit) receives a supply of oil from operating outdoor units where the oil level is not low (oil-supply outdoor units). (1) Control at the oil-supply outdoor unit begins 3 minutes after the oil level at the outdoor unit dose not become 2. Oil supply is performed for a maximum of 5 minutes from each unit. (2) When oil supply is ended, oil supply from that outdoor unit will not occur again for a period of [(No. of outdoor units minus1) x 5 minutes]. In addition, oil supply is ended if the oil-receiving outdoor unit oil level changes to 2, or if the oil-supply outdoor unit oil level becomes low. (3) The supply of oil is received from 1 unit at a time, in sequence, according to the order of priority of their inverter compressors. (4) Operation during unit refrigerant oil recovery (A) Oil-receiving outdoor unit (B) Oil-supply outdoor unit Meaning Conditions of oil Judgement 5-1. Oil Control 5-1-1. Oil level Oil level The compressor oil is short against the required oil level sufficient for normal operation. The compressor contains sufficient oil but there is a possibility of shortage against the required oil level. The compressor contains oil more than the oil level which is necessary and sufficient for normal operation. There is no problem. Confirm that oil is returned after performing the oil control operation. Confirm that oil level is recovered to the required level after performing the oil recovery control between systems. At the time immediately after the oil level changes from 2 to 1, there is a specified amount of oil in the compressor. Namely, soon after the oil level is changed to 1, the oil in the compressor is not empty. If the oil level “0” indication continues for more than 5 to 10 minutes, it seems short of oil in the system. Check for any oil leakage as well as the refrigerant tubing. 5-1-2. Oil level detection Excess oil in the compressor is sent by bypass via a capillary tube to the low-pressure circuit. The temperature detected by a temperature sensor is used to determine whether it is oil (warm) or refrigerant (cold). 5-1-3. Self-separator oil recovery control * When a low oil level is detected, this control recovers the oil which has accumulated in that oil separator and sends it to the compressor. Operation when oil level is not 2. 5-1-4. Unit refrigerant oil recovery control – utilizing balance tubes The recovery valve turns ON and remains ON. The balance valve turns ON and remains ON. The bypass valve repeatedly turns ON and OFF according to a constant cycle. 5-1-5. Indoor unit refrigerant oil self-recovery control Refer to the items concerned with indoor unit special control. Sufficient Slightly low Extremely low 2 1 0 1 - 14 5. Other Controls W-2WAY ECO-i SYSTEM Control Functions

(A) Cooling operation (B) Mixed cooling/heating operation The main purpose of this valve is to detect the flow of refrigerant (refrigerant volume) on the indoor-unit side when the outdoor unit heat exchanger is functioning as an evaporator. When the valve determines that there are signs of excess refrigerant, refrigerant is recovered at the receiver tank. This valve is ON during heating operation and when the outdoor unit heat exchanger is functioning as an evapora- tor during mixed heating/cooling operation. It also turns ON in order to recover refrigerant at the outdoor unit after heating operation is stopped. (1) (2) (3) (A) Heating operation (4) This valve turns OFF when an abnormal drop in discharge gas temperature is detected. (5) This valve turns OFF when a drop in the detected receiver tank temperature contin- ues for a set length of time, and when liquid back-flow is judged to be occurring. Hp Lp 6-1. Refrigerant Control Valve [RCV] The main purpose of this valve is to detect the flow of refrigerant (refrigerant volume) on the indoor-unit side when the outdoor unit heat exchanger is functioning as a condenser. When the valve determines that there are signs of a low refrigerant level, refrigerant is supplied from the receiver tank to the system. The OFF conditions take priority over the ON conditions for this valve. This valve is OFF when the outdoor unit is stopped. This valve is ON when special control is in progress. This valve turns ON when symptoms of insufficient refrigerant gas occur at an indoor unit. This valve turns ON when the outdoor air temperature is 59°F or below. (Under these conditions the high pressure is low and refrigerant flow becomes poor.) This valve turns OFF when symptoms of refrigerant overcharge are detected at the outdoor unit. The RCV turns ON at stopped outdoor units when the heat exchanger at anoth- er outdoor unit is functioning as a condenser. 6-2. Refrigerant Balance Valve [RBV] – Gas Purge Valve * This valve is never turned ON at the same time with the RCV. This valve turns ON once after the outdoor unit starts. This valve turns ON for 30 – 50 seconds after the outdoor unit stops, and then turns OFF. The OFF conditions take priority over the ON conditions for this valve. This valve is ON during heating operation and when it turns ON for the purpose of recovering refrigerant in the outdoor unit at the end of the heating operation. After the valve turns from ON to OFF, it will not turn ON again for 15 minutes. This valve turns ON when poor refrigerant flow at an indoor unit is detected, and when symptoms of overcharge are detected, if the heat exchanger at the outdoor unit is functioning as an evaporator. 1 - 15 W-2WAY ECO-i SYSTEM Control Functions 6. Operation of Solenoid Valves

(2) When unit is operating (A) (B) (C) (D) (E) (F) (G) (1) When unit is stopped (2) When unit is operating 6-3. Recovery Valve (ORVR) This valve recovers refrigerant oil from the balance tube to the compressor. This valve is always OFF. This valve turns ON when separator oil self-recovery control is in progress. This valve is ON when unit refrigerant oil recovery control is in progress (oil-receiving unit). This valve is ON when control the system in case of insufficient refrigerant gas. This valve turns ON for 60 seconds after a constant-speed compressor starts. This valve turns ON for 120 seconds after defrost control ends. This valve turns ON for 10 seconds after the outdoor unit stops. This valve remains OFF at all times other than (A) through (F) above. 6-4. Bypass Valve (BPV) This valve flushes the oil from the balance tubes. In addition, it is used for recovering refrigerant from stopped out- door units during cooling operation. This valve is always OFF. This valve is ON at the oil-supply outdoor unit when unit refrigerant oil recovery control is in progress. * This valve repeatedly turns ON/OFF at regular intervals during unit refrigerant oil recovery control. (It is not constantly ON.) 1 - 16 6. Operation of Solenoid Valves W-2WAY ECO-i SYSTEM Control Functions

[CHDX07263, CHDX09663] Capacity Electronic control valve Electronic control valve 1 Electronic control valve 2 Electronic control valve 4 Heat exchanger 1 valve Heat exchanger 2 valve For SC circuit Heat exchanger 1 valve Heat exchanger 2 valve For SC circuit 7-2. Power Initialization If no indoor units have started (even once) after the power was turned ON, the outdoor unit electronic control valve operates at 480 pulses. 7-3. Heat Exchangers which are controlled by each Electronic Thermostatic Expansion Valve The configuration of heat exchangers is as shown in the figure below. MOV3 is excluded. Heat exchanger 2 Operation of Electronic Thermostatic Expansion Valve during normal unit operation If any one compressor in the outdoor unit is operating, the outdoor heat exchanger coil is used. In cooling operation, all the inverter compressors are designed to operate, therefore, all the outdoor heat exchangers in the outdoor units will be used. SH control controls the difference between the liquid temperature and gas temperature to 2°F ~ 10°F. During heating mode SH operation in the heat exchanger 2 side, in order to prevent a liquid-back or high load operation from occurring a control may be implemented so that refrigerant may not flow intentionally to the heat exchanger. 1 - 17 W-2WAY ECO-i SYSTEM Control Functions 7. Outdoor Unit Electronic Thermostatic Expansion Valves [MOV1, MOV2 & MOV4]

(1) SC Control (Cooling Mode only During cooling operation, the liquid refrigerant which condenses at the outdoor unit heat exchanger flows into the receiver tank, and SC (sub-cool = supercooling) approaches 0°F. When SC is small and the length of the tubing connecting the indoor and outdoor units is long, the refrigerant flow in the indoor unit will be reduced sig- nificantly. To prevent this trouble from occurring, MOV4 operates so as to increase supercooling in the double tube coil near the outlet of the outdoor unit. MOV4 controls refrigerant so that it will not flow back to the compressor in the liquid state with a suction tem- perature sensor near the accumulator and a low pressure sensor. (2) Operation when discharge temperature is high When the discharge temperature increases, the SC circuit electronic thermostatic expansion valve opens to 480 pulses to cool down the compressor. This operation takes priority over operation intended to increase SC. It is performed at top priority in all operating modes. In addition, the valve opening adjustment will be made when the discharge temperature falls. Gas refrigerant returns to the accumulator. Liquid refrigerant (large SC) Liquid refrigerant (SC = 0°F) Refrigerant on the outer side evaporates, cooling the liquid refrigerant on the inner side. Electronic control valve 4 (expansion valve) controls the flow. Does not fully evaporate, resulting in liquid back-up. Liquid refrigerant returns to the accumulator. Liquid refrigerant Electronic control valve 4 opens to 480 pulses. Liquid refrigerant 1 - 18 7. Outdoor Unit Electronic Thermostatic Expansion Valves [MOV1, MOV2 & MOV4] W-2WAY ECO-i SYSTEM Control Functions

* 8-3. Fixed Initial Fan Mode For the first 30 seconds after operation starts, the mode is fixed at the initial mode which was calculated from the relationship between the outdoor air temperature and the outdoor unit horsepower. If the outdoor unit horsepower changes dramatically, say for about 2 hp, the initial mode may be recalculated and may be again fixed for 30 seconds. 8-4. Operation after Fixed Initial Fan Mode (A) Fan mode is increased when the high pressure satulation temperature sensed by the pressure sensor is high, and is decreased when the pressure sensor temperature is low. (B) (A) (B) (C) (1) (2) * 1 14 14 These outdoor units utilize a DC fan motor that can be controlled in a maximum of 16 steps (16 modes). However, fan modes 15 and 16 can only be used if high static-pressure mode has been set. * For information concerning EEPROM settings, refer to the field application functions. 8-2. Outdoor Fan Min. Fan Mode and Max. Fan Mode Min. fan mode Max. fan mode Cooling operation Heating operation Outdoor air temp. > 59°F: 1 Outdoor air temp. < 59°F: 0 After the fixed initial fan mode, the fan mode is increased or decreased according to the operating conditions. If the condensation temperature is low, the fan mode is increased at regular intervals. If the condensation temperature is high, the fan mode is decreased in order to prevent excessive loads. (1) When all indoor units are operating in cooling mode The fan mode may be decreased when symptoms of insufficient refrigerant gas are detected at an indoor unit. (2) When all indoor units are operating in heating mode The fan mode may be increased when the outdoor liquid temperature drops to 44°F or below. 8-5. Snow Removal Control When the outdoor air temperature is 50°F or below, the fan operates for 30 seconds every 2 hours in fan mode 8, even when the outdoor unit is stopped or the heat exchanger is not in use. This control is intended to prevent snow from accumulating on stopped fans. (Because the outdoor air temperature cannot be accurately detected when the unit is stopped, a higher outdoor air temperature is used for the control condition, in order to ensure correct operation.) If the fan mode becomes 0 during cooling operation, the fan mode is changed to 1. This control is predictive control. Use a snowfall sensor as necessary according to the installation conditions. 8-6. When the Compressor Magnet Switch Seizing Alarm Occurs Because there is the possibility that the high pressure has increased, the fan operates in Max. fan mode. 8-7. Other This unit includes settings for high static-pressure and for Quiet mode. For information about these settings, refer to the field application functions. * The fan mode is always increased when the high pressure satulation temperature sensed by the pressure sensor is 113°F or higher. Even if the fan mode is 0 during cooling operation, the fan mode may change to 1 at regular intervals for tem- perature protection of the inverter hybrid IC. 1 - 19 W-2WAY ECO-i SYSTEM Control Functions 8. Outdoor Fan Control

parallel I/O, and demand control is performed. The demand values can be set as needed with this device. For more information, refer to the field application func- tions. Control Demand meaning Operates to maximum capacity. No control Operates to the upper limit for the rated current. Operates to 70% of the upper limit for the rated current. Always in stop condition. Demand setting Contact 1 Contact 2 Input present Input not present : : * The rated current indicates the current value that is listed in the catalog or similar material. 1 - 20 9. Demand Control W-2WAY ECO-i SYSTEM Control Functions

(1) Cooling operation Position of electronic control valve Stopped Fan Thermostat OFF Thermostat ON Cooling Outdoor unit operating Outdoor unit stopped Performs SH control in the range of 55 – 480 pulses. * The SH target value is controlled so that the E3 - E1 becomes between 2°F to 6°F, depending on the operating conditions. However, a decline in the required level may cause the SH target value to increase. Be aware that in this case, the electronic control valve closes slightly. This can be easily identified incorrectly as insufficient gas. (A) Except Type D 20 20 20 20 (2) Heating operation Position of electronic control valve Outdoor unit operating Stopped Outdoor unit stopped Fan Heating Thermostat OFF Thermostat ON 85 85 85 Liquid refrigerant is gradually returned to the outdoor unit at pulses ranging from 55 to 80. Liquid refrigerant is gradually returned to the outdoor unit at pulses ranging from 55 to 80. Liquid refrigerant is gradually returned to the outdoor unit at pulses ranging from 55 to 80. Performs SC distribution control within the range of 55– 480 pulses. * The SC target value is controlled so that the high pressure saturated temp. - E1 becomes between 10°F to 40°F , depending on the operating conditions. * The SC target value is controlled so that the high pressure saturated temp. - E1 becomes between 10°F to 40°F, depending on the operating conditions. However, if installation is combined with except Type D, the high pressure saturated temp. - E1 may be controlled between 10°F to 80°F. (B) Type D Position of electronic control valve Stopped Fan Heating Thermostat OFF Thermostat ON Performs SC distribution control within the range of 55 – 480 pulses. Outdoor unit stopped Outdoor unit operating 20 20 20 20 1 - 21 W-2WAY ECO-i SYSTEM Control Functions 10. Indoor Unit Control of the Electronic Control Valve

Control Operating mode Subject indoor units Position of electronic control valve 4-way valve adjustment control Reverse cycle defrost control Outdoor cycle defrost control System refrigerant oil recovery control Cooling Heating Heating Cooling/ heating Cooling Heating All indoor units All indoor units Stopped Fan Thermostat ON Thermostat OFF Heating Heating Stopped Fan Thermostat ON Thermostat OFF All indoor units All indoor units Fixed pulse for cooling, according to indoor unit capacity 250 Cooling control, according to indoor unit capacity Cooling control, according to indoor unit capacity Fixed pulse for heating, according to indoor unit capacity Heating control, according to indoor unit capacity However, position is 20 pulses for Type D. 60 pulses 60 pulses 60 pulses 60 pulses Fixed pulse for cooling, according to indoor unit capacity 250 1 - 22 10. Indoor Unit Control of the Electronic Control Valve W-2WAY ECO-i SYSTEM Control Functions

ON ON ON 20 pulses 20 pulses 20 pulses A gas tube valve kit may be connected to the Type D indoor unit. When the gas tube valve kit is connected, operations of gas tube valve kit and indoor unit electronic thermostatic expansion valve are as shown in the table. Stopped Fan Cooling Heating Superheat control (65 – 480) 20 pulses Superheat control (50 – 480) OFF OFF OFF OFF Thermostat Thermostat Thermostat Thermostat OFF ON OFF 1 - 23 W-2WAY ECO-i SYSTEM Control Functions 11. Rap Valve Kit Control

During stopped, fan or thermostat OFF condition, indoor unit expansion valve is opened regularly for 1 to 2 min- utes regularly (at an interval of once every 2 hours.) During the thermostat ON, the indoor unit electronic thermostatic expansion valve is opened about 10 pulses from the current status. 1 - 24 12. Indoor Unit Refrigerant Oil Self Recovery Control W-2WAY ECO-i SYSTEM Control Functions

This device sets an upper limit discharge temperature of 222°F for all compressors. When the discharge tem- perature reaches 222°F, that compressor is stopped and restarted. If the same high discharge condition occurs 4 times, then an alarm occurs. After a compressor has stopped, that compressor will not operate until the temperature has dropped to or below the start-prohibit temperature. Discharge temperature protection list (2) Discharge sensor trouble detection control An alarm occurs if the discharge temperature remains abnormally high (above 158°F), when the system has been stopped for 60 minutes. * In this case, possible causes include sensor failure and compressor overheating caused by an insufficient level of refrigerant. The alarm also occurs if the sensor temperature is at or above the abnormal temperature (176°F) when 20 min- utes have passed after the compressor stopped. * In this case, it is possible that the discharge temperature from a different outdoor unit is being detected, due to an error in the installation of the discharge thermistor. Discharge sensor failure list 158°F 158°F P03 P17 Compressor No. Compressor 1 Compressor 2 Type Inverter Constant-speed Stop temp. 222°F 222°F Start-prohibit temp. Alarm display Type Alarm display F04 F05 Compressor No. Compressor 1 Compressor 2 Inverter Constant-speed 1 - 25 W-2WAY ECO-i SYSTEM Control Functions 13. Discharge Temperature

compressor. 96 Occurs during ordinary operation when overcurrent (27 A) is detected. (1) Fan motor (2) Inverter compressor (4) CT circuit detection trouble List of Alarms (3) Constant-speed compressor List of overcurrent and lock currents An alarm occurs when overcurrent or lock current is detected. The inverter current includes a primary current and secondary current. The alarm judgment utilizes both cur- rents. Generally, the secondary current is larger that the primary current. Alarm Description P22 Occurs when the fan motor detects over current, or when the motor is locked and does not turn. Alarm Description P16 P26 P29 H31 Occurs under the same conditions as P16 when the inverter compressor is operating at or above 80 Hz. Occurs when missing phase or overcurrent (48 A) is detected at inverter compressor start. (the alarm at frequencies below 25 Hz) Occurs when HIC detects overcurrent (75 A), or when an abnormal high temperature (302°F) is reached. Compressor 2 23.1 27.3 Outdoor unit type Constant-speed compressor Overload current [A] Lock current [A] Compressor No. Compressor 2 Detected current Alarm display Overcurrent Lock current H11 H12 Compressor 1 (inverter compressor) Compressor 2 (constant- speed compressor) Alarm H03 H13 Description Occurs when a current value of 1.5 A or less is detected when the constant-speed compressor is operating. If the inverter compressor operating frequency is low, the current value is also low. Therefore this alarm is detected only when the compressor is stopped. The operating current of the constant-speed compressors is always higher than 1.5 A. Therefore, this alarm occurs as the result of an open circuit or failure. 1 - 26 14. Current Protection W-2WAY ECO-i SYSTEM Control Functions

This system contains 2 types of pressure sensors: a high-pressure sensor and a low-pressure sensor. Alarms are emitted when the high-pressure sensor becomes an electrical open-circuit or a short-circuit condi- tions, and a broken wiring, short-circuit or poor connection to the PCB in the high-pressure sensor circuit. Low-pressure sensor failure Alarms are emitted when the low-pressure sensor becomes an electrical open-circuit or a short-circuit condi- tions, and a broken wiring, short-circuit or poor connection to the PCB in the low-pressure sensor circuit. Alarm display High-pressure sensor failure Low-pressure sensor failure F16 F17 1 - 27 W-2WAY ECO-i SYSTEM Control Functions 15. Pressure Sensor Failure

(B) At the S010 switch on the PCB of the failed outdoor unit, turn ON the switch for the compressor to dis able, and turn ON the “backup” switch. Backup Operation 16-1. Automatic Backup Operation This system includes a function for automatic backup operation. An alarm is also displayed to inform the operator that a failure has occurred. (1) Alarms that result in automatic backup operation When compressor trouble or fan motor trouble makes emergency continued operation impossible, automatic backup operation mode is engaged. Automatic backup mode is not engaged in cases of communications alarms, automatic reset alarms, and other instances when emergency operation is possible by pressing the remote controller buttons or changing other conditions. The alarms that result in automatic backup mode are P16, P22, P26, P29, H11, H12, and H31. (2) Start of automatic backup operation If the above alarms occur, the alarm is displayed on the control device. Pressing the control device button again starts automatic backup mode. (3) Operation [1] When 1 outdoor unit is installed When 1 compressor has failed, backup operation is possible using the other compressors (only in the 09663 model (8 Ton)). However, operation does not occur when the outdoor fan is unable to operate as a result of alarm P22. [2] When multiple outdoor units are installed When automatic backup mode is engaged, the outdoor unit where the above alarm occurred stops operating. However, if one or more of the compressors is able to operate, then this outdoor unit operates only when the operation of all outdoor units is required for special control (such as 4-way valve adjustment) or other system purposes. (4) Alarm display If a wired remote controller is present, display blinks during operation. (5) Canceling automatic backup operation Repair the outdoor unit where the failure occurred. When repairs are completed, reset the power on outdoor unit No.1. After automatic backup mode has been engaged, it will not be canceled automatically when the repair of the failed outdoor unit is completed. Automatic backup mode will be canceled only when the power on outdoor unit No.1 is reset. Therefore, after repair work is completed, be sure to check whether or not automatic backup mode has been canceled. How to check: [1] Use test run or other means to verify that all outdoor units operate continuously. [2] If a wired remote controller is present, check that display has disappeared. 16-2. Manual Backup If an alarm that does not result in automatic backup occurs frequently, possible causes include failure (such as refrigerant leakage) of a functional part at an outdoor unit other than the unit where the alarm occurs. In this case, because the outdoor unit service valve must be closed, backup operation must be performed manually. (1) Backup operation procedure [1] Disconnecting the failed outdoor unit 1 - 28 16. Backup Operation W-2WAY ECO-i SYSTEM Control Functions

At the S010 switch on the PCB of the failed outdoor unit, turn ON the switch for the compressor to disable, and turn ON the “backup” switch. ON (C) Close all service valves at the failed outdoor units. (D) Reset the power at outdoor unit No.1. Switches to turn ON Outdoor unit tonnage 8 Ton INV+AC1+BU * When the PCB of the main unit is normal, by implementing the above settings while leaving the communica- tion lines between indoor and outdoor units as they are, backup operation of units are possible. In this case, the outdoor unit that backed up all compressors is not identified as an outdoor unit, however, it can work as the command controller. OFF OFF OFF ON ON (A) Compressor 1 backup S010 (B) Compressor 2 backup INV AC1 AC2 ( * ) * AC2 switch is not available. Backup 1 - 29 W-2WAY ECO-i SYSTEM Control Functions 16. Backup Operation

This setting controls the operation of the drain pump. 17-3. Delayed Start for Each System: Outdoor EEPROM 3E (set only on outdoor unit No. 1) The operation start time can be delayed according to the set system addresses. This setting reduces the voltage drop by preventing multiple systems from starting at the same time when opera- tion is restarted after multiple operating systems were stopped due to a power outage or other cause. 17-4. Automatic Backup: Outdoor EEPROM 48 (set only on outdoor unit No. 1) 0 1 2 3 14 1 12 2 11 3 10 The outdoor unit EEPROM settings can be used for the following functions. 17-1. Outdoor Unit Noise Countermeasure: EEPROM 05 (set at each outdoor unit) This unit includes 3 types of Quiet modes. (However, when they are engaged, operation is in Quiet mode 24 hours a day.) Selecting a Quiet mode results in operation that gives priority to reducing noise. Because these modes involve restrictions on outdoor unit fan modes and the operation frequency, the capacity will be somewhat reduced. Normal operation (setting at time of factory shipment) Noise reduced by approx. 1 – 2 dB from the catalog value. Noise reduced by approx. 2 – 3 dB from the catalog value. Noise reduced by approx. 5 dB from the catalog value. Approx. 0.5 hp Approx. 1.2 hp Approx. 1.8 hp 0 0 1 2 3 The drain pump operates for 20 minutes at 20-minute intervals. The drain pump operates constantly. Setting Max. fan mode Effect Amount of capacity reduction Setting Setting Effect Description 0 Normal control (setting at time of factory ship ment) The drain pump operates for 20 minutes at 2-hour intervals. No delayed start (setting at time of factory shipment) Start begins after [1 second x System address] Start begins after [2 seconds x System address] Start begins after [3 seconds x System address] Automatic backup is set to occur at the time the unit is shipped from the factory. However, the automatic backup function can be disabled by changing this setting to 1. * If Quiet mode is set, the capacity will begin to decrease during heating operation at low outdoor temperatures, when the outdoor air temperature is below standard conditions. 1 - 30 17. Service Maintenance Functions W-2WAY ECO-i SYSTEM Control Functions

capacity. – 17-5. Optional Solenoid Valve Control Operation Setting: Outdoor EEPROM C0 (set at each outdoor unit) 17-6. High Static Pressure Mode: Outdoor EEPROM 8F (set at each outdoor unit) This product can be made compatible with high static pressure by changing the settings. By changing the setting item 8F to “6,” this product can be made compatible with outdoor unit static pressure of approximately 0.0085 psi (10 hp type only). 17-7. Compressor Operating Sequence: Outdoor EEPROM 46 (set at outdoor units which include CCU functions) When this setting is set to “1,” the compressors start in sequence beginning from the No. 1 outdoor unit. (The setting is “0” at the time of shipment. With this setting, compressors with lower operating time are started first in order to balance the compressor operating times.) 17-8. Demand Value Setting: Outdoor EEPROM 1A, 1B (set at outdoor units that include CCU functions) Setting Operation Setting No. Compatible static pressure (psi) Speed Demand setting Demand meaning Control No output (setting at time of factory shipment) Refrigerant shut-off valve control (for cooling when the outdoor air temperature is below standard conditions) External liquid valve control (used in special cases when the discharge gas temperature is especially likely to rise) 1 2 4 5 0.0037 0.0061 0.0085 Contact 1 Contact 2 No limit Demand can be set from 40 – 200% at EEPROM 1A. Demand can be set from 40 – 200 % at EEPROM 1B. Remains stopped. Current is limited to the set values. Current is limited to the set values. 1 - 31 W-2WAY ECO-i SYSTEM Control Functions 17. Service Maintenance Functions

* If the snowfall sensor is used, then depending on the circumstances it is necessary to make the correct setting at all outdoor units in the system. * If “control is not performed” is set, control by the above signal is ignored. This setting is used in order to conserve energy at outdoor units that include a snowfall-protection hood. Recommended: If a low-speed fan mode is required (for all-year cooling or other reasons), install a snowfall-pro- tection hood and set this setting to ON. [1] Outdoor units where “sensor input present” is set send the snowfall sensor input information every 10 min- utes to all linked systems if the system wiring is linked. [2] At systems where “control is performed” is set, the above information is used to control operation of the out door fan. - [3] At systems where “control is not performed” is set, the snowfall sensor input and above information ignored, and the outdoor fan does not operate. [4] 18-2. Function for Automatic Judgment of Insufficient Refrigerant Gas and Overcharg e Short-circuit the CHECK pin on the No. 1 outdoor for 4 seconds or longer to engage this mode. (The LED on the outdoor unit PCB begins blinking.) After judgment mode starts, judgment occurs when all outdoor units in the system have been operating contin- uously for 30 minutes or longer. 0 1 2 3 A unit identified as having a snowfall sensor attached will periodically send a signal indicating the snowfall sensor input status to all outdoor units in the same system (or all wired outdoor units in the case of linked systems). It is therefore unnecessary to install and wire multiple snowfall sensors. Sensor input not present. Control is performed. (Setting at time of factory shipment) Sensor input present. Control is performed. Sensor input not present. Control is not performed. Sensor input present. Control is not performed. Setting Operation (1) Snow fall sensor settings (2) Control operation In case of W-2WAY ECO-i system, control can be performed when snowfall sensor input is connected to any outdoor unit. Snowfall sensor input information is detected once every 10 minutes. Therefore, the outdoor fan may continue operating for up to 10 minutes even when there is no snowfall sensor input. In addition, the outdoor fan may remain stopped for up to 10 minutes when snowfall sensor input is present. This system includes a simple function for judging the level of refrigerant. However, be aware that false judgments may occur if the control elements of the outdoor unit or indoor unit fail. (1) Starting refrigerant level judgment mode (2) Conditions for refrigerant level judgment * Refrigerant level judgment requires that all outdoor units operate continuously for 30 minutes or longer. This is in order to prevent incorrect adjustment of the refrigerant level based on false detection caused by refrigerant accumulation or recovery at stopped outdoor units, which is due to failures of functional elements. After the judgment is displayed, repeated judgment will occur under new operating conditions if all outdoor units continue operating. Therefore, the judgment display may change when later judgments occur. * Judgment mode is automatically canceled after 4 hours. 1 - 32 18. Other Functions W-2WAY ECO-i SYSTEM Control Functions

other information. [1] Judgment mode is canceled automatically when 4 hours have passed after it was started. [2] Forced cancel Short-circuit the CHECK pin while the judgment mode display is active in order to cancel judgment mode. Judgment in automatic judgment mode can be problematic in some cases. Therefore, the following guidelines are provided for general judgment of the refrigerant amount. - - - Judgment items Judgment mode Normal Insufficient gas Overcharge Judgment not possible Blinking ON Blinking OFF Blinking alternately Blinking ON OFF Blinking LED1 LED2 Recommended response Charge with refrigerant a little at a time. Recover refrigerant a little at a time. If the insufficient gas or overcharge judgment is not stable, then recover refrigerant a little at a time when the overcharge display appears. End refrigerant adjustment when the normal or insufficient gas display appears. (4) Canceling judgment mode When judgment mode is cancelled, the LED returns to the standard status display (OFF unless an alarm or other event has occurred). Automatic cancel General Guidelines for Insufficient Gas and Overcharge • Symptoms of insufficient gas • Symptoms of overcharge There is an indoor unit where the position of the electronic control valve is much higher (open by 300 pulses or more) than it was at start, and the difference [E3 – E1] at that indoor unit is large (30°F or more). There is an outdoor unit where the position of the electronic control valve is much higher (open by 300 pulses or more) than it was at start, and the difference [Liquid temp. – Gas temp.] at that outdoor unit is large (30°F or more). The high-pressure sensor temperature is 134°F or higher, and the difference [Pressure sensor temp. – Liquid temp.] at that outdoor unit is large (30°F or more). There is an indoor unit where the position of the electronic control valve is much higher (open by 300 pulses or more) than it was at start, and the difference [Pressure sensor temp. – E3] at that indoor unit is large (50°F or more). These are only guidelines, therefore the judgment may vary depending on the installation conditions, load char- acteristics, and other elements. (3) Outdoor unit PCB LED indications in judgment mode Cooling operation Heating operation Cooling operation Heating operation 1 - 33 W-2WAY ECO-i SYSTEM Control Functions 18. Other Functions

W-2WAY ECO-i SYSTEM Outdoor Unit Repair Procedures Contents 2. OUTDOOR UNIT REPAIR PROCEDURES 1. Removing Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 2. Removing Electrical Component Box and Duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 3. Discharging Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 4. Backup Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 5. Recovering Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 6. Checking for Leakage After Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 7. Evacuating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 8. Charging Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 9. Pumping Out Refrigerant from Outdoor Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 10. Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 11. High and Low Pressure Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35 12. Replacing 4-way Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36

1. Removing Panels W-2WAY ECO-i SYSTEM Outdoor Unit Repair Procedures Fig. 1 Front panel Procedures: 1. Removing Panels 2. Removing Electrical Component Box and Duct 3. Discharging Compressor Oil 4. Backup Operation 5. Recovering Refrigerant 6. Checking for Leakage After Repair 7. Evacuating System 8. Charging Compressor Oil 9. Pumping Out Refrigerant from Outdoor Unit (when repairing parts other than compressor) 10. Compressor 11. High and Low Pressure Sensors 12. Replacing the 4-way Valve (1) Front panel removal (Fig. 1) • Remove the front panel (remove 11 screws). (2) Power outlet panel & valve cover removal (Fig. 2) • Remove the power outlet panel (remove 2 screws). • Remove the tubing cover (remove 2 screws). Fig. 2 Tubing cover Power outlet panel

W-2WAY ECO-i SYSTEM Outdoor Unit Repair Procedures 2. Removing Electrical Component Box and Duct (1) Remove the electrical component box cover (remove 6 screws). (Fig. 3) • When closing the cover after the repair work, set the upper fringe of the cover should come to align inside the electrical component box. (Fig. 3A) (2) Remove power and control wires from terminals. (3) Remove internal wires with extended connectors on the outdoor control PCB. (Solenoid valves, thermistors, crankcase heaters and others) (4) Disconnect power lines connected to the sec- ondary terminals of the magnetic contactor for the compressor. (5) Remove the electrical component box (remove 2 screws). (Fig. 4) Be sure to release the locking mechanism before disconnecting each connector. (6) Remove the center duct. (Fig. 5) • The center duct is fitted into the upper and lower ducts, and held in place by the electrical component box, an arrangement that makes possible indepen- dent removal of the center duct. CAUTION Be sure to turn off the power before removing the electrical component box. Then check that the power LED (D53) on the control PCB of the outdoor unit is not lit. Fig. 4 Electrical component box Fig. 5 Lower duct Upper duct Center duct Electrical component box cover A Fig. 3 Fig. 3A

2. Removing Electrical Component Box and Duct W-2WAY ECO-i SYSTEM Outdoor Unit Repair Procedures (7) Remove the lower duct: (remove 2 screws, and a hook) (8) Remove the upper duct: (remove 3 screws) (Fig. 7) Lower duct Upper duct Fig. 6 Fig. 7

W-2WAY ECO-i SYSTEM Outdoor Unit Repair Procedures 3. Discharging Compressor Oil Discharged oil can be used for checking the condition of the system. Based on the appearance and color of the discharged oil, a judgment can be made on whether the system is operating normally or not. 3-1. Discharging Oil from Oil Separator Recover the refrigerant from the outdoor unit following the procedure given in “5. Recovering Refrigerant.” Install hoses as indicated on the equipment and feed nitrogen gas gradually to provide pressure to the system from the low-pressure outlet and collect oil in a pan or container. (Fig. 8) The low-pressure outlet port is at the Lo side of the right side. A faulty outdoor unit may remain pressurized. The oil outlet port employs a Schrader-type push-to-release valve. Be careful to avoid accidental oil release when using the port. 3-2. Discharging Oil in Compressor Recover the refrigerant in the outdoor unit following the procedures in “5. Recovering Refrigerant.” Remove the compressor and discharge the oil in it. Refer to “10. Compressor” for detailed procedures. 3-3. Checking the Oil Acceptance/rejection criteria for the oil It is difficult to measure the total acid value in the field, therefore oil hue and odor are the rule of thumb. Checking for carbon deposits and abrasive metal powder can additionally be used to assess the system condition. CAUTION Judgment criteria for changing oil* Condition of refrigeration cycle Color Odor Total acid value Hue Normal Yellowish None 0.02 or less 3.5 or less 0.06 or over 4.0 or over Abnormal overheat- operation Brownish Smells somewhat (not as strong as below) Changing the oil and system cleaning with dry-cores are necessary. Motor burnout Brownish / blackish Pungent / burnt odor Changing the oil and system cleaning with dry-cores are necessary. Condition of oil Nitrogen gas Manifold gauge Packless valve or the like Container Low-pressure outlet port (For 5/16" (7.94mm)-dia. connector) Oil outlet port (For 1/4" (6.35mm) -dia. connector) Lo Hi Fig. 8 • • *

4. Backup Operation W-2WAY ECO-i SYSTEM Outdoor Unit Repair Procedures This system includes an emergency automatic backup function that allows the A/C to operate during the period after trouble occurs until repairs are made. However, during repair and at other times, use manual backup opera- tion. 4-1. Automatic Backup For details, refer to the control functions section. After the alarm details are sent to the control device, control for automatic backup operation begins when the ON/OFF button of the wired remote controller is pressed again (operation is started after the alarm is cleared). During this operating mode, “CHECK” flashes on the wired remote controller only to inform the user that operation is in backup mode. However this is not displayed on any other control devices. • In order to cancel automatic backup mode, it is necessary to reset the power on the control PCB of the outdoor unit where the outdoor unit No. setting (S007) on the control PCB is set to No. 1 (main unit). (It is also available by resetting power of all the outdoor units.) If the power is not reset on the control PCB of the No. 1 outdoor unit (main unit), backup mode operation will continue after the repairs are completed. Backup operation is intended as emergency operation until repairs are made. Have repairs made as soon as pos- sible. 4-2. Manual Backup This backup operation is the conventional method of backup operation. It involves disconnecting the failed outdoor unit from the system, and operating only the normal outdoor units. 4-2-1. Backup operation by disconnecting the outdoor unit (1) Changing the outdoor unit control PCB settings • Settings at No. 1 unit (main unit) • Settings at normal outdoor units other than the No. 1 unit No particular changes • Settings at the failed outdoor unit No particular changes However, close all service valves (gas tubes, liquid tube, and balance tube) at the failed outdoor unit, and dis- connect the wiring between the outdoor units. CAUTION Switch on outdoor unit control PCB Action System address (S003, S002) No change No. of indoor units (S005, S004) No change No. of outdoor units (S006) Subtract the number of failed units from the current setting. Outdoor unit No. (S007) No change

W-2WAY ECO-i SYSTEM Outdoor Unit Repair Procedures 4. Backup Operation If the No. 1 unit (main unit) has failed, a different outdoor unit must be set as the No. 1 unit (main unit). • Settings at the failed No. 1 outdoor unit – No particular changes – However, close all service valves (gas tube, liquid tube, balance tube) at the failed outdoor unit, and dis- connect the wiring between the outdoor units. • Settings at No. 1 unit (main unit) To this outdoor unit, connect the inter-unit communication line which was previously connected to the No. 1 unit (main unit). After recovery work is completed, wire the communication lines between indoor and outdoor units again. If it not finished yet, an alarm is emitted immediately. • Settings at other outdoor units No particular changes. (2) Adjusting the refrigerant for backup operation During backup operation, all of the service valves on the failed unit are closed. However, if a check of the backup operating conditions shows that the level of gas is low, recover the refrigerant from the failed outdoor unit. If the level of gas is too high, collect refrigerant at the failed outdoor unit. Recovering refrigerant With the normal outdoor units operating, monitor the operating condition and open/close the gas tube ser- vice valve on the failed outdoor unit where all the service valves were closed. In this way, recover refriger- ant from the failed outdoor unit in order to adjust the amount of refrigerant in the system. After adjusting the amount of refrigerant, close the gas tube valve at the failed outdoor unit. Collecting refrigerant in the failed outdoor unit • Short-circuit the vacuum application pin (CN102) on the control PCB of the failed outdoor unit where the service valves are closed, then turn the power ON. Also disconnect the wiring between the outdoor units. • With the normal outdoor units operating, monitor the operating condition and open/close the liquid tube ser- vice valve on the failed outdoor unit where all the service valves were closed. In this way, collect refrigerant in the failed outdoor unit in order to adjust the amount of refrigerant in the system. • After adjusting the amount of refrigerant, turn OFF the power at the failed outdoor unit, release the short- circuit at the vacuum application pin, and close the liquid tube valve at the failed outdoor unit. * Refrigerant recovery is not affected by the power status of the failed outdoor unit. However, collecting refrigerant in the failed outdoor unit is affected by whether the power at that outdoor unit can be turned ON. If the power cannot be turned ON, use a refrigerant recovery device and recover the refrigerant into a recovery cylinder in order to adjust the amount of refrigerant in the system. CAUTION Switch on outdoor unit control PCB Action System address (S003, S002) Make the same settings as on the failed No. 1 unit. No. of indoor units (S005, S004) Make the same settings as on the failed No. 1 unit. No. of outdoor units (S006) Subtract the number of failed units from the current setting. Setting outdoor unit No. (S007) Change to “1.”

4. Backup Operation W-2WAY ECO-i SYSTEM Outdoor Unit Repair Procedures 4-2-2. Backup operation by setting the failed compressor not to operate Backup operation settings for each compressor INV compressor AC1 compressor Setting for backup operation OK Failed DIP switch S010: Turn BACK UP and AC1 ON. Failed OK DIP switch S010: Turn BACK UP and INV ON. Failed Failed DIP switch S010: Turn BACK UP, INV, and AC1 ON.

W-2WAY ECO-i SYSTEM Outdoor Unit Repair Procedures 5. Recovering Refrigerant The following equipment and tools are required: Jumper wire with clips, adjustable wrench, set of manifold gauge valves specially designed for refrigerant R410A only, vacuum pump, refrigerant recovery unit, pre-purged refrigerant cylinder for recovery, flathead screwdriver, and outdoor unit maintenance remote controller. 5-1. Refrigerant Recovery Procedures (from outdoor unit) (1) Turn off the power of the outdoor unit beforehand (at power mains). (2) Fully close each service valve on the liquid tube, gas tubes, and the balance tube of the outdoor unit. (3) Connect the outdoor unit’s high-pressure and low-pressure outlet ports with the Hi and Lo sides of the manifold gauge valves using hoses. (Fig. 9) The remaining refrigerant in the faulty outdoor unit may create internal pressure. Before connecting hoses, be sure to confirm that each of the manifold gauge valves is tightly closed. Note that the connection ports employ Schrader-type push-to-release valves. (4) Connect the manifold gauge valves, refrigerant recovery unit, and recovery cylinder using hoses. To avoid the entry of air into the refrigerant tubing, carry out this connection work carefully. (Fig. 9) For detailed procedures such as connecting the refrigerant recovery unit with the recovery cylinder and methods used for recovery, follow the specific instructions that came with the refrigerant recovery unit. (5) Locate the AP (Air Purge) pins on the control PCB in the faulty outdoor unit and short them using the clips of the jumper wire. Then restore electrical power to the outdoor unit. By short-circuiting the AP pins, each solenoid valve in the outdoor unit is forcibly opened as soon as power comes on, which releases all remaining refrigerant into the recovery cylinder. Since neglecting this procedure may leave some refrigerant in the system, it is important that you carry out this step. (6) Carry out refrigerant recovery. To determine the completion of refrigerant recovery, follow the instructions that came with the refrigerant recovery unit. CAUTION CAUTION CAUTION CAUTION Fig. 9 Refrigerant recovery cylinder Low-pressure outlet port (For 5/16" (7.94mm)-dia. connector) Refrigerant recovery unit Manifold gauge Lo Hi High-pressure outlet port (For 5/16" (7.94mm) -dia. connector)

5. Recovering Refrigerant W-2WAY ECO-i SYSTEM Outdoor Unit Repair Procedures 5-2. Refrigerant Recovery Procedures (Indoor Unit) The flowchart below shows the refrigerant recovery procedures you must follow when replacing or repairing the indoor unit due to trouble in the refrigerant circuit. Service work performed on indoor units is done simultaneously using the service ports at the liquid (narrow tube) side and the gas (wide tube) side ball valves. Refer to each section in the “Installation Instructions” on refrigerant charging, leak checking, and evacuation procedures. 5-2-1. Cooling operation (for all units) (1) If the remote controller (RCS-TM80BG) is used for maintenance of the outdoor unit Connect the outdoor unit maintenance remote controller to the RC connector (CN006) (3P) (BLU) on any one of the outdoor unit control PCBs. Then start a test run of all units. (Press and hold the (CHECK) button for 4 seconds or longer.) Press the (MODE) button and change to cooling operation and ensure that the cooling is performed. Refer to the test run service manual for the detail of the outdoor maintenance remote controller operation. It may be possible to determine whether operation is cooling or heating by touching the gas tubing. Cooling : low temperature (68 °F or lower) Heating : high temperature (140 °F or higher) The gas tubing becomes hot (140 °F or higher) in heating mode. Be careful so as not to be burnt when touching the tubing. CAUTION START 5-2-1. Cooling operation (for all units) Ball valve is provided in the indoor unit Turn off all equipment in system Replace or repair faulty unit Check for leakage in repaired unit Evacuate air from repaired unit Ready for operation END Charge refrigerant in repaired unit (Amount of charge should equal that recovered by refrigerant recovery unit) Charge refrigerant in repaired unit H (Amount of charge should equal that recovered by refrigerant recovery unit) 5-2-3. Refrigerant recovery procedures (2) Turn off all equipment in system Other indoor units can operate normally Replace or repair faulty unit Check for leakage in repaired unit H Evacuate air from repaired unit H Open ball valve Ready for normal operation END END Ready for normal operation Open the ball valve Evacuate air in repaired unit H Check for leakage in repaired unit H Replace or repair faulty unit Charge refrigerant in repaired unit H (Amount of charge should equal that recovered by refrigerant recovery unit) Change controllable number of indoor units (including changes in group control and integrated-control settings) 5-2-2. Refrigerant recovery procedures (1) When replacing or repairing a faulty unit, let other normal indoor units run (excluding indoor unit where refrigerant is recovered) Modify power to permit turning off power to refrigerant-recovered indoor units independently Power can independently be turned off for indoor unit where refrigerant is recovered Change controllable number of indoor units (including changes in group control and integrated-control settings) NO NO NO YES Fig.8 YES YES 1 2

W-2WAY ECO-i SYSTEM Outdoor Unit Repair Procedures 5. Recovering Refrigerant (2) If the remote controller (RCS-TM80BG) is not available for maintenance of the outdoor unit Determine the outdoor unit where the unit No. setting (S007) (3P DIP switch) (Blue) on the outdoor unit control PCB is set to No. 1. Short-circuit the test-run pin (CN023) on the PCB to start test run operation. Leave the unit running for a while, and touch the gas tubing with fingers to determine whether the unit is running in cooling or heating mode. If it is in heating, follow the step and later procedures. Release the short-circuit at the test-run pin (CN023) on the outdoor unit control PCB of the No. 1 unit. Then short-circuit the stop pin (CN104) to stop operation. Short-circuit the mode-change pin (CN101) on the outdoor unit control PCB of the No. 1 unit. Switching of the 4-way valve occurs immediately before operation starts. Therefore it does not change at this time. (Mode change cannot be judged from the sound.) Short-circuit the test-run pin (CN023) on the PCB to start test run operation. Leave the unit running for a while, and touch the gas tubing with fingers to determine that the unit is running in cooling mode. 5-2-2. Refrigerant recovery procedures (1) (using indoor unit ball valve) (1) If a ball valve with a service port has been provided in the indoor unit as shown in Fig. 10, follow the instructions given in (2) through (6) below. If the service port is instead located in the outdoor side, follow the instructions in “5-2-3. Refrigerant recovery procedures (2).” (2) After running the unit in Cooling mode for about 5 minutes as described in “5-2-1. Cooling operation (for all units),” fully close the liquid tube ball valve. (3) Run the unit in Cooling mode for 10 to 20 minutes more. (4) Fully close the gas tube ball valve, and stop the operation of all units. (5) Use hoses to connect the manifold gauge valves, refrigerant recovery unit, and refrigerant recovery cylinder with each other. (Fig. 10)Do each connection quickly to prevent air from entering the tubing. Remaining refrigerant may create internal pressure, therefore care should be taken when connecting the hoses. (6) Recover the remaining refrigerant from the indoor unit using the refrigerant recovery unit. To determine completion of refrigerant recovery, follow the instructions that came with the refrigerant recovery unit. CAUTION NOTE Hi Manifold gauge Refrigerant recovery cylinder Outdoor unit side Gas tube Liquid tube Indoor unit Refrigerant recovery unit Service port Ball valve (separately purchased) Lo 1 2 3 4 5 6 Fig. 10 4 Cooling : low temperature (68 °F or lower) Heating : high temperature (140 °F or higher) The gas tubing becomes hot (140 °F or higher) in heating mode. Be careful so as not to be burnt when touching the tubing. * CAUTION

5. Recovering Refrigerant W-2WAY ECO-i SYSTEM Outdoor Unit Repair Procedures 5-2-3. Refrigerant recovery procedures (2): Indoor unit with no ball valve equipped Refrigerant in all indoor units and the refrigerant tubing circuit must be pumped into the outdoor unit. The maximum refrigerant storage capacity per a single outdoor unit is approx. 529 oz. Thus, in order to collect all refrigerant from the system, a separate refrigerant recovery unit is necessary. Follow these procedures to correctly perform pump down. Perform work correctly, according to the work procedures given below. Connect the manifold gauge to the high- and low-pressure outlet ports on the outdoor unit where pump down will be performed. Be sure that no air enters the tubing at this time. Follow the instructions in “5-2-1. Cooling operation (for all units)” and operate all units in Cooling mode for approximately 5 minutes. Then fully close the liquid tube valve on the outdoor unit where pump down will be performed. When the high-pressure gauge reaches 406.1 psi or higher, or the low-pressure gauge reaches 72.5 psi or below, at the outdoor unit where pump down is being performed, press the ON/OFF button on the outdoor unit maintenance remote controller to stop operation at all units. Then immediately fully close the suction tube valve on the outdoor unit where pump down is being performed. * If the outdoor unit maintenance remote controller is unavailable, follow the procedure below to stop all of the units. Pull out the SCT connector (2P) (YEL) (CN231) on the outdoor unit control PCB of the unit where pump down is being performed. When the SCT connector is pulled out, immediately alarm F12 (sensor trouble) occurs and all outdoor units stop operating. Be sure that you do NOT grasp the lead wire when pulling out the con- nector. Removing any other connector may not cause the units to stop. Therefore be sure to pull out the SCT connector only. It is not necessary to recover the refrigerant from the balance tube. Therefore do not operate the balance tube valve. Turn off power to all equipment in the system. Then pull out the RC1 connector (4P) (BLU) (CN106) on the out- door control PCB in the outdoor unit for which pump down has been completed. * By pulling out the RC1 connector, communication between the main and the sub outdoor units will be isolated. Change the setting of controllable outdoor unit numbers (reduce by 1 unit). * If the setting is incorrect, the E30 alarm (outdoor unit serial communication signal error) occurs and the unit will not operate. Turn on power for all equipment in the system and let the remaining outdoor units run in Cooling mode. Repeat steps and and complete pump down for all outdoor units. Using hoses with Schrader-type push-to-release valves, connect the manifold gauge valves to the suction line service port, the discharge line service port and the liquid line service port in the next outdoor unit to undergo pump down. (Fig. 11) Remaining refrigerant in the system may cause internal pressure. Check that each valve on the manifold gauge is tightly closed. A Schrader-type push-to-release valve is provided for each connection port. Use hoses to connect the manifold gauge valves, refrigerant recovery unit, and refrigerant recovery cylinder. Quickly connect each part to prevent air from entering the tubing. Recover remaining refrigerant from the inter-unit tubing and indoor units using the refrigerant recovery unit. To determine the completion of refrigerant recovery, follow the instructions that came with the refrigerant recovery unit. 2 1 NOTE CAUTION CAUTION 1 2 3 5 6 7 8 10 9 4

W-2WAY ECO-i SYSTEM Outdoor Unit Repair Procedures 5. Recovering Refrigerant 5-3. Recovery of Refrigerant from Entire System (1) Turn off power to the entire outdoor system. (2) Short-circuit the AP (Air Purge) pins (CN102) on the outdoor control PCB of all outdoor units, then supply power to the outdoor units. * By short-circuiting the AP pins and supplying power to the outdoor units, the solenoid valve in each unit is forcibly opened and all remaining refrigerant can be recovered. (3) If any unit has encountered a power failure, follow the instructions in “5-1. Refrigerant Recovery Procedures (from Outdoor Units)” and perform refrigerant recovery for the faulty outdoor unit. (4) Connect the manifold gauge to the high- and low-pressure outlet ports (Schrader-type valves) on any outdoor unit. (Fig. 11) Remaining refrigerant may cause internal pressure. Check that each valve on the manifold gauge valves is tightly closed. The connection port uses a Schrader-type push-to-release valve. (5) Connect the manifold gauge valves, refrigerant recovery unit, and refrigerant recovery cylinder. Quickly connect each part to prevent air from entering the tubing. (6) Check that each service valve of the gas tubes, liquid tube, and the balance tube for the outdoor unit has opened, then perform refrigerant recovery. * If only a single outdoor unit is installed, the balance tube is not used. Therefore, leave this valve closed. To determine the completion of refrigerant recovery, follow the instructions that came with the refrigerant recovery unit. NOTE CAUTION Refrigerant recovery cylinder Gas tube service port (For 5/16" (7.94mm)-dia. connector) Refrigerant recover unit Lo Hi Manifold gauge Liquid tube service port (For 5/16" (7.94mm)-dia. connector) Fig. 11

6. Checking for Leakage After Repair W-2WAY ECO-i SYSTEM Outdoor Unit Repair Procedures 6-1. Pressure Check for Leakage of Outdoor Unit After completing repair of the outdoor unit, carry out the following leakage check. (1) Check that all service valves for gas tubes, liquid tube, and balance tube in the repaired outdoor unit (units necessary to carry out the pressurized leak check) are fully closed. (2) Connect the manifold gauge valves to the high- and low-pressure outlet ports of the outdoor unit. (3) Feed nitrogen gas into the circuit until 72.5 psi pressure is reached. If it is apparent that the nitrogen gas is not entering the repaired section, interrupt the feeding. Short-circuit the AP pins (CN102) on the outdoor unit control PCB, turn on power to run the outdoor unit, then resume feeding nitrogen. (4) Apply soapy water to the repaired part (such as a newly brazed part), and briefly inspect for any leakage. If there are any leaks, bubbles will show on the tubing surface. * To continue the air-tight check after the brief leak inspection, turn on power while short-circuiting the AP pins. Again feed nitrogen gas to obtain a system pressure of 72.5 psi. Then measure both the outdoor ambient temperature and the pressure in the system. Leave the system in this state for 1 full day and night, and again measure the outdoor ambient temperature and pressure (to determine any reduced values). During the inspection, it is recommended that an awning or cover be used to shield the unit in case of rain. If no problem is found, purge all nitrogen from the system. 6-2. Checking for Leakage in Refrigerant Tubing Between Indoor and Outdoor Units Refer to the “Installation Instructions” that came with the outdoor unit. Low-pressure outlet port (For 5/16" (7.94mm)-dia. connector) Nitrogen gas Lo Hi Manifold gauge High-pressure outlet port (For 5/16" (7.94mm)-dia. connector) Fig. 12

W-2WAY ECO-i SYSTEM Outdoor Unit Repair Procedures 7. Evacuating System This procedure is carried out to ensure there is no remaining refrigerant or other gases (nitrogen, etc.) in the repaired outdoor unit and tubing. 7-1. Evacuating Repaired Outdoor Unit (1) Check that each service valve of the gas tubes, liquid tube, and balance tube in the outdoor unit are fully closed. (2) Connect the manifold gauge valves to the high-pressure and low-pressure sensor outlets of the outdoor unit. (Fig. 13) (3) Connect the manifold gauge valves to the vacuum pump. * If the AP pins (CN102) on the outdoor control PCB have already been short-circuited, step (4) is not neces- sary. (4) Turn off power to the repaired outdoor unit and short-circuit the AP (Air Purge) pins on the outdoor control PCB. By short-circuiting the AP pins and turning on power to the outdoor unit, all elec- tronic valves in the outdoor unit are forcibly opened and any remaining nitrogen gas can be recovered. Failure to perform this procedure may result in nitrogen gas remaining in the refrigerant circuit and causing operating problems. Therefore, never skip this step. (5) Turn the power ON at the outdoor unit where vacuum will be applied. Then run the vacuum pump and continue evacuation until the vacuum condition falls to less than –14.7 psig (5 Torr). To ensure proper evacuation, refer to the operating instructions that came with the vacuum pump. 7-2. Evacuating Refrigerant Tubing Between Indoor and Outdoor Units Refer to the “Installation Instructions” that came with the outdoor unit. CAUTION CAUTION Fig. 13 Lo Hi Manifold gauge High-pressure outlet port (For 5/16" (7.94mm)-dia. connector) Vacuum pump Low-pressure outlet port (For 5/16" (7.94mm)-dia. connector)

8. Charging Compressor Oil W-2WAY ECO-i SYSTEM Outdoor Unit Repair Procedures 8-1. If Refrigerant Has Already Been Charged to Outdoor Unit Be sure to use an exclusive oil-charging tank for charging compressor oil. Prior to charging, carry out vacuum drying inside the tank and take care that no air (in the form of bubbles) is permitted to enter the tank. The oil charging procedures are given below. * The receiver tank used for maintenance may be used as an exclusive oil-charging tank. When installing the oil-charging tank to the refrigerant system to serve as a safety bypass circuit for refrigerant, connect it to the gas tube service port carefully to avoid releasing refrigerant into the atmosphere. (DPR : 623-081-7937) Nipple Packless valve (Receiver-tank: 638-015-2988) Perform oil charging work carefully so that no liquid refrigerant enters the charging tank. CAUTION (1) Evacuation drying in oil-charging tank With the lower side valve fully closed, open the upper side valve and connect it to the vacuum pump via the manifold gauge valves as shown below. Run the vacuum pump and evacuate the tank until the pressure falls to below –14.7 psig (5 Torr) for the evacuation drying. After the evacuation drying is finished, fully close the upper valve. Next, fully close the manifold gauge valves and stop the vacuum pump. To ensure proper evacuation, refer to the operating instructions that came with the vacuum pump. CAUTION Lo Hi Manifold gauge Open Close Vacuum pump Upper side valve Lower side valve Close Fig. 14 Fig. 15

W-2WAY ECO-i SYSTEM Outdoor Unit Repair Procedures 8. Charging Compressor Oil (2) Charging compressor oil into oil-charging tank Connect a piece of pipe to the lower valve and then insert the other end deeply into the bottom of the oil con- tainer. Make sure you avoid letting any air be sucked into the tube. Next, run the vacuum pump and open the manifold gauge valves, then open the upper and lower valves to begin charging oil into the charging tank. When the predetermined amount of oil has been charged into the oil-charging tank, immediately close the lower valve. Next, run the vacuum pump until the system pressure reaches lower than -14.7 psig (5 Torr). Close the upper valve and then, stop the vacuum pump. Do this operation quickly because compressor oil easily absorbs moisture from the air. (3) Charging compressor oil into outdoor unit Connect the lower valve to the low-pressure outlet (with Schrader-type push-to-release valve) in the outdoor unit to be oil-charged, and then connect the high-pressure outlet (with push-to-release valve) to the upper valve via the manifold gauge valves (at Hi-pressure gauge side). In addition, connect the gas tube service port (with push-to-release valve) to the DPR (Discharge Pressure Regulator). Carry out the connection work quickly to avoid letting air enter. • The hoses may be subject to internal pressure from the refrigerant inside the out door unit. A Schrader-type push-to-release valve is provided at each connection port. • Since the DPR valve opens at pressures of 362.6 psi and above, be sure to con- nect the DPR to the gas tube service port (low-pressure side). CAUTION CAUTION Upper valve Lower valve Vacuum pump Manifold gauge Oil Close Open Close Open DPR Low-pressure outlet port (For 5/16" (7.94mm)- dia. connector) Upper valve Lower valve Close Close Gas tube service port (For 5/16" (7.94mm)- dia. connector) Manifold gauge Lo Hi High-pressure outlet port (For 5/16" (7.94mm)- dia. connector) Fig. 16 Fig. 17

8. Charging Compressor Oil W-2WAY ECO-i SYSTEM Outdoor Unit Repair Procedures Next follow the instructions in “5-2-1. Cooling operation (for all units)” at the outdoor unit where oil will be charged, and start cooling operation at all units. When the operating conditions have stabilized, perform steps 1, 2, and 3 in sequence and open the valves. When this is done, the refrigerant pressure from operation forces the oil out of the oil charge tank, and oil is charged into the outdoor unit from the low-pressure outlet port. From time to time close the upper valve on the top of the oil charge tank (only this valve) and shake the tank to check the amount of remaining oil. To terminate the oil charging work, do as follows: To end the charge process, first close the valve on the high-pressure side of the manifold gauge. Then wait several tens of seconds after the pressure display on the manifold gauge low-pressure gauge stabilizes (in order to equalize the pressure with the low-pressure outlet port and to vaporize the refrigerant in the charge tank). Then perform steps 1 and 3 in sequence and fully close the valves. Finally, connect the refrigerant recovery unit to the Lo-gauge side, shut down all indoor and outdoor units, and then recover the remaining refrigerant in the oil-charging tank, manifold gauge valves, and connecting hoses. Perform these procedures quickly and securely so that no air can enter. After, charge the necessary amount of new refrigerant by referring to the “Installation Instructions” that came with the outdoor unit. To determine the completion of refrigerant recovery, follow the instructions that came with the refrigerant recovery unit. 8-2. If Outdoor Unit Has Not Been Charged with Refrigerant When a compressor has been replaced or in any other case where the outdoor unit has not been charged with refrigerant, first charge with refrigerant then follow the instructions in “8-1. If Refrigerant Has Already Been Charged to Outdoor Unit” and charge with oil. Or, alternatively, follow the procedure below. (1) Connect a tube to the oil outlet port on the outdoor unit to be charged with oil. Insert the other end of the tube into the oil container. (2) Follow the instructions in “7. Evacuating System,” and apply vacuum to the outdoor unit to be charged with oil. When this is done, oil is charged into the outdoor unit through the oil outlet port. (3) When the unit has been charged with the designated amount of oil, stop the vacuum pump. The oil absorbs moisture readily. This work must be completed quickly. CAUTION NOTE DPR Low-pressure outlet port (For 5/16" (7.94mm)- dia. connector) High-pressure outlet port (For 5/16" (7.94mm)- dia. connector) Upper valve Lower valve Manifold gauge Lo Hi Procedure 2: Open Procedure 3: Open Procedure 1: Open Connect from here to refrigerant recovery unit Gas tube service port (For 5/16" (7.94mm)- dia. connector) Fig. 18

W-2WAY ECO-i SYSTEM Outdoor Unit Repair Procedures 8. Charging Compressor Oil 8-3. Charging Additional Compressor Oil (after replacing compressor) The rated amount of oil is pre-charged in the compressors as given below: When replacing a faulty compressor, be sure to first measure the amount of remaining oil in the compressor. Charge additional new oil equal to the difference in the remaining oil and the rated amount as listed above. For example: Type of replaced compressor: JT160G-KTTJ Remaining oil in the removed compressor: 0.58 gal Additional oil to be charged: 0.58 gal (remaining oil in the removed compressor) – 0.55 gal (rated oil amount) = 0.026 gal * If the result is a negative amount (remaining oil in the removed compressor is less than the rated amount), it is not necessary to discharge the extra oil from the system. For the method used for additional oil charging after compressor replacement, refer to “8-1. If Refrigerant Has Already Been Charged to Outdoor Unit.” Model name Compressor model Q'ty Pre-charged amount of oil (liters) CHDX07263 C-9RVN273H0S (Inverter-controlled rotary compressor) 1 1.9 CHDX09663 C-9RVN273H0S (Inverter-controlled rotary compressor) 1 1.9 JT160G-KTTJ (Constant-speed scroll compressor) 1 2.1 Low-pressure outlet port (For 5/16" (7.94mm)-dia. connector) High-pressure outlet port (For 5/16" (7.94mm)-dia. connector) Oil Oil tube outlet port (For 1/4" (6.35mm)-dia. connector) Vacuum pump Manifold gauge Hi Lo Fig. 19

9. Pumping Out Refrigerant from Outdoor Unit W-2WAY ECO-i SYSTEM Outdoor Unit Repair Procedures Required equipment and tools: This work is performed in order to collect the refrigerant from an outdoor unit where repairs (other than compressor replacement) will be performed into other outdoor units and indoor units, and the refrigerant tubing. 9-1. If Remote Controller (RCS-TM80BG) is Used for Maintenance of Outdoor Unit (1) Refer to “4. Backup Operation” and perform backup operation. (2) Connect the manifold gauge valves at the Lo side to the low-pressure outlet port of the outdoor unit to be repaired. Also connect the refrigerant recovery cylinder to any one of the normal outdoor units at the liquid line service port (Schrader-type push-to-release valve). Perform the connection work quickly so that no air is allowed to enter. (Fig. 20) * Connecting the refrigerant recovery cylinder is done to prevent pressure from rising excessively during backup operation by recovering the refrigerant from the outdoor unit to be repaired. (Measure the weight of the refrigerant and cylinder itself beforehand and provide sufficient safety measures, such as installing a high-pressure cutout in the circuit.) The hoses may be subject to internal pressure from the refrigerant inside the out- door unit. Check that the manifold gauge valves are fully closed beforehand. A Schrader-type push-to-release valve is provided at each connection port. (3) Connect the outdoor unit maintenance remote controller to the RC connector (CN006) (3P) (BLU) on the out- door unit control PCB of the outdoor unit to be repaired. Then start a test run of all units. (Press and hold the (CHECK) button for 4 seconds or longer.) (4) Use the outdoor unit maintenance remote controller to check the operating status of the indoor units. Check that all units are operating in Heating mode. For details concerning operation of the outdoor unit maintenance remote controller, refer to the “Outdoor unit maintenance remote controller” item. It is also possible to check the operating conditions either in cooling or heating mode by touching the gas tube. (5) Close the suction tube and balance tube on the outdoor unit to be repaired. Then slowly close the liquid tube service valve. (6) When the low pressure at the outdoor unit to be repaired reaches 72.5 psi or below, press the ON/OFF button on the outdoor unit maintenance remote controller to stop all the units. Then immediately fully close the gas tube valve on that outdoor unit. While closing the valves, the rise in discharge temperature or another factor may cause a protective device to activate, stopping the operation of the outdoor unit. If this occurs, immediately fully close the gas tube valve on the outdoor unit to be repaired. (7) Connect the high-pressure gauge side of the manifold gauge to the high-pressure outlet port on the outdoor unit to be repaired, and connect the manifold gauge to the refrigerant recovery device. Be sure that no air enters the tubing at this time. CAUTION CAUTION CAUTION Jumper wire with clips, adjustable wrench, set of manifold gauge valves for the refrigerant R410A, refrigerant recovery unit, pre-purged refrigerant cylinder for recovery, flat-head screwdriver, and outdoor unit maintenance remote controller. Cooling mode : low temperature (68 F or lower) Heating mode : high temperature (140 F or higher) The gas tubing becomes hot (140 F or higher) in heating. Be careful so as not to be burnt when touching the tubing.

W-2WAY ECO-i SYSTEM Outdoor Unit Repair Procedures 9. Pumping Out Refrigerant from Outdoor Unit (8) Short-circuit the vacuum application pin on the outdoor unit control PCB of the unit to be repaired. Then turn ON the outdoor unit power. When the vacuum application pin is short-circuited and the power is turned ON, all solenoid valves in the outdoor unit are forced open, allowing the refrigerant to be recovered from all tubes which are separated by solenoid valves. If this work is not performed, it will not be possible to recover all of the refrigerant at the refrigerant recovery device. Be sure to perform this step. Open both Hi- and Lo-side valves on the manifold gauge valves, and recover the refrigerant remaining in the outdoor unit. After that, measure the amount of recovered refrigerant. To determine the completion of refrigerant recovery, follow the instructions that came with the refrigerant recovery unit. 9-2. If Remote Controller is Not Available for maintenance of Outdoor Unit (1) Refer to “4. Backup Operation” and perform backup operation. (2) Connect the manifold gauge valves at the Lo side to the low-pressure outlet port of the outdoor unit to be repaired. Also connect the refrigerant recovery cylinder to any one of the normal outdoor units at the liquid line service port (Schrader-type push-to-release valve). Perform the connection work quickly so that no air is allowed to enter. (Fig. 20) * Connecting the refrigerant recovery cylinder is done to prevent pressure from rising excessively during the backup operation by recovering the refrigerant from the outdoor unit to be repaired. (Measure the weight of the refrigerant and cylinder itself beforehand and provide sufficient safety measures, such as installing a high-pressure cutout in the circuit.) The hoses may be subject to internal pressure from the refrigerant inside the out- door unit. Check that the manifold gauge valves are fully closed beforehand. A Schrader-type push-to-release valve is provided at each connection port. (3) Determine the outdoor unit where the unit No. setting (S007)(3P DIP switch)(BLU) on the outdoor unit control PCB is set to No.1. (4) Short-circuit the test-run pin (CN023) to start operation. (5) Leave the unit running for a while, and then touch the gas tubing with fingers to determine whether the unit is running in cooling or heating mode. If it is in heating, follow the step (6) and later procedures. (6) When the unit is operating in heating mode, release the short-circuit at the test-run pin on the outdoor unit con- trol PCB of the No. 1 unit. Then short-circuit the stop pin (CN104) to stop operation. (7) Short-circuit the mode-change pin (CN101) on the outdoor unit control PCB of the No. 1 unit. Switching of the 4-way valve occurs immediately before operation starts. Therefore it does not change at this time. (Mode change cannot be judged from the sound.) (8) Short-circuit the test-run pin (CN023) to start operation, leave the unit running for a while. Touch the gas tubing with fingers to determine whether the unit is running in cooling. NOTE CAUTION CAUTION CAUTION * Cooling : low temperature (68 F or lower) Heating : high temperature (140 F or higher) The gas tubing becomes hot (140 F or higher) in heating mode. Be careful so as not to be burnt when touching the tubing.

9. Pumping Out Refrigerant from Outdoor Unit W-2WAY ECO-i SYSTEM Outdoor Unit Repair Procedures (9) Close the gas tube and balance tube on the outdoor unit to be repaired. Then slowly close the liquid tube ser- vice valve. * When the low pressure at the outdoor unit to be repaired reaches 72.5 psi or below, pull out the SCT connec- tor (2P) (YEL) (CN231) from the outdoor unit control PCB of that outdoor unit. Then immediately fully close the gas tube valve on that outdoor unit. * Pulling out the SCT connector immediately stops all of the outdoor units. While closing the valves, the rise in discharge temperature or another factor may cause a protective device to activate, stopping the operation of the outdoor unit. If this occurs, immediately fully close the gas tube valve on the outdoor unit to be repaired. (10) Connect the high-pressure gauge side of the manifold gauge to the high-pressure outlet port on the outdoor unit to be repaired, and connect the manifold gauge to the refrigerant recovery device. Be sure that no air enters the tubing at this time. (11) Open both Hi- and Lo-side valves on the manifold gauge valves, and recover the refrigerant remaining in the outdoor unit. After that, measure the amount of recovered refrigerant. To determine the completion of refrigerant recovery, follow the instructions that came with the refrigerant recovery unit. CAUTION NOTE High-pressure outlet port (For 5/16" (7.94mm)-dia. connector) Low-pressure outlet port (For 5/16" (7.94mm)-dia. connector) Liquid tube service port (For 5/16" (7.94mm)-dia. connector) Connect from here to refrigerant recovery unit Faulty outdoor unit Other outdoor unit Refrigerant recovery cylinder Measuring scale Manifold gauge Fig. 20

W-2WAY ECO-i SYSTEM Outdoor Unit Repair Procedures 10. Compressor 10-1. Compressor Trouble Diagnosis and Check Methods Generally, compressor failures can be classified into the following categories. (1) Mechanical trouble (A) Locking (intrusion of foreign objects, galling, etc.) (B) Pressure rise failure (damaged valve, seal, bearing, or other component) (C) Noise (damaged stator rotor, valve, or other component) (2) Electrical trouble (A) Coil burning (B) Open circuit (C) Insulation failure (D) Short circuit Trouble diagnosis is based on the following remote controller displays: [H03] (Compressor 1: INV compressor, center), [H11] [H12] [H13] (Compressor 2: constant-speed compressor 1, left side when viewed from front), [H21] [H22] [H23] (Compressor 3: constant-speed compressor 2, right side when viewed from front (not present in type 90). A judgment is made based on factors that include the following: coil resistance (varies depending on the compressor), insulation resistance, current, leakage breaker operation, oil and refrigerant fouling, odor, pressure, and noise. Reference: Insulation resistance (Use a DC 500 V insulation resistance meter and measure the insulation resis- tance between the electrified and non-electrified parts.) (a) Motor Min. 300 M (b) Compressor Min. 100 M (servicing part) (c) Unit Min. 10 M (This is due to the presence of refrigerant, which decreases the insulation resistance.) * Minimum insulation resistance as required by generally accepted requirements is 1 M . Reference: Symptoms of motor burning 1. Ground fault results in breaker operation. 2. Short circuit results in different coil resistance at different phases. 3. Open circuit JUDGMENT START Is there burning of the failed compressor motor? Follow the instructions in “3. Discharging Compressor Oil” and drain the oil from all compressors in the same system. Then inspect. Is the color phase 4.0 or above, or is a sharp odor present? Go to “10-2-1. Replacing only the failed compressor.” Follow the instructions in “3. Discharging Compressor Oil” and drain the oil from the failed compressor. Then inspect. Go to “10-2-3. Replacing all compressors in a system.” Are there 2 or more outdoor units where the compressor oil color phase is 4.0 or higher or where a sharp odor is present? Follow the instructions in “10-2-4. Dry core cleaning” and perform dry core cleaning of all outdoor units. Go to “10-2-2. Replacing all compressors in a failed unit.” Follow the instructions in “10-2-4. Dry core cleaning” and perform dry core cleaning of the failed outdoor unit. NO NO NO YES YES YES

10. Compressor W-2WAY ECO-i SYSTEM Outdoor Unit Repair Procedures 10-2. Replacing the Compressor(s) 10-2-1. Replacing only the failed compressor (1) If backup operation is required, follow the instructions in “4. Backup Operation” and engage backup operation. (2) Follow the instructions in “10-3. Removing and Installing Compressors” and replace the failed compressor. (3) Fully close the high- and low-pressure gauge valves on the manifold gauge, then stop the vacuum pump. (4) Disconnect the manifold gauge from vacuum pump. Connect the manifold gauge to the cylinder where the refrigerant was recovered. At this time, be careful that air does not enter the tubing. (5) Open the valve on the refrigerant recovery cylinder and the high-pressure gauge valve on the manifold gauge to charge with refrigerant. At this time, the low-pressure gauge valve on the manifold gauge remains fully closed. If the recovered refrigerant becomes mixed with another refrigerant or another gas (such as nitrogen or air), do not use the recovered refrigerant for charging. Charge with the designated amount of new refrigerant. (6) When charging has been completed with an amount of new refrigerant equal to the amount of recovered refrigerant, or when charging with the same amount of new refrigerant has not been completed but no more refrigerant will enter the unit, fully close the high-pressure gauge valve on the manifold gauge. Next, turn the power OFF at the repaired outdoor unit, then remove the short circuit at the AP pin (CN102). Finally, fully open all valves on the gas tube, liquid tube, and balance tube. However, leave the balance tube fully closed if only a single outdoor unit is installed. (7) If backup operation was engaged, follow the instructions in “4. Backup Operation” and perform backup opera- tion recovery. (8) If charging with an amount of new refrigerant equal to the amount of recovered refrigerant was not possible, fully close the high-pressure gauge valve on the manifold gauge. Then, while the unit is operating in “5-2-1. Cooling operation (for all units)”, open the low-pressure gauge valve on the manifold gauge and charge with the designated amount of refrigerant. When charging with liquid refrigerant, add refrigerant a little at a time in order to prevent liquid back-flow. (9) Fully close the low-pressure gauge valves on the manifold gauge, follow the instructions in “8. Charging Com- pressor Oil,” and charge with oil if necessary. (10) Remove the manifold gauge. The connecting port employs a Schrader-type push-to-release valve. When discon- necting the hose, pressure will be applied from the refrigerant in the outdoor unit. CAUTION CAUTION CAUTION

W-2WAY ECO-i SYSTEM Outdoor Unit Repair Procedures 10. Compressor 10-2-2. Replacing all compressors in a failed unit (1) Follow the instructions in “3. Discharging Compressor Oil” and drain the oil from the oil separator in the failed unit. Measure the amount of drained oil. (2) If backup operation is required, follow the instructions in “4. Backup Operation” and engage backup operation. (3) Follow the instructions in “10-3. Removing and Installing Compressors” and replace all compressors in the failed unit. (4) Fully close the high- and low-pressure gauge valves on the manifold gauge, then stop the vacuum pump. (5) Disconnect the manifold gauge from the vacuum pump. Connect the manifold gauge to the refrigerant cylinder. At this time, be careful that air does not enter the tubing. Do not reuse the recovered refrigerant. Use a refrigerant cylinder that contains new refrigerant. (6) Open the valve on the refrigerant cylinder, and open the high-pressure gauge valve on the manifold gauge (with the low-pressure gauge valve closed). When charging has been completed with an amount of new refrigerant equal to the amount of recovered refrigerant, or when charging with the same amount of new refrigerant has not been completed but no more refrigerant will enter the unit, fully close the high-pressure gauge valve on the manifold gauge. Next, turn the power OFF at the repaired outdoor unit, then remove the short circuit at the AP pin (CN102). Finally, fully open all valves on the gas tube, liquid tube, and balance tube. However, leave the balance tube fully closed if only a single outdoor unit is installed. (7) If backup operation was engaged, follow the instructions in “4. Backup Operation” and perform backup opera- tion recovery. (8) If charging with an amount of new refrigerant equal to the amount of recovered refrigerant was not possible, fully close the high-pressure gauge valve on the manifold gauge. Then, while the unit is operating according to “5-2-1. Cooling operation (for all units),” open the low-pressure gauge valve on the manifold gauge and charge with the designated amount of refrigerant. When charging with liquid refrigerant, add refrigerant a little at a time in order to prevent liquid back-flow. (9) Fully close the low-pressure gauge valves on the manifold gauge, follow the instructions in “8. Charging Com- pressor Oil,” and charge with the necessary amount of oil. Also add an amount of oil that is equivalent to the amount that was drained from the oil separator. (10) Remove the manifold gauge. The connecting port employs a Schrader-type push-to-release valve. When discon- necting the hose, pressure will be applied from the refrigerant in the outdoor unit. (11) Follow the instructions in “10-2-4. Dry core cleaning” and perform dry core cleaning of the outdoor unit that failed. CAUTION CAUTION CAUTION

10. Compressor W-2WAY ECO-i SYSTEM Outdoor Unit Repair Procedures 10-2-3. Replacing all compressors in a system (1) Follow the instructions in “3. Discharging Compressor Oil” and drain the oil from the oil separators in all out- door units. Measure the amount of drained oil. (2) Follow the instructions in “10-3. Removing and Installing Compressors” and replace all compressors in the system. (3) Follow the instructions in “6. Checking for Leakage After Repair” and check for leaks at all outdoor units and in the tubing. (4) Follow the instructions in “7. Evacuating System” and apply vacuum to all outdoor units and tubing. (5) Fully close the high- and low-pressure gauge valves on the manifold gauge, then stop the vacuum pump. (6) Disconnect the manifold gauge from vacuum pump. Connect the manifold gauge to the refrigerant cylinder. Be especially careful that air does not enter the tubing. Do not reuse the recovered refrigerant. Use a refrigerant cylinder that contains un- used refrigerant. (7) Open the valve on the refrigerant cylinder, and open the high-pressure gauge valve on the manifold gauge. When charging has been completed with an amount of new refrigerant equal to the amount of recovered refrig- erant, or when charging with the same amount of new refrigerant has not been completed but no more refriger- ant will enter the unit, first turn the power OFF at the repaired outdoor unit, then remove the short circuit at the AP pin (CN102). Then fully open all valves on the gas tube, liquid tube, and balance tube. However, leave the balance tube fully closed if only a single outdoor unit is installed. (8) If backup operation was engaged, follow the instructions in “4. Backup Operation” and perform backup opera- tion recovery. (9) If charging with an amount of new refrigerant equal to the amount of recovered refrigerant was not possible, fully close the high-pressure gauge valve on the manifold gauge. Then, while the unit is operating in Cooling mode, open the low-pressure gauge valve on the manifold gauge and charge with the designated amount of refrigerant. When charging with liquid refrigerant, add refrigerant a little at a time in order to prevent liquid back-flow. (10) Fully close the low-pressure gauge valves on the manifold gauge, follow the instructions in “8. Charging Com- pressor Oil,” and charge with the necessary amount of oil. Also add an amount of oil that is equivalent to the amount that was drained from the oil separators. (11) The connecting port employs a Schrader-type valve. When disconnecting the hose, pressure will be applied from the refrigerant in the outdoor unit. (12) Follow the instructions in “10-2-4. Dry core cleaning” and perform dry core cleaning of all outdoor units. CAUTION CAUTION CAUTION Remove the manifold gauge.

W-2WAY ECO-i SYSTEM Outdoor Unit Repair Procedures 10. Compressor 10-2-4. Dry core cleaning If burning or other failures occur repeatedly at compressors within the same system, in many cases the cause is acid, sludge, carbon, or other substances that remain in the refrigeration cycle as the result of insufficient cleaning. If, when the oil is inspected, there is an outdoor unit where the oil color phase is 4.0 or higher, or where a sharp odor is present, carry out all steps below to perform dry core cleaning. And use the bidirectional dry core for refrigerant R410A. (A) If a ball valve is installed on the outdoor unit (1) Refer to “5-2-1. Cooling operation (for all units)” and operate all outdoor units in either Heating or Cooling mode. (2) If all units are operated in Cooling mode, close first the liquid tube service valve then the ball valve on all out- door units where dry cores will be attached. If all units are operated in Heating mode, close first the ball valve then the liquid tube service valve on all out- door units where dry cores will be attached. This step is performed in order to expel refrigerant from the tubing between the liquid tube service valve and the ball valve. Approximately 4 – 5 seconds is a sufficient interval between closing each of the 2 valves. (3) If the outdoor unit maintenance remote controller is not available, use the following method to stop the oper- ation of all units: Pull out the SCT connector (2P) (YEL) (CN231) from the outdoor unit control PCB of the unit where pump-down is being performed. When the SCT connector is pulled out, alarm F12 (sensor trouble) immediately occurs and all outdoor units stop operating. Be sure that you do NOT grasp the lead wire when pulling out the connector. Removing any other connector may not cause the units to stop. Therefore be sure to pull out only the SCT connector. (4) Connect a refrigerant recovery device to the liquid tube service port (Schrader-type valve) of all outdoor units where dry cores will be attached, then recover the refrigerant from the tubing. Be sure that no air enters the tubing at this time. When the hose is connected, internal pressure is applied by the remaining refriger- ant in the inter-unit tubing. The connection port employs a Schrader-type valve. To determine when refrigerant recovery is compete, follow the instructions in the instruction manual of the refrigerant recovery device. (5) As shown in Fig. 21, disconnect the tube that runs from the liquid tube valve to the ball valve on all outdoor units where dry cores will be attached. Then attach the dry cores. (6) At all outdoor units where dry cores are attached, pressurize with 478.6 psi of nitrogen from the liquid tube service port and check for leaks. (7) After evacuating all nitrogen gas from the tubing, apply vacuum from the liquid tube service port to all outdoor units where dry cores are attached until the pressure is –14.7 psig (5 Torr) or less. (8) Fully open the liquid tube valve and ball valve on all outdoor units where dry cores are attached. (9) Operate all outdoor units for approximately 3 hours (in either Heating or Cooling mode or mixed Cooling and Heating mode). (10) Follow the above procedure, and replace all dry cores with new dry cores. (11) Operate all outdoor units for approximately 20 minutes (in either Heating or Cooling mode or mixed Cooling and Heating mode). (12) Follow the instructions in “3. Discharging Compressor Oil” and drain a small amount of the oil from the oil separators of all outdoor units where dry cores are attached. Check the color phase, odor, and other characteristics. (13) If the results show that dry core cleaning is still necessary (for example, a color phase of 4.0 or higher)*, return to Step 11 and repeat until the results are normal (including a color phase of 3.5 or less)*. * Color sample sheet for degree of stain Perform another dry core replacement after approximately 30 hours of system operation. ON/OFF CAUTION CAUTION * * Press the button on the outdoor unit maintenance remote controller to stop the operation of all units.

10. Compressor W-2WAY ECO-i SYSTEM Outdoor Unit Repair Procedures (16) After evacuating all nitrogen gas from the tubing, apply vacuum to all outdoor units where dry cores were removed until the pressure is –14.7 psig (5 Torr) or less. (17) INSTALLATION: Refer to the “Information for the Person in Charge of Installation” items. Charge with an amount of refrigerant equal to the amount that was recovered. (B) If a ball valve is not installed on the outdoor unit (1) Refer to “5-2-3. Refrigerant recovery procedures (2) : Indoor unit with no ball valve equipped.” Perform pump down of the refrigerant from all indoor units and inter-unit tubing to the outdoor unit side. (2) Cut the liquid (narrow) tube at all outdoor units where dry cores will be attached, then attach the dry cores and ball valves as shown in Fig. 21. (3) Fig. 21 Balance tube Normal unit Liquid tube service valve Outdoor unit Cleaning dry core Dry core (bidirectional: for R410A refrigerant) Ball valve Liquid tube Gas tube For the next steps, refer to (6) – (17) in (A) on the previous page. (14) Perform steps (1) – (4), and remove all dry cores. Then connect the tubing between the liquid (narrow) tube valves and the ball valves. (15) At all outdoor units where dry cores were removed, pressurize with 478.6 psi of nitrogen from the liquid tube service port and check for leaks.

W-2WAY ECO-i SYSTEM Outdoor Unit Repair Procedures 10. Compressor Removal (1) Connect a manifold gauge to the high- and low-pressure outlet ports at the outdoor unit where the compressor will be replaced. Connect the manifold gauge to a nitrogen cylinder and perform nitrogen gas replacement in the outdoor unit tubings. (2) Follow the instructions in “1. Removing Panels” and “2. Removing Electrical Component Box and Duct” and remove the corresponding parts from the outdoor unit where the compressor will be replaced. (3) Remove the cap at the compressor terminal plate. Disconnect the power terminal. (4) (5) (6) (7) (8) (9) Pull the compressor toward you. NOTE CAUTION CAUTION Fig. 22 Remove the discharge sensor Bolt Washer (1) Rubber washer (1) Bolt Washer (1) Rubber washer (1) Front view 10-3. Removing and Installing Compressors When removing and installing compressors, use sufficient caution to ensure that moisture or other substances do not enter the refrigerant tubing system. 10-3-1. Replacing compressors * For all types 90 and 140, follow the replacement procedure below. (A) Replacing the inverter compressor (Compressor 1 on remote controller alarm display) Remove the crankcase heater. Remove the 3 bolts, and remove the washers and rubber washers (quantities indicated in the figure below). Disconnect the tube-with-flare-nut using two adjustable wrenches. At this time, cover the tube in place with waste cloth while watching out for oil leaks. Then cap the disconnected tube and mount the flare nut on the compressor. Tighten the flare nut with a seal bonnet (1/4") in it. If oil remaining in the compressor reaches the equalized oil level, oil will come pouring out when the tube-with-flare-nut is removed. Prepare to disconnect the 2 brazed locations shown in the figure. Protect the sensors and the surrounding plates, rubber, lead wires, clamps, and other items. Remove the discharge sensor shown in the figure 22. Disconnect the 2 brazed locations shown in the figure below. When pulling the compressor toward you, be careful not to cause any abnormal deformation of the tube-with-flare-nut. Brazed locations (2) Tube-with-flare-nut Bolt Washer (1) Rubber washer (1) Crankcase heater Inverter compressor

10. Compressor W-2WAY ECO-i SYSTEM Outdoor Unit Repair Procedures (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) CAUTION CAUTION Fig. 23 Crankcase heater Cushioning rubber (Inner 1 leg) Cushioning rubber (Temporary fastening bolts - 2 inner legs) Front view Fig. 24 Installation Remove the rubber stopper and tube cap (brazed) from the new compressor. Install the crankcase heater onto the new compressor. Place the 2 pieces of cushioning rubber in the designated positions on the compressor. Place the 2 pieces of cushioning rubber onto the legs of the new compressor. When setting the compressor into the unit, be careful not to cause any abnormal deformation of the tube-with-flare-nut. CAUTION Place the remaining cushioning rubber onto the new compressor, at the position shown in the figure below. Remove the bolts that are temporarily fastening the pieces of cushioning rubber (inner 2 legs), and anchor the 3 compressor legs using the bolts, washers, and rubber washers. Remove the flare nut from the new compressor, and connect the tube-with-flare-nut. Shape the tubes and insert them at the 2 brazing locations. Connect a manifold gauge to the high- and low-pressure outlet ports at the outdoor unit where the compres- sor was replaced. Connect the manifold gauge to a nitrogen cylinder and perform nitrogen gas replacement. Perform copper brazing at the 2 brazing locations. Follow the instructions in “6. Checking for Leakage After Repair” and check for leaks at the outdoor unit where the compressor was replaced. At this time, also check for leaks at the flare nut connection on the tube-with-flare-nut. Re-install all components that were removed. Re-install the electrical component box in the same position as it was before. Be sure to check for looseness of the power terminal connection at the compressor terminal plate, and to check by pulling vertically on the connections. If the termi- nals become disconnected easily, replace the wiring Assy. Follow the instructions in “7. Evacuating System” and apply vacuum to the outdoor unit where the compres- sor was replaced. Brazed locations (2) Bolt Washer (1) Rubber washer (1) Tube-with-flare-nut

W-2WAY ECO-i SYSTEM Outdoor Unit Repair Procedures 10. Compressor Removal (1) (2) Follow the instructions in “1. Removing Panels” and “2. Removing Electrical Component Box and Duct” and remove the corresponding parts from the outdoor unit where the compressor will be replaced. (3) (4) (5) (6) (7) Disconnect the 3 brazed locations shown in the figure 25. (8) CAUTION Fig. 25 Crankcase heater Bolt Washer: 1 Rubber washer: 1 (1 each at the 3 locations) Protect the oil equalizer tube connectors Front view (Type 96) Remove discharge sensor Constant-speed compressor (left side) (B) Replacing the constant-speed compressor 1 (Compressor 2 on remote controller alarm display) Connect the manifold gauge to the high- and low-pressure outlet ports at the outdoor unit where the compres- sor will be replaced. Connect the manifold gauge to a nitrogen cylinder and perform nitrogen gas replacement. Remove the cap at the compressor terminal plate. Disconnect the power terminal. Remove the crankcase heater. Remove the bolts(3 locations), washers, and spacers (1 each at the 3 locations shown in the figure). * The compressor rear leg is not anchored. Prepare to disconnect the 3 brazed locations shown in the figure. Brazed locations (3) • Protect the sensors and surrounding plates, rubber, lead wires, clamps, and other items. Pay particular attention to protection of the oil equalizer tube connector parts, and removal of the discharge sensor. An O-ring is mounted inside the oil equalizer tube connector parts. It must be protected and do not lose it. * First disconnect the ø1/4" (ø6.35 mm) tube, then disconnect the ø1/2" (ø12.7 mm) and ø7/8" (ø22.22 mm) tubes. Pull the compressor toward you.

10. Compressor W-2WAY ECO-i SYSTEM Outdoor Unit Repair Procedures (1) (2) * (3) (4) (5) Temporary mount 2 cushion rubbers with bolts at the position as shown in the figure 27. Set up the leg of the new compressor onto the 2 cushion rubbers. Fig. 26 O-ring Fixing nut at the main unit side Fig. 27 Front view Cushion rubbers Bolts (Temporary mounting: 2 locations at back side, each 1 piece) Remove the 2 brazed tube caps (2 pieces) from the compressor. Remove hexagonal caps from the compressor. When removing the hexagonal caps, hold the fixing nut at the main unit side so as not to loose it with a wrench or spanner. And then, loosen and remove the hexagonal cap. Remove the oil equalizer tube connector parts along with the O-ring from the removed compressor and mount them on the replaced new compressor. Install the crankcase heater onto the new compressor. Hexagonal cap Oil equalizer tube connector parts Installation

W-2WAY ECO-i SYSTEM Outdoor Unit Repair Procedures 10. Compressor (6) (7) (8) (9) (10) (12) (13) Follow the instructions in “7. Evacuating System” and apply vacuum to the outdoor unit where the compres- sor was replaced. CAUTION CAUTION Fig. 28 Cushioning rubber guide Brazing locations (3) Front view Bolt 1 Protect the oil equalizer tube connectors Washer: Rubber washer: 1 (1 each at the 3 locations) Set the remaining cushioning rubber beneath the new compressor leg at the locations shown in the figure 28. Remove the bolts which are temporarily fastening the 2 pieces of cushioning rubber, and anchor the 3 com- pressor legs using the bolts, washers, and rubber washers. Insert the pre-shaped tube assembly at the 3 brazing locations indicated. Connect the manifold gauge to the high- and low-pressure outlet ports at the outdoor unit where the compres- sor was replaced. Connect the manifold gauge to a nitrogen cylinder and perform nitrogen gas replacement. Perform copper brazing at the 3 brazing locations. In the same way as during removal, pay particular attention to protection of the oil equalizing tube connector parts shown in the figure 28. An O-ring is mounted inside the oil equalizer tube connector parts. It must be pro- tected and do not lose it. Follow the instructions in “6. Checking for Leakage After Repair” and check for leaks at the outdoor unit where the compressor was replaced. Re-install all components that were removed. Re-install the electrical component box in the same position as it was before. (11) Be sure to check for looseness of the power terminal connection at the compress or terminal plate, and to check by pulling vertically on the connections. If the termi- nals become disconnected easily, replace the wiring Assy.

10. Compressor W-2WAY ECO-i SYSTEM Outdoor Unit Repair Procedures (1) (1) (C) Replacing multiple compressors Removal Follow the instructions in “(A) Replacing the inverter compressor,” “(B) Replacing constant-speed compressor,” and remove the compressors. * There is no predetermined sequence for removal; any compressor may be removed first. Installation Follow the instructions in “(A) Replacing the inverter compressor,” “(B) Replacing constant-speed compressor,” and install the compressors. * There is no predetermined sequence for installation; any compressor may be installed first.

W-2WAY ECO-i SYSTEM Outdoor Unit Repair Procedures 11. High and Low Pressure Sensors (1) (2) (3) (1) CAUTION Fig. 29 High pressure sensor The outdoor unit connection ports for the high and low pressure sensors employ Schrader-type push-to-release valves. Therefore it is not necessary to recover refrigerant when removing and installing them. 11-1. Removing the High and Low Pressure Sensor Follow the instructions in “1. Removing Panels” and “2. Removing Electrical Component Box and Duct” and remove the corresponding components from the outdoor unit where the high pressure sensor will be removed. Disconnect the high & low pressure sensor connector socket (3P) (BLK) & (WHT) from terminals CN009 and CN024 on the outdoor unit control PCB of the outdoor unit where the high & low pressure sensor will be removed. Use 2 adjustable wrenches in combination to remove the high & low pressure sensors. When removing the high & low pressure sensors, internal pressure will be applied by the refrigerant in the outdoor unit. The high & low pressure sensor connection ports on the outdoor unit employs a Schrader-type valve. Low pressure sensor Use 2 adjustable wrenches in combination to install the high and low pressure sensors. 11-2. Installing the High and Low Pressure Sensors

12. Replacing 4-way Valve W-2WAY ECO-i SYSTEM Outdoor Unit Repair Procedures (1) (2) (3) Connect the manifold gauge to the high and low-pressure outlet ports at the outdoor unit where the 4-way valve will be replaced. Connect the manifold gauge to a nitrogen cylinder and perform nitrogen gas replace- ment. (4) Prepare the brazing kit to disconnect the brazed parts (4 locations). (5) (6) (7) CAUTION Brazed parts (4 locations) Fig. 30 When replacing 4-way valve of type 96 (for type with 1 or 2 compressor), be sure to protect check valves, which are located adjacent to the 4-way valve, while performing replacement work. Type 72 (for type with 1 compressor) is not located near to the check valves, therefore no protection is necessary. 12-1. When the replacement is available from the right side of the unit Remove the front panel of the outdoor unit, then remove the right side panel of the unit. Follow the instructions in “9. Pumping Out Refrigerant from Outdoor Unit”, recover the refrigerant of the out- door unit where the 4-way valve is located. Protect the check valves as shown in the figure 30. 4-way valve Check valve After replacing the 4-way valve, follow the instructions in “6. Checking for Leakage After Repair”, and “7. Evacuating System”. The outdoor unit after replaced 4-way valve shall be checked for gas leakage and per- form system evacuation. Fully open service valves on the outdoor unit. However, if only one outdoor unit is installed, leave the balance tube kept closed. Charge the recovered refrigerant with the Refrigerant Recovery Unit by referring to the Installation Instruc- tions that came with the outdoor unit and the refrigerant recovery unit.

W-2WAY ECO-i SYSTEM Outdoor Unit Repair Procedures 12. Replacing 4-way Valve (1) (2) (3) (4) CAUTION Brazed parts (4 locations) Fig. 31 12-2. When the replacement is not available from the right side of the unit Follow the instructions of “10. Compressor” and remove the constant-speed compressor 2. Connect the manifold gauge to the high and low-pressure outlet ports at the outdoor unit where the 4-way valve will be replaced. Connect the manifold gauge to a nitrogen cylinder and perform nitrogen gas replacement. Prepare the brazing kit to disconnect the brazed parts (4 locations). Protect the check valves as shown in the figure 31. Check valve 4-way valve After replacing the 4-way valve, follow the instructionsin “10. Compressor”, and reinstall the removed constant- speed compressor 2 in the outdoor unit.

W-2WAY ECO-i SYSTEM Outdoor Unit Maintenance Remote Controller Contents 3. OUTDOOR UNIT MAINTENANCE REMOTE CONTROLLER 1. Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 2. Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 3. Ordinary Display Controls and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 4. Monitoring Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 5. Outdoor Unit Alarm History Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 6. Mode Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

1. Overview W-2WAY ECO-i SYSTEM Outdoor Unit Maintenance Remote Controller OUTDOOR UNIT MAINTENANCE REMOTE CONTROLLER (RCS-TM80BG) for W-2WAY ECO-i NAbout the outdoor unit maintenance remote controller The outdoor unit utilizes nonvolatile memory (EEPROM) on its PCB. This allows EEPROM data to replace the setting switches that were present on previous PCBs. The outdoor unit maintenance remote controller is used to set and change these EEPROM data. In addition to setting and checking the outdoor unit EEPROM data, this remote controller can also be used to monitor the outdoor unit alarm history, monitor the various indoor and outdoor temperatures, and check the indoor unit connection status (number of units, operating mode, etc.). NOTE Outdoor unit maintenance remote controller does not function as an ordinary remote controller. It is therefore only used for test runs and during servicing. L The special service checker wiring is required in order to connect the outdoor unit maintenance remote controller to the outdoor unit PCB. L Ordinary remote controllers or other controller are still required for the indoor units, even when the outdoor unit maintenance remote controller is connected. RCS-TM80BG [Service Checker Section] System diagram (Servicing No.: 6231785082) Special service checker wiring Remote controller Ass’y Operation manual included in package. Outdoor unit Inter-unit control wiring Outdoor unit control PCB Indoor unit Indoor unit Remote controller Remote controller Outdoor unit maintenance remote controller

W-2WAY ECO-i SYSTEM Outdoor Unit Maintenance Remote Controller 2. Functions NFunctions on the ordinary display (1) Functions: Button operations can be used to perform the following functions. • Start/stop of all indoor units • Switching between cooling and heating • Test run of all indoor units • Double-speed operation of indoor units (Do not use for actual operation. Doing so may damage the devices.) (2) Display: The following can be displayed. • Alarm details display • No. of indoor/outdoor units • Unit Nos. of connected indoor/outdoor units • Indoor/outdoor unit operating status (blinks when an alarm occurs) • Indoor unit thermostat ON • Display of individual outdoor unit alarms • Total operating time of outdoor unit compressors • Oil level of the outdoor unit oil sensor • Total outdoor unit power ON time • Outdoor unit microcomputer version, other information NTemperature monitor • Displays the indoor/outdoor unit sensor temperatures. NOutdoor unit alarm history monitor • Displays the outdoor unit alarm history. NMode settings • Setting mode 1 and setting mode 2 are used to make the outdoor EEPROM setting.

3. Ordinary Display Controls and Functions W-2WAY ECO-i SYSTEM Outdoor Unit Maintenance Remote Controller NFunctions on the ordinary display • Connect the special service checker wiring to the outdoor unit PCB. The connection is shown in the figure below. L If the communications line in the inter-unit control wiring is connected, it can be left as-is. L In case of an independent outdoor unit (1 maintenance remote controller connected to 1 outdoor unit, automatic address setting for indoor units not completed), both setting mode 1 and setting mode 2 can be used. L The overall system status for that refrigerant system is displayed. Special service checker wiring PCB connector (3P, BLU) RC (3P, BLU) Outdoor unit PCB Relay connector (2P, WHT) Remote controller Ass’y

W-2WAY ECO-i SYSTEM Outdoor Unit Maintenance Remote Controller 3. Ordinary Display Controls and Functions Fig. 1 L All units start/stop (Fig. 1) The (ON/OFF operation) button can be used to start and stop all the indoor units. • The LED illuminates if any indoor units is operating. • The LED blinks if an alarm at any of the operating indoor units occurs. L Cooling/heating change (Fig. 1) The (MODE) button can be used to change between heating and cooling operation. • The display indicates the operating mode of the indoor unit with the lowest unit No. L All units test run (Fig. 2) The (CHECK) button can be used to start and stop a test run for all indoor units. • Press and hold for 4 seconds to turn ON. During the test run “TEST” is displayed. • The status of test runs performed from the indoor unit remote controller is not displayed on the outdoor unit maintenance remote controller. Fig. 2 LED L Double-speed • Do not use for actual operation. (Doing so may damage the devices.) The timer button can be used to change between double-speed and normal operation. • During double-speed operation, the SLEEPING MODE mark is displayed.

3. Ordinary Display Controls and Functions W-2WAY ECO-i SYSTEM Outdoor Unit Maintenance Remote Controller NDisplay (functions) • Use the temperature setting and buttons to change the item code. Item code Item Remarks Œ Outdoor unit alarm  Alarm code display No. of connected indoor units Quantity Unit Nos. of connected indoor unit 7-segment display Operating status of indoor unit 7-segment display Thermostat ON status of indoor unit 7-segment display No. of connected outdoor units 1 – 2 Unit Nos. of connected outdoor units 7-segment display Operating status of outdoor unit compressor 7-segment display Compressor 1 operating time 0 – 99999999 hrs Compressor 2 operating time 0 – 99999999 hrs Compressor 3 operating time Compressor 1 oil level 0 = Empty 1 = Insufficient 2 = Sufficient Compressor 2 oil level 0 = Empty 1 = Insufficient 2 = Sufficient Compressor 3 oil level Outdoor unit power ON time 0 – 99999999 hrs Compressor 1 operation count 0 – 65535 times Compressor 2 operation count 0 – 65535 times Compressor 3 operation count Alarm history 1 (most recent) Display only. Alarm code and unit No. of unit where alarm occurred are displayed alternately. 0 = CCU 1 – 2 = Outdoor unit Alarm history 2 Alarm history 3 Alarm history 4 Alarm history 5 Alarm history 6 Alarm history 7 Alarm history 8 (oldest) Firmware version Display the version No. × 100. Program version Display the version No. × 100.

W-2WAY ECO-i SYSTEM Outdoor Unit Maintenance Remote Controller 3. Ordinary Display Controls and Functions (3) XX-YY R.C. Displays the outdoor unit sub-bus address which is currently selected. XX = Outdoor system address on main bus line (1 – 30) YY = Outdoor unit sub-bus address (1 – 8). “1” appears when there is only 1 outdoor unit. LED 1 2 3 Locations where Œ, , and Ž are displayed as shown in Fig. 3. 01: 4 units connected 02: Fig. 3 Fig. 4 Fig. 5

3. Ordinary Display Controls and Functions W-2WAY ECO-i SYSTEM Outdoor Unit Maintenance Remote Controller N Concerning the 7-segment, 4-digit display remote controller timer display The unit Nos. of connected units are indicated by four 7-segment digits ( ) and a colon. 1 2 7 12 17 3 13 18 8 4 14 19 9 5 10 15 20 6 11 16 21 22 27 32 37 23 33 38 28 24 34 39 29 25 30 35 40 26 31 36 1 ~ 20 21 ~ 40 41 ~ 60 61 ~ 80 1 ~ 20 21 ~ 40 41 ~ 60 61 ~ 80 LThe meaning of the colon changes in the same way to indicate unit Nos. up to 80. LSample displays of the connected indoor unit Nos.: NOTE The change of the colon display (between unit Nos. 1-20 to unit Nos. 21-40) occurs automatically every 10 seconds. (However the display does not change if there are no higher-number units connected.) To change the display to the higher-number units before 10 seconds have passed, press the (FLAP) button. N The total compressor operating time is displayed (in 1-hour units) using 8 digits. • When the first 4 digits are displayed, the top dot of the colon is illuminated. (Figure (A)) • When the last 4 digits are displayed, the colon dot is OFF. (Figure (B)) • The display of the first 4 digits and last 4 digits changes automatically after 10 seconds. The display can also be changed by pressing the (FLAP) button. NOTE With the outdoor unit maintenance remote controller (when connected to the outdoor unit), the unit remote controller check functions will not operate. • Display of unit No. 1 • Display of unit Nos. 1 and 2 • Display of unit Nos. 1, 2, and 3 • Display of unit Nos. 1, 2, 3, and 4 L Display of unit Nos. 1 − 20 L Display of unit Nos. 21 − 40 OFF OFF OFF OFF OFF OFF OFF OFF ON ON ON ON ON ON ON ON Meaning of display colon is not displayed. Meaning of display colon (B) (A) 10: (A) and (B) are displayed alternately. (The example here (0000, 0062) indicates 62 hours.)

W-2WAY ECO-i SYSTEM Outdoor Unit Maintenance Remote Controller 4. Monitoring Operations Display the indoor unit and outdoor unit sensor temperatures. Œ Press and hold the (CHECK) button and buttons simultaneously for 4 seconds or longer to engage temperature monitor mode. During temperature monitoring, is illuminates. (The display and operations are the same as for monitor mode using the indoor unit remote controller.)  Press the button and select the indoor unit to monitor. Ž Press the temperature setting and buttons and select the item code of the temperature to monitor. The unit No. of the selected indoor unit, and the temperature data, are displayed.  To end monitoring, press the (CHECK) button. The display returns to the normal display. NOTE The display does not blink. 1 4 2 3

4. Monitoring Operations W-2WAY ECO-i SYSTEM Outdoor Unit Maintenance Remote Controller NDisplay of unit No. 1 (main unit) DN Description Remarks Intake temp. °F E1 °F E2 °F E3 °F Indoor unit Discharge temp. °F Discharge temp. setting °F Indoor unit electronic control valve position STEP Discharge temp. 1 °F Discharge temp. 2 °F High-pressure sensor temp. °F Heat exchanger gas 1 °F Heat exchanger liquid 1 °F Heat exchanger gas 2 °F Heat exchanger liquid 2 °F Outdoor air temp. °F Not used Inverter primary current A CT2 A Outdoor unit MOV1 pulse STEP MOV2 pulse STEP Discharge temp. 3 °F CT3 A MOV3 pulse STEP MOV4 pulse STEP Heat exchanger gas 3 °F Heat exchanger liquid 3 °F Low-pressure sensor temp. °F Suction temp. °F Oil 1 °F Oil 2 °F Oil 3 °F Actual operating frequency Hz NOTE 0A and subsequent items are outdoor unit data. 0A – 22 are for unit No. 1. 2A – 42 are for unit No. 2.

W-2WAY ECO-i SYSTEM Outdoor Unit Maintenance Remote Controller 5. Outdoor Unit Alarm History Monitor • Displays outdoor unit alarms only. • Check the indoor unit alarm histories separately using the indoor unit remote controllers or other control device. Œ Press and hold the (CHECK) button and button simultaneously for 4 seconds or longer to engage outdoor unit alarm history mode. During temperature monitoring, illuminates. The display and operations are the same as for the alarm history monitor performed from the indoor unit remote controller. However the “unit No.” display shows the outdoor unit address.  Press the button and select the outdoor unit for which to monitor the alarm history. Ž Press the temperature setting and buttons and select the item code for the alarm history. The select outdoor unit address, the item code, and the alarm history (alarm data) are displayed. The outdoor unit address is displayed as R.C. XX-YY. System XX = Outdoor unit system address R.C. XX = Outdoor unit system address YY = Outdoor unit sub-bus address Item codes 01-08 are displayed. 01 indicates the most recent alarm. The alarm history displays the alarm code. (If no alarm are present, then -- -- is displayed.)  To clear the alarm history, press the button. (The outdoor unit alarm history will be cleared.)  To exit, press the (CHECK) button. The display returns to the normal display. 1 2 4 5 3

6. Mode Settings W-2WAY ECO-i SYSTEM Outdoor Unit Maintenance Remote Controller N Setting mode 1 Œ Press and hold the (CHECK) button and (VENTILATION) button simultaneously for 4 seconds or longer.  Press the temperature setting and buttons to change the item code. The item codes and setting data are shown in the table of “List of Item Codes” on the next page. Ž Press the timer time and buttons to change the setting data. To confirm the changed setting data, press the button. (At this time, all displays stop blinking and remain lit.)  During this mode, “ ” is displayed, blinking. The outdoor unit address display section displays “ALL,” the item code and number (DN value in the table), and the setting data (8 digits). (The setting data is displayed in 8 digits. The display changes between the first 4 digits (Fig. A ) and the last 4 digits (Fig. B ). When the first 4 digits are displayed, the top dot of the colon is illuminated.)  To exit the setting mode, press the (CHECK) button. 1 2 3 5 5 3 1 2 A and B are displayed alternately. (Example shows display of 0000 0001.) A Display of first 4 digits B Display of last 4 digits DN Parameter Description Snowfall sensor usage 0 = Sensor input not present. Control is performed. 1 = Sensor input present. Control is performed. 2 = Sensor input not present. Control is not performed. 3 = Sensor input present. Control is not performed. Outdoor unit fan Quiet mode 0 = Disabled 1 = Quiet mode 1 2 = Quiet mode 2 3 = Quiet mode 3 4 = Quiet mode 4 Energy saving mode 0 = None 1 = Discharge temp. control only (Mode 3) 2 = Demand only (Mode 2) 3 = Discharge temp. control + Demand (Mode 1) Energy saving operation plug 0 = Independent 1 = All indoor units linked Demand 1 current 0 = 0% 1 = 40 … 4 = 70 7 = 100 8 = 120 9 = 140 10 = 160 11 = 200 12 = –1 (no limit) Demand 2 current 0 = 0% 1 = 40 … 4 = 70 7 = 100 8 = 120 9 = 140 10 = 160 11 = 200 12 = –1 (no limit)

W-2WAY ECO-i SYSTEM Outdoor Unit Maintenance Remote Controller 6. Mode Settings N Setting mode 2 Œ Press and hold the (CHECK) button, button, and button simultaneously for 4 seconds or longer.  Press the temperature setting and buttons to change the item code. The item codes and setting data are shown in the table below. Ž Press the timer time and buttons to change the setting data. To confirm the changed setting data, press the button. (At this time, all displays stop blinking and remain lit.)  During this mode, “ ” is displayed, blinking. The display shows the set outdoor unit address “System XX-YY” (System XX = System address, YY = Address at outdoor unit sub-bus), item code number (DN value in the table below), and the setting data (8 digits). (The setting data is displayed in 8 digits. The display changes between the first 4 digits (Fig. A ) and the last 4 digits (Fig. B ). When the first 4 digits are displayed, the top point of the colon is lit.)  To exit setting mode, press the (CHECK) button. Returns to the normal display mode. A B 1 5 3 2 List of Item Codes DN Parameter Description 81 Outdoor unit capacity 0 = Disabled 224 = 72 Type 280 = 96 Type 1 2 5 3 Display of first 4 digits A and B are displayed alternately. (Example shows 0000 0410 (R410A).) Display of last 4 digits Fig. 7

W-2WAY ECO-i SYSTEM Remote Controller Functions Contents 4. REMOTE CONTROLLER FUNCTIONS 1. Simple Settings Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 2. Detailed Settings Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 3. Remote Controller Servicing Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

1. Simple Settings Function W-2WAY ECO-i SYSTEM Remote Controller Functions This allows the filter lifetime, operating mode priority change, central control address, and other settings to be made for an individual or group- control indoor unit to which the remote controller used for simple settings is connected. When simple settings mode is engaged, operation stops at the individual or group-control indoor unit to which the remote controller for simple settings is connected. ŒPress and hold the and buttons simultaneously for 4 seconds or longer. “ ,” unit No. “ ” (or “ ” in the case of group control), item code “ ,” and settings data “ ” are displayed blinking on the remote controller LCD display (Fig. 1). At this time, the indoor unit fan (or all indoor unit fans in the case of group control) begins operating. Ž If group control is in effect, press the button and select the address (unit No.) of the indoor unit to set. At this time, the fan at the indoor unit begins operating. * If unit No. “ ” is displayed, the same setting will be made for all indoor units. Press the temperature setting / buttons to select the item code to change. Press the timer time / buttons to select the desired setting data. * For item codes and setting data, refer to the following page. ‘Press the button. (The display stops blinking and remains lit, and setting is completed.) ’Press the button to return to normal remote controller display. • Fig. 1 RCS-TM80BG 3 4 7 2 6 5 1 [Remote Controller Functions Section]

W-2WAY ECO-i SYSTEM Remote Controller Functions 1. Simple Settings Function List of Simple Setting Items Item code Item Setting data No. Description Filter sign ON time (fitlter life time) 0000 Not displayed 0001 150 hours 0002 2,500 hours 0003 5,000 hours 0004 10,000 hours 0005 Use the filter clogging sensor. Degree of filter fouling 0000 Standard (setting at time of shipping) 0001 Highly fouled (Filter sign ON time is reduced to one-half the set time.) Central control address 0001 Central control address 1 0002 Central control address 2 0003 Central control address 3 0064 Central control address 64 0099 No central control address set (setting at time of shipping) Operating mode priority change 0000 Normal (setting at time of shipping) 0001 Priority Fan speed when heating thermostat is OFF Compressor ON Compressor OFF 0000 MED 1 min., LO 3 min. LO 0001 MED LO 0002 LO LO 0004 MED 1 min., LO 3 min. MED 0005 MED MED 0006 LO MED Heating intake temperature shift 0000 No shift 0001 Shifts intake temperature 2°F down. 0002 Shifts intake temperature 4°F down. 0003 Shifts intake temperature 6°F down. 0004 Shifts intake temperature 8°F down. 0005 Shifts intake temperature 10°F down. 0006 Shifts intake temperature 12°F down. Electric heater installation 0000 No heater 0001 Heater installed Humidifying when heater thermostat is OFF 0000 No (setting at time of shipping) 0001 Yes Permit/prohibit automatic heating/cooling 0000 Permit 0001 Prohibit Cool-only 0000 Normal 0001 Cool only (Set “1” for item code OD.) NOTE In order to avoid water leakage and damage to the fan, do not set for humidifying when the thermostat is OFF unless a vaporizing humidifier is used. Consider the device purpose and type when changing the settings. Incorrect settings may result in malfunction. Do not change any setting data that does not appear in this list. The 10-hp 4-way ceiling cassette has 2 indoor unit addresses. Set both of them. • • • •

2. Detailed Settings Function W-2WAY ECO-i SYSTEM Remote Controller Functions This allows the system address, indoor unit address, and other settings to be made for the individual or group-control indoor unit to which the remote controller used for detailed settings is connected. When detailed settings mode is engaged, operation stops at the individual or group-control indoor unit where the remote controller used for detailed settings is connected. Simple settings items can also be set at this time. ŒPress and hold the , and buttons simultaneously for 4 seconds or longer. “ ,” unit No. “ ” (or “ ” in the case of group control), item code “ ,” and settings data “ ” are displayed blinking on the remote controller LCD display (Fig. 2). At this time, the indoor unit fan (or all indoor unit fans in the case of group control) begins operating. ŽIf group control is in effect, press the button and select the address (unit No.) of the indoor unit to set. At this time, the fan at the indoor unit begins operating. Press the temperature setting / buttons to select the item code to change. Press the timer time / buttons to select the desired setting data. * For item codes and setting data, refer to the following page. ‘Press the button. (The display stops blinking and remains lit, and setting is completed.) ’Press the button to return to normal remote controller display. • Fig. 2 RCS-TM80BG 6 5 1 7 3 4 1 2

W-2WAY ECO-i SYSTEM Remote Controller Functions 2. Detailed Settings Function List of Detailed Setting Items Item code Item Setting data No. Description No. Description No. Description 0000 Semi-Concealed (A) 0001 4-Way Air Discharge (Mini) Semi-Concealed (X, XM) 0005 0006 Concealed-Duct High Static Pressure (D) 0007 Ceiling-Mounted (T) 0008 Indoor unit capacity 0001 0003 0005 0007 0012 0015 0017 140 (Type 48) System address 0001 0002 0003 0030 0099 Indoor unit address 0001 0002 0003 0064 0099 Group control address 0000 0001 0002 0099 Cooling temperature shift –010 –009 –001 0000 0001 0009 0010 0000 0001 0002 in 5-minute 0123 0124 0125 1-Way Air Discharge Slim Concealed-Duct (U, UM) Wall-mounted (K) 0010 0011 Wall-mounted (F) Concealed Floor Standing (FM) 80 (Type 24) 28 (Type 9) 22 (Type 7) 45 (Type 15) 112 (Type 36) 36 (Type 12) 0009 56 (Type 18, 19) 0011 71 (Type 24) For FHX2462 and FMHX2462 (Except FHX2462, FMHX2462) Type 0018 160 (Type 54) Unit No. 1 Unit No. 2 Unit No. 3 Unit No. 3 Unit No. 2 Unit No. 1 Not set Unit No. 30 Unit No. 64 Not set Individual (1:1 = Indoor unit with no group wiring) Main unit (One of the group-control indoor units) Sub unit (All group-control indoor units except for main unit) Not set Shifts intake temperature by –20°F. Shifts intake temperature by –18°F. Shifts intake temperature by –2°F. No intake temperature shift Shifts intake temperature by +2°F. Shifts intake temperature by +18°F. Shifts intake temperature by +20°F. Function disabled Stops automatically 5 minutes after operation starts. Stops automatically 10 minutes after operation starts. Stops automatically 615 minutes after operation starts. Stops automatically 620 minutes after operation starts. Stops automatically 625 minutes after operation starts. Automatic stop time after operation start *Can be set units. intake

2. Detailed Settings Function W-2WAY ECO-i SYSTEM Remote Controller Functions Item code Item Setting data No. Description (1B) Forced thermostat ON time 0000 5 minutes 0001 4 minutes Cooling discharge temperature shift –010 –20°F –009 –18°F –008 –16°F 0010 20°F Heating discharge temperature shift –010 –20°F –009 –18°F –008 –16°F 0010 20°F Temperature shift for cooling/heating change in auto heat/cool mode 0001 ±2°F 0002 ±4°F 0003 ±6°F 0007 ±14°F (Upper limit) Change to remote control temperature setting range Cooling 0018 64°F (Lower limit at shipment) 0019 66°F (Lower limit) 0029 84°F 0030 86°F (Upper limit at shipment) (Upper limit) Heating 0016 60°F (Lower limit at shipment) 0017 62°F (Lower limit) 0029 84°F 0030 86°F (Upper limit at shipment) (Upper limit) Drying 0018 64°F (Lower limit at shipment) 0019 66°F (Lower limit) 0029 84°F 0030 86°F (Upper limit at shipment) (Upper limit) Auto heat/cool 0017 62°F (Lower limit at shipment) 0018 64°F (Lower limit) 0026 78°F 0027 80°F (Upper limit at shipment) Humidifier operation 0000 Normal 0001 Ignore heat exchanger temperature conditions. Filter (CN70) input switching 0000 Filter input (differential pressure switch input) 0001 Alarm input (for trouble input about air cleaner or similar device) 0002 Humidifier input (Operates linked with drain pump when humidifier is ON.) Indoor unit electronic control valve 0000 Present (Setting at shipment) 0002 None T10 terminal switching 0000 Normal (Used as optional relay PCB or JEMA standard HA terminal.) 0001 Used for OFF reminder 0002 Fire prevention input

W-2WAY ECO-i SYSTEM Remote Controller Functions 2. Detailed Settings Function Item code Item Setting data No. Description Automatic drain pump operation 0000 No forced operation 0001 Forced operation for 1 minute 0060 Continuous operation Ventilation fan operation 0000 None 0001 Ventilation fan operated by remote controller. Wired remote controller sensor 0000 Not used. (Body sensor is used.) 0001 Remote control sensor is used. “Operation change control in progress” display 0000 Normal (displayed) 0001 Not displayed OFF reminder function for when weekly timer is used 0000 None 0001 Only stop time setting is enabled. Discharge temperature control 0000 Discharge temperature control OFF 0001 Discharge temperature control ON Heat exchanger temperature for cold air discharge (Heat exchanger control point for control to prevent cold air) 0013 Control temperature 55°F 0014 Control temperature 57°F 0025 Control temperature 77°F 0026 Control temperature 78°F Fan output switching 0000 Output linked with fan. (ON when indoor unit fan is operating.) 0001 Fan mode operation output Drain pump delayed start time 0000 No delayed start 0001 1 sec. delayed start 0002 2 sec. delayed start 0058 58 sec. delayed start 0059 59 sec. delayed start 0060 60 sec. delayed start Humidifier setting 0000 Humidifier output OFF. Drain pump stopped. 0001 Humidifier output ON. Drain pump operates. 0002 Humidifier output ON. Drain pump operates for 1 minute when total humidifier operating time reaches 60 minutes. 0003 Humidifier output ON. Drain pump stopped. Flap operation mode 0000 Standard setting 0001 Draft reduction mode (Flap lower-limit position is shifted upwards.) Flap swing mode 0000 Smudging reduction mode (Flap swing upper-limit position is shifted downwards.) 0001 Normal mode 0002 Draft reduction mode (Flap swing lower-limit position is upwards.)

2. Detailed Settings Function W-2WAY ECO-i SYSTEM Remote Controller Functions Item code Item Setting data No. Description Fan tap setting (Fan tap change in order to prevent drop in air discharge caused by filter installation) DC fan tap operating mode Purpose 0000 Standard Standard (setting at shipment) 0001 High ceiling use High ceiling setting 1 (with standard panel) For low static-pressure filter Ultra long-life filter, oil guard panel, ammonia deodorizing filter, optical regenerative deodorizing filter 0003 High ceiling use High ceiling setting 2 (with standard panel) For low static-pressure filter (Antibacterial) high-performance filter (90%) (Antibacterial) high-performance filter (65%) Air-cleaning unit, air-cleaning unit + optical regenerative deodorizing filter, deodorant (activated charcoal) filter For air-blocking material For 3-way discharge, when discharge duct is connected 0006 For air-blocking material For 2-way discharge Humidifier ON time (ON time per 60 seconds) 0000 No humidifier output 0001 1 sec. 0002 2 sec. 0058 58 sec. 0059 59 sec. 0060 Continuously ON Repeat timer switching 0000 Function disabled 0001 Function enabled Timer function change prohibit 0000 Function disabled 0001 Function enabled Smudging control 0000 No smudging control

W-2WAY ECO-i SYSTEM Remote Controller Functions 2. Detailed Settings Function Simple setting items Item code Item Description 01 Filter sign ON time setting (filter lifetime) Changes the indoor unit filter lifetime when a high-performance filter or other optional product is installed. 02 Degree of filter fouling Reduces the filter sign ON time to 1/2 of the standard time (setting at the time of shipping) for cases when filter fouling is more severe than normal. Filter sign ON times for each model Model data Model Filter sign ON time Standard Long-life Super long-life High performance 65 High performance 90 Pressure differential switch 0000 1-Way Air Discharge Semi-Concealed (A) × 75 2500 1250 × × × × × × × 0001 4-Way Air Discharge (Mini)Semi-Concealed (X, XM) × × 2500 1250 5000 2500 2500 1250 × × × 0005 (Slim)Concealed Duct (U, UM)) × × × 1250 5000 2500 2500 1250 5000 2500 × 0006 Concealed Duct High Static Pressure (D) × × × 1250 × × 2500 1250 5000 2500 × 0007 Ceiling-Mounted (T) × × 2500 1250 × × 2500 1250 × × × 0008 Wall-Mounted (K) 150 75 × × × × × × × × × 0010 Floor-Standing (F) 150 75 × × × × × × × × × 0011 Concealed-Floor Standing (FM) 150 75 × × × × × × × × × Unit: hour NOTE × indicates that there is no corresponding filter. 150 indicates the filter sign ON time that is set at shipment. High fouling: Set when is selected for the degree of filter fouling (item code ). • • • Standard Standard Standard Standard Standard High fouling High fouling High fouling High fouling High fouling