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ELECTROLUX HOME PRODUCTS PTY LTD

ABN 51 004 762 341

Issue: 2
Technical Publication Nº KSSSI54 Date: 05/07

WEB SITE ADDRESS:www.partnship.com.au


ELECTROLUX

INVERTER
SPLIT SYSTEM
AIR CONDITIONER

SERVICE MANUAL
SECTION PAGE Nº
SPECIFIACTIONS 1-1 & 1-2
EXTERNAL DIMENSIONS 1-3 & 1-4
WIRING DIAGRAMS 1-4 & 1-5
DESCRIPTION OF ELECTRICAL PARTS 1-5
EXPLANATION OF CIRCUIT AND OPERATION 2-1 & 2-2
CIRCUIT & PRINTED WIRING BOARD DIAGRAMS 2-3 to 2-7
ELECTRONIC FUNCTION 2-7 to 2-16
TROUBLESHOOTING (SELF DIAGNOSIS FUNCTION) 3-1 to 3-4
TROUBLESHOOTING & TEST PROCEDURES (VARIOUS COMPONENTS) 3-5 to 3-8
REFRIGERATION FLOW DIAGRAM WITH STANDARD CONDITIONS 4-1
PERFORMANCE DIAGRAMS 4-2
REFRIGERANT PIPE SPECIFICATIONS 4-2
DISASSEMBLE PROCEDURE 5-1 to 5-9

MODELS:

ESD24HRA
ESD30HRA
© Copyright 2007 ELECTROLUX HOME PRODUCTS PTY LTD Technical Services
ESD24HRA
CHAPTER 1. PRODUCT SPECIFICATIONS5GTXKEG/CPWCN
ESD24HRA


[1] SPECIFICATION
1. ESD24HRA

ITEMS INDOOR UNIT OUTDOOR UNIT


Cooling capacity (Min. - Max.) W 6600 (1735 - 7275)
Heating capacity (Min. - Max.) W 7900 (1940 - 8810)
Moisture removal (at cooling)✩ Liters/h 2.6
Electrical data
Phase Single
Rated frequency Hz 50
Rated voltage V 220 - 240V
Rated current ✩ Cool A 9.9 (2.14 - 12.63)
(Min. - Max.) Heat A 11.0 (2.23 - 14.38)
Rated input ✩ Cool W 2270 (481 - 2917)
(Min. - Max.) Heat W 2550 (503 - 3325)
Power factor ✩ Cool % 100
(230V) Heat % 100
Compressor Type Hermetically sealed rotary type
Model DA150A1F-20F
Oil charge Ester oil VG74 650ml
Refrigerant system Evaporator Louver Fin and Grooved tube type
Condenser Corrugate Fin and Grooved tube type
Control Expansion valve
Refrigerant (R410A) 1800g
De-lce system Micro computer controlled reversed systems
Noise level High dB(A) 47/47 55/56
(cooling/ Heating) Low dB(A) 43/43 -
Soft dB(A) 36/36 -
Fan system
Drive Direct drive
Air flow quantity High m3/min. 16.9/16.9 56/56
(cooling/ Heating) Low m3/min. 13.9/13.9 –
Soft m3/min. 10.5/11.8 –
Fan Centrifugal fan Propeller fan
Connections
Refrigerant coupling Flare type
Refrigerant tube size Gas, Liquid 5/8", 3/8"
Drain piping mm O.D I 20
Others
Safety device Compressor: Thermal protector
Fan motors: Thermal fuse
Fuse, Micro computer control
Air filters Polypropylene net (Washable)
Net dimensions Width mm 1040 890
Height mm 325 800
Depth mm 229 320
Net weight kg 16 61

NOTE: The condition of star "✩" marked item are ‘ISO5151’: 1994(E), condition T1, Voltage 230V.

1–1
ESD24HRA
2. ESD30HRA

ITEMS INDOOR UNIT OUTDOOR UNIT


Cooling capacity (Min. - Max.) W 7700 (2635 - 7807)
Heating capacity (Min. - Max.) W 8200 (3079 - 9197)
Moisture removal (at cooling)✩ Liters/h 3.3
Electrical data
Phase Single
Rated frequency Hz 50
Rated voltage V 220 - 240V
Rated current ✩ Cool A 13.5 (3.15 - 15.74)
(Min. - Max.) Heat A 12.0 (3.59 - 15.44)
Rated input ✩ Cool W 3130 (711 - 3637)
(Min. - Max.) Heat W 2770 (816 - 3570)
Power factor ✩ Cool % 100
(230V) Heat % 100
Compressor Type Hermetically sealed rotary type
Model DA220A2F-21L
Oil charge Easter oil VG74, 900ml
Refrigerant system Evaporator Louver Fin and Grooved tube type
Condenser Corrugate Fin and Grooved tube type
Control Expansion valve
Refrigerant (R410A) 1800g
De-lce system Micro computer controlled reversed systems
Noise level High dB(A) 47/47 55/56
(cooling/Heating) Low dB(A) 43/43 -
Soft dB(A) 36/36 -
Fan system
Drive Direct drive
Air flow quantity High m3/min. 16.9/16.9 56/56
(cooling/Heating) Low m3/min. 13.9/13.9 -
Soft m3/min. 10.5/11.8 -
Fan Centrifugal fan Propeller fan
Connections
Refrigerant coupling Flare type
Refrigerant tube size Gas, Liquid 5/8", 3/8"
Drain piping mm O.D I 20
Others
Safety device Compressor: Thermal protector
Fan motors: Thermal fuse
Fuse, Micro computer control
Air filters Polypropylene net (Washable)
Net dimensions Width mm 1040 890
Height mm 325 800
Depth mm 229 320
Net weight kg 16 66

NOTE: The condition of star "✩" marked item are ‘ISO5151’ : 1994(E), condition T1, Voltage 230V.

1–2
ESD24HRA
[2] EXTERNAL DIMENSION
1. Indoor unit

1040 229

325
58 18.5
175

22.0

Remote controller [Length unit : mm]

2. Outdoor unit

150 590 150


75
51.3
Ø 4.5 16
361
383

890 37 320
800

1–3
ESD24HRA
3. Installation dimensions
1040(Unit size)

33
E
E E
D
I J

325
H D C

F A
G B

50
42

137 80 Center of wall hole: 80 137


I F Leftward piping A J
Outline of indoor unit
Center of wall hole:
Backward piping

[3] WIRING DIAGRAMS


1. INDOOR UNIT

1–4
ESD24HRA
2. OUTDOOR UNIT

(CC287)
The voltage is high at C16A, C16B(electrolytic capacitors) on outdoor unit. For maintenance discharge at C16A, C16B to prevent electric shock,
in case that FUSE101(protector) has been fused, the voltage is kept high at C16A, C16B.

The microcomputer's GND line which


control the thermistor,etc. share the
same line of 370V line. This circuit is
non-insulation type. Do not touch
the control circuit components as it
may result in electrical shock hazard.
Do not earth osilloscope etc.during
mesurement , as it may result in
damage.
Do not earth osilloscope etc.
during measurement, as it may
result in damage.

FMC2 FMC1

POWER
SUPPLY
UNIT

1A
250V

[4] ELECTRICAL PARTS


1. INDOOR UNIT 2. OUTDOOR UNIT

Part Name Items Specifications Part Name Items Specifications


ESD24HRA ESD30HRA ESD24HRA ESD30HRA
Terminal Board Rating 300V 25A Fan motor Capacitor Rating 500V 3.0PF
Fan motor Capacitor Rating 450V 2PF Fuse 1 Rating 250V, 20A
Transformer Rating Pri 220 - 240VAC Sec. 19.0VDC Fuse 2 Rating 250V, 20A
Fan motor Rating 220 - 240VAC 50Hz 41W 4-Pole Fuse 3 Rating 250V, 3.15A
Type MLB238 Fuse 4 Rating 250V, 1A
Power Supply Cord Rating — — Compressor Rating 1100W 2000W
— — Type DA150A1F-20F DA220A2F-21L
Louver Motor Rating DC12V Fan motor Rating 220 - 240VAC, 50Hz, 75W, 6-Pole
Type MP24GA Type MLB268
Fuse 1 Rating 250V 2.5A

1–5
ESD24HRA
CHAPTER 2. EXPLANATION OF CIRCUIT5GTXKEG/CPWCN
ESD24HRA


AND OPERATION
[1] BLOCK DIAGRAMS
1. Indoor unit

DC power supply circuit AC power


2.5A
Fan motor phase control circuit Indoor fan motor FUSE1

Rotation pulse input circuit Fan motor pulse detect


AC clock circuit
Louver motor drive circuit Flow direction control

Remote controller signal reception circuit Wireless remote control operation


Buzzer drive circuit Audible operation confirmation
CPU reset circuit
CPU oscillator circuit
CPU
Room temp. detect circuit Room temp. thermistor
Heat exchanger pipe thermo circuit Heat exchanger pipe thermistor
Compensation circuit/ select circuit Blower temperature, fan speed, model select
Compensation circuit Outdoor ratings
Switchover circuit Wireless, preheat
Serial I/O circuit Indoor/outdoor control signal I/O Unit-unit wiring
(AC power and
Compressor relay drive circuit Outdoor unit power supply on/off control serial signals)
LED drive circuit LED display
Auto restart circuit
Test run circuit Test run (forced operation)
Auxiliary mode Auxiliary mode button ON/OFF
Power on circuit Self diagnostics, fault diagnosis
Cluster generator drive circuit Cluster generator

2–1
ESD24HRA
2. Outdoor unit

1A 20A
Power supply Fuse Fuse Unit-unit wiring (AC power
Smoothing Active filter Filter
circuit circuit circuit circuit and serial signals)

CPU oscillator circuit


3.15A Fuse
DC over voltage detection circuit
4-way valve relay drive circuit 4-way valve
Outdoor fan relay drive circuit Outdoor fan motor
20A Fuse
Power transistor module drive circuit Power transistor module
Serial I/O circuit
CPU reset circuit
CPU
position detection circuit Compressor

DC overcurrent detection circuit


DC current detection circuit
AC overcurrent detection circuit Current transformer
Compressor thermo circuit Compressor thermistor
Heat exchanger pipe thermo circuit Heat exchanger pipe thermistor
Outdoor temp. thermo. circuit Outdoor temperature thermistor

Suction pipe thermo circuit Suction pipe thermistor

Heat-sink temp.thermo circuit Heat-sink temperature thermistor


LED drive circuit LED
Expansion valve drive circuit Expansion valve

2–2
1. Indoor unit

POWER
SUPPLY N IN RY1 CN4 RY1
L 1 2 470
SINGLE JP52 12V SSR1
PHASE FUSE1 IN OUT 1/2W
2.5A IC2 R56
TERMINAL
BOARD 1 250V 5V IC5 9

C2
D5

JP10
C3
IN OUT

C4
T 470

0.1u
NR1
IC3

7812
SSR2

OUT
+ +

C6
PA

C5
1W R58

47u

D1 - 4
+ 1

C1
0.1u

1000u
7805

25V
2

0.1u
100u
10V

50V

35V
50V
TR1 3

275V
JP11 8 LOUVER
N N 4 MOTOR
THERMAL IC6 9 BZ1

33K
(NOTE)
1.1. Electronic control circuit diagram

1 FUSE GND 5 :TEST POINT

TO
OUTDOOR
UNIT
2 S R57 CN7 SW1 : AUX. (TEST RUN)

R15 33K
1.8K

R16
TERMINAL
BOARD 2
47
8 1/2W IC101
10K
3 3
R54 R55

L1
2 2 +

0.1u
C102

C101

0.01u
1 1

R17
100
1W
10V 25V
BCN1 47u

SSR1
1

C7
2 BCN101

275V
3 Q5
INTERNAL
THERMOSTAT C32 0.01u 16V PA

0.033u
275V
C8
1 1 1
C31 0.01u 16V (FULL POWER)
3 2 2
C30 0.01u 16V 1/2W 620 R106 LED106
HALL 450V 2u (CLEAN)
IC 5 3 3
C9 R60 33K 1/2W 620 R105 LED105

1
2
3
4
CN1 4 4
[2] MICROCOMPUTER CONTROL SYSTEM

R59 R66 3K R102

C33
33K

0.1u
6.8K 6.8K
FAN R18 R19 IC8 3.3K 5 5

NC
NC
NC
NC
NC
NC
NC
2.7K R101

SSR2
MOTOR 2W 2W
6 6

8
7
6
5

25V
56 R107
XA

48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
7 7

FR
CN2 C10

ON

0.1u
T
1 8 8

275V
R67 R62

P00
P01
P02
P03
P04
P05
P06
P07
P10
P11
P12
P13
P14
P15
P16
P17

6.8K
6.8K
3 BCN2 CN101
NF1 6 5 4 3 2 1
BCN103

2–3
CN80 49 P37 P20 32
1 50 P36 P21 31 BCN102
1 2 3 4 3 2 1
3 51 P35 P22 30
R61 52 P34 P23 29
10K R68 1K NC 53 P33 P24 28 NC JP53
1K 54 P32 P25 27 NC BL LED107
R21 IC1 (CLUSTER)
6 R20 10K 55 P31 M3803** P26 26 NC

AUTO
RESTART
C18 NC 56 P30 (PATTERN P27 25 NC
57 Vcc SIDE) Vss 24
25V 58 Vref Xout 23
0.1u OSC1 CN103
59 AVss Xin 22 3 2 1

R14
CLUSTER 8M R51 10K PA
60 P67 P40 21

R12
GENERATOR

680
R10
C29

R6
R8
61 P66 P41 20 SW1 PA
62 P65 RESET 19 1 CN99 R48 1 (TIMER)
3 IC4 10K 0.1u 25V
63 P64 CNVss(Vpp) 18 1 LED102
BUSY R52
64 P63 P42 17 2 (OPERATION)

R47
2 12V 3.3K Q2 LED101

R46
3

C22
C34

2W
3

680 680
3 5V 2 25V CN6

R13

R5
R7
R9
R11
P62
P61
P60
P57
P56
P55
P54
P53
P52
P51
P50
P47
P46
P45
P44
P43
1

R24 - 28
4 CLOCK
R50
R49

5V

16V C24
50V

16V C23
0.1u C28

1
2
3
4
5
6
7
8
9

R23
16V

10
11
12
13
14
15
16

680
1000p 680 5 SERIAL 1 TH2

4.7K

0.01u
0.01u
0.01u
0.01u
1u

16V C21
R53

C20 PIPE TMP.


6 OE 2 4.43kohm (25ºC)
10K

680
7 RESET 680 R44 +
3.3K

50V

2W 11K 2W D10
C27
10u
16V

R34 3 TH1
R45

3.3K 8 MO ROOM TMP.


10K

D11
2
6.8KF

3 2 9 GND 4 10kohm (25ºC)

11K R22
3 R42

R30
4 680 +
C26
10u
16V

5
R43

1 Q1 TH3

C17
16V

100K
10KF

PC1 33K

16V
C16
1 VALVE TMP.
+ R65 4.43kohm(25ºC)
4 1 6

4.7K
250V
50V
0.01u

0.01u
R40

1000P
R33

C15

20K R32
680 + PA

1.8K
CN5

0.01u
22K R31
C25
10u
16V

C14

ZD1
R41

35V
50V C13
0.047u

100u C12
R29
PC2
6.8KF

3 2 R63 2.7K R35


-24V MODEL 33K TEST
R1 R2 R36 JP
33K WIRELESS
R37 JP1
R3 R4
33K PREHEAT
R38 JP2 NONE 13K 24K 13K 15K NONE JP NONE JP 13K 15K 13K 15K 13K 15K JP10
33K HOT KEEP I
R39 JP3
33K POWER ON
JP99
NO. JP1 JP2 JP3 JP99 R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 JP10/
CN4
ESD24HRA
ESD24HRA
1.2. Printed wiring board

from
TERMINAL BOARD BOTTOM "L"

from
TERMINAL BOARD TOP "1"
to
TERMINAL BOARD TOP "2"

to
TERMINAL BOARD TOP "N"
from
FAN MOTOR
from
CLUSTER GENERATOR

from
FAN MOTOR
from
THERMISTOR
from
LOUVER MOTOR

2–4
R100 R101 C16A C16B
L1 ESD24HRA 5W 0.015 NONE 1500uF420V 1000uF420V

GRAY ESD30HRA 5W 0.020 5W 0.020 1500uF420V 1500uF420V


BLUE ORANGE
275V 1uF L4 275V 1uF CT1 T5 DB1 WHITE WHITE
L3
MRY1 +
FC4 1 3 1 3 (IPM PWB)
BLUE 275V 1uF C2 C1

R1A
YELLOW YELLOW 20A 250V P QM101(IPM)

1/4W
C3 L1 L2

510k
YELLOW C16A C16B FC6
C14 22
GREEN/ FUSE1 + FC5
YELLOW 4 4 AC1 FC2 TP
BROWN 2 2 R103 FUSE101 0.33uF 0.022uF S
IN OUT P 1/4W 630V 50V

R1B
510k
C15
PTC1 C121 C120

1/4W
C14,15:
T1 250V 130k

275V 2.2uF
2. Outdoor unit

20A C9, C11: + + 17


10000pF C9 C11 R104 FC1
250V L5 50V 1000pF U TU RED
SA1 AF1 1/4W 23
C119

C13
C8, C10: ACT(PFC) 130k 16 C
C12, C13: - - V 24
WHITE
NR1 4700pF C8 C10 T6 AC2 SACT32420 e R102 TV
D1 W 25
GREEN 250V

C12
R105 1.8kF
BLACK lo 1/4W ZD101 TW ORANGE
T4 - BLUE
FUSE3 BROWN CN13 BLUE 130k
R10 R106 R
1.0kF - 1 2 3 4 5 6 BLUE 1/4W N
NR2 250V TN R101
3.15A 130k
N 26
R100
18kF

D4
D5
Q1 KRC102S CN114 4 3 2 1
Z
1 R113

R7
BLUE YELLOW

150k
1/2W
150k
1/2W
2 1A R12A,12B,12C,13A,13B,13C: 15V

(TERMINAL BOARD)
250V 1M 1/4W
5V 13V FUSE6 1/2W BCN13 1 2 3 4 5 6 5V 18V D17 R55,56: 1/2W 196kF
TB TR1 D13 1.5k 1 2 4 6 CN2

50V
C6
0.01uF

R5
R25 4 3 2 1 CN14 100 R55 R56
PC1 C19 1 12 250V R46 R44 IC5
4 RY3 R22 R21 1/4W 3 R48 1/4W
1 R12A R13A 220pF 13 0.01uF 10k 1.8k 1.8k + KIA339P
R24 1.65kF 0.1uF 1 7
3 C23

R3
2kV 1/4W R30 560F 630V

47k
2 3 D8 R12B R13B D14 13V 6 R47 R57 R58

1/4W
D9 22k C82 -
C20 R17 0.033uF 1/4W 100
9

R45
PC81716 R13C

D2
D3
R12C +
2.1. Electronic control circuit diagram

1.8k
68k 25V 14 9
2W 10 C24 + C29 R49
Fan Motor + 50V + + R23
R94 - 10uF 10 11 35V 34.8kF 8 100 1/4W R59 R60
Capacitor SSR1 - - - 18V 5V -
R11 1/2W IC8 R35

150k
C7 150uF

1/4W
500V 3uF R18

150k
R50 100

680uF
470 R36

4.64kF

680uF
R26
50V 8 1 2 3 4 D11 8 +
C5 5.6k MM1431A D16 1M 13
IC4 11

R6 1/2W

R4 1/2W
1000pF

R33
STR-L472 1.5k C25 C26 R27 KIA7805API 5V
R37 R40 1/4W
10 R61 R62

FMC1
BLUE 7 10 9 6 1/4W 25V 25V 10k 5 + 3 D21 1.8k 1k 12 -
IC7

R19
2k
Q2 2

1/4W
R8A D15 18V 7805 KIA339F R51 R57,R59,R61:
R9

R32
2SA + C31 7.5kF 1/2W 196kF
R8B 100 1W ZD1 1586G 10V
4 -
12
R58,R60,R62:

SSR1
1W 5 C36

RY1
100 100 C21 + C30 - 100uF IC5 C34 50V R38 C37 C38 C39 C40 R52 R54

D12
1W 0.1uF 0.1uF 10k 50V 50V C38,C39,C40: R53 1/2W 180kF
C4A R20 3300pF 6 - C33

FMC2
C32 0.1uF 0.1uF

RY3
RY2
C4B

R32,R33:1/2W270kF
C4C 1/4W 3.3k 50V 330pF R52,R53,R54:
C27 R28 C28 50V C35 Q4 14.7kF
275V 275V 680 1/4W D10 R31 R34 50V 13V
BLACK 275V R14 35V 10k 0.1uF FB1 4.64kF 0.01uF 0.1uF 50V KRA106S R43 R41 (valve)
0.033uF 0.033uF 0.033uF 150uF 0.01uF 1k 1k GR
1/4W 9.53kF FB3 6
R99 R29 4.7k R
1 5
7 5 3 1 3 C18 ZD2 R42
R64 BL
R15 1k B 4
470pF R16 C22 680pF 1.0kF
Low 3.3 3.3 Q3 + O
CN10 High CN4 O 3
1/2W 1/2W Y
(EEPROM) 5V - C41 Y 2
5V KRC105S R65 10k flash
S24CS02 10V W
writer W 1
IC6 4.7k 1k monitor 220uF
4 5 4 R69 R67 1 H
Fan 4-WAY 1
3 6 3 R66 10k 2
R63
2 CN12
Motor Valve C42 2 7 2 3
6.49kF I
3
50V 1 8 1 4
R68 4 J
0.1uF R70 1k CNM 5
PC817X3 P
D18 3.3k CNE 4.7k R 6 RY2
R74 PC3 5V 7 5V R201 100kF IC3
S KID65004AP
4 1000pF 8
1 T
4.7k 9
5V
(CONTROL PWB) C49 50V Q 15V
50V R71 C48 D20 RY1

2–5
0.1uF 2 3 CND 20kF R204
CN5 4700pF R200 R202 200kF
JPF1 1k 8 - 2
250V 1
BLUE N C50 4 1 MRY1
1 3
2W 2W 2W 4 +
1k R72 R205
ORANGE 1k 1k 56k R203 200kF
2 2.0kF
A 3 C81
JPF2 R75A R75B R75C PC2 2 R77 PST993D C17
PC853X R73 R IC2 50V C80 50V
1.8k 270 0.1uF 50V 0.1uF
5V 5V IC9
R78 C44 C43 1000pF NJM2904M
270 50V 10V
C47 0.1uF 100uF
Q9 (IPM PWB) 0.1uF
50V C46 C45 C109
KRC105S 0.1uF 50V 50V 10k 1 VPI 2 D101
0.1uF 1uF R76 C113 UP VUFB
3
1000pF +
C101
FUSE5 15V f C106 - 25V
VUFS 4
R82 OSC1 0.1uF 100uF
C51
4MHz 5 0.1uF
5V 24 23 222 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 C114 VP VPI
C110
15V R81 6 D102
R83 + C52 10k JPF 5V 1000pF VVFB 7
33

C53 S CN-2 +
- 5V 10k 5V C102
R84 R79A 1

X1
X0
VSS
P41
P42
RST
P43
P44
P45
P46
P47
P50
P51
P60
P61
P62
P63
P64
P65
P66
P67
AVSS
AVCC
AVR

Q8 25 MD0 VVFS C107 - 25V


3.3k Q7 R79B P70 80 2 9 8 100uF
26 MD1 3
0.1uF
10k P71 79 FB4 C115 WP
Q 27 MD2 0.1uF
5V R80 P72 78 1000pF C111
NC 28 P40
R108-R111:
1/4W

P73 77 R96 VPI 10 D103


D19
CN101

10k NC 29 P37 10k


P74 76 VWFB 12
R85 1 NC 30 P36
CN3 8 5 4 3 2 1 P75 75 R97 1k +
2 31 P35 19
3.3k P76 74 1 1 Z
3 32 P34 UN C108 -
R110

(U) P77 R98A U U C116 VWFS 13


73
R108

4 33 P33 2 2 1000pF
R86 IC1 (V) P80 72
0.1uF
C54 5 34 P32 R98B V C103
(W) P81 71 3 V 3
10k NC 35 P31 25V
(U) P82 R98C W
R111

CN-1 NC 36 70 W 100uF
P30 4 4
R109

(X) P83 69 20 D100


R88A-R88G:10k NC 37 P27 R98D X X
(V) P84 68 5 5 C117 VN
NC 38 P26
R88G (Y) P85 67 R98E Y Y 1000pF 0.1uF
5V NC 39 P25 6 6
(W) P86 66 C118 C112
R88F NC 40 P24 (Z)
R98F Z Z 1000pF VNI 14
P87 65 7 7 21
+
P23
VCC
P22
P21
P20
P17
P16
P15
P14
P13
P12
P11
P10
P07
P06
P05
P04
P03
P02
P01
P00
VCC
VSS
C

FB2 R88E R98A- WN


R98F: 8 8 R107 R112 -
R207 R88D 6.8k 6.8k VNC 15 e
3 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 1/4W
TH6 9 9 C104 ZD100
C77

R88C 100 25V +


NC

130k
NC

1 VPC 11 330uF HZ24-2


C78

10 10 C105 -
(heatsink) R88B 25V
100uF C122 IPM
50V

C74
C73
C75
C76

5V 18
CN6 330k C72 15V 0.1uF FO
W O I H C74-C76: C123
50V
0.1uF

R206 50V
0.01uF

R88A 0.1uF 50V BCN1 0.1uF


10 R89 Y B J 1000pF
50V

10k
0.1uF

9 JPP JPT
5V
TH4 8
R90
(suction) 7 1k C71
C70 R92
6 50V 50V 10k
TH3
(outdoor) 5 0.01uF 0.01uF
R93
4 10k
TH2 T
3 5V
(heat exchange) JP1 JP2
R91
2 2.2k
TH1 P
1

R87F
R87E

3.6kF
R87D
R87B
R87C
R87A
(compressor)
winter MAX LED1
C62

R87A - R87E: COOL


CN8 6.8kF f

C60
C55
C68

C59
C57
C56

C58
C63
C64

C67
C66
C65

(thermistor) C55 - C60:10uF16V C62 - C68:0.01uF50V


ESD24HRA
ESD24HRA
2.2. Printed wiring board

2.2.1 Control PWB

from from NON CONNECTION from 4-WAY VALVE


IPM "U", "V", "W" IPM PWB CN114
DSGY-A

from FAN MOTOR

to DIODE BRIDGE
DB1 " "

to MRY1 IN

from
HEATSINK
THERMISTOR

from
THERMISTOR

from CONTROL BOX

from
TERMINAL BOARD "N"

from
TERMINAL BOARD "1"

to IPM PWB CN101


to ACTIVE FILTER "ACT"
from EXPANSION VALVE
from TERMINAL BOARD "N" and "2"

2–6
ESD24HRA
2.2.2 IPM PWB

from ELECTROLYTIC CAPACITOR C16B(+)


from CONTROL PWB CN14

from ELECTROLYTIC
CAPACITOR C16B(-)

from COMPRESSOR CORD


W "ORANGE"

from COMPRESSOR CORD


from COMPRESSOR CORD U "RED"
V "WHITE"

from CONTROL PWB BCN1

[3] FUNCTION
1. INDOOR UNIT
1.1. Temperature Adjustment Control for indoor freezing prevention
1) Cooling If the temperature of the indoor heat exchanger stays below
approximately 0qC for four minutes during cooling or dry, this con-
When the room temperature is higher than the preset temperature
trol stops the compressor. Over 2qC the compressor will run again.
by 2qC or more, the unit runs at the maximum operation frequency
until the temperature comes down to the preset temperature. When 2) Heating
reaching the preset temperature, the unit runs at the frequency cal- Control for cold air blowing prevention
culated by the fuzzy operation and switches to the normal control.
When heating begins, this control stops the indoor fan until the tem-
2) Heating perature of the indoor heat exchanger reaches 23qC. It also stops
When the room temperature is lower than the preset temperature the fan if the temperature goes below 21qC during operation.
by 3.5qC or more, the unit runs at the maximum operation fre-
quency until the temperature comes down to the preset tempera-
Temperature of the indoor heat exchanger
ture. When reaching the preset temperature, the unit runs at the Preset fan speed
frequency calculated by the fuzzy operation and switches to the 38
normal control. 35
3) Dry The indoor fan operates at low speed
26
After operation begins, 2 minutes of the room temperature is stored
in memory, and that becomes the set value. 23
The indoor fan stops
1.2. Indoor fan control
1) Cooling 1.3. Hot keep
The fan speed can be selected from “Auto”, “Soft”, “Low”, and If the room temperature is in the Hot keep(1) or Hot keep(2) zone dur-
“HIgh”.When “Soft”, “Low” or “HIgh” is selected, the fan speed is ing heating, the compressor is turned on and off to preventoverheat-
constant regardless of the room temperature. When “Auto” is ing. The fan goes off 30 seconds after the compressor goes off.
selected, the fan speed automatically changes between “Soft” and
“HIgh” depending on the difference between the room and pre-
settemperature.

2–7
ESD24HRA
*During Cooling / Dry
ZONE COMPRESSOR INTER- FAN
MITTENT TIME Timer set time
Hot keep (1) Up to 3 3 min. On
(When room temper- times 3 min. Off Same as com-
ature reaches setting 6 min. On pressor Room
After 4th
temperature) 3 min. Off temperature
1ºC
Hot keep (2) 6 min. On
Up to 1st The fan contin- 1
(Room temperature 8 min. Off
ues to repeat “6 hour
becomes higher 1qC
min. on - 8 min.
or more than setting After 2nd Off
off”. Timer operation starts Stops
temperature)

1.4. Automatic operation 1.7. Swing louvre


The operating mode and temperature setting are determined by the The louvre is moved by a stepping motor to perform swing and fixing in
room temperature and the external air temperature. the set position. If the “SWING” button is pressed during swing, it will
The operating mode will changeover automatically with the fol- stop. If the “SWING” button is pressed while it is stopped, it will swing.
lowing condition. The vertical adjustment louvre will change its angle continuously.
Press the SWING button again when the vertical adjustment louvre is
Outdoor
temperature (ºC)
at the desired position.
0 10 18 28 34
• The louvre will stop moving within the range shown in the diagram.
Cooling Cooling Cooling Cooling Cooling Cooling
(24ºC) (25ºC) (26ºC)
• The adjusted position will be memorized and will be automatically
(26ºC) (25ºC) (24ºC)
29 set to the same position when operated the next time.
Heating Heating Heating (Dry)
(24ºC) (23ºC) (22ºC) (Room temperature
21
- 2ºC) Adjustment range
Room COOL and DRY modes HEAT mode
temperature (ºC)

1. From cooling to heating


Cooling mode will changeover to heating mode when condition of
indoor temperature 1.7qC lower than the set temperature condi-
tions for 5 minutes.
2. From heating to cooling
Heating mode will change over to cooling mode when condition of 1.8. One-hour operation
indoor temperature 1.3qC higher than the set temperature condi-
tions for 25 minutes under Hot keep condition. If this button is pressed when operation is stopped, operation will
begin and then stop after 1 hour. If pressed when it is operating, will
3. When the set temperature is adjusted within the range of r2qC by stop after one hour.
the remote control’s key. ( ), the changeover judgement room
temp. will also be shifted within the range of r2qC. 1.9. Full power operation
1.5. ON-timer Immediately begins cooling or heating at maximum power and air flow.

The ON-timer is set by pressing the ON-timer button. In order to attain (During heating)
the set temperature at the set time, the operation starting time is cor- Operates at setting of 32qC.
rected by neuro and fuzzy computing one hour before the set time.
(During cooling)
1.6. OFF-timer Operates at setting of 18qC.
The OFF-timer is set by pressing the OFF-timer button. Operation is
1.10. Power ON start
as follows:
If a jumper wire is inserted into the place indicated JP99 on the indoor
Set temperature control board, and the circuit breaker is turn ON. Cooling or heating
will be automatically determined by the room temperature sensor on
Cooling By fuzzy computing the main unit, and operation will begin.
Heating Set the shift up time
Cooling setting + 1ºC 1.11. Auto Restart
Final Heating setting - 3ºC
When power failure occurs, after power is recovered, the unit will auto-
Dry Same as above (Final setting + 1ºC) matically restart in the same setting which were active before the
power failure.
*During Heating
Operating mode (Cool, Heat, Dry)
Timer set time • Temperature adjustment (within 2qC range) automatic operation
• Temperature setting
• Fan setting
3ºC Room
• Air flow direction
1
temperature
hour • Power ON/OFF
• Automatic operation mode setting

Timer operation starts Stops • Swing louvre

2–8
ESD24HRA
Setting not memorized
• Timer setting
• Full power setting

1.12. Error diagnostic display (Indoor unit)


1) If the operation is stopped and the emergency operation button is
pressed down for 5 seconds or more, the self-diagnosis memory
can be recalled.
2) Details of self-diagnosis (error mode) are informed by the flashing
number as well as the lighting pattern of the operation lamp which 1
flashes with the timer lamp. (For details, refer to Error diagnostic
method.)

1.13. Compressor relay


1) It is ON during operation, and when operation is stopped, goes
OFF after a delay of 100 seconds (not immediately). 1• The
During operation, press the PLASMACLUSTER button.
remote control will display " "
• The blue PLASMACLUSTER lamp on the unit wll light up.
Air conditioner ON
operation TO CANCEL
OFF
Press the PLASMACLUSTER button again.
ON
Compressor • The PLASMACLUSTER lamp on the unit will turn off.
relay OFF NOTES:
• Use of the PLASMACLUSTER operation will be memorized,
and it will be activated the next time you turn on the air con-
100 sec. ditioner.
• When the PLASMACLUSTER button is pressed while the unit
2) The minimum OFF time of the relay is 80 seconds. It will not go ON is not operating, the PLASMACLUSTER operation will be
again before 80 seconds elapses. performed without accompanying air conditioning mode (eg,
HEATING or COOLING). The mode symbol of the remote
control will go off and the fan speed can not be set AUTO.
Air conditioner ON ON
operation OFF 1.15. Self clean operation
ON ON
Compressor
relay OFF
100 sec. 80 sec.

3) If air conditioner operation is turned on again during the 100 sec-


ond delay before the compressor relay goes off, the compressor
relay will stay on.

Air conditioner ON ON
MODE 1h
operation OFF
CLEAN 1
ON
Compressor FAN

relay
100 sec.
1 Press the SELF CLEAN button when the unit is
not operating.
The remote control displays " ".
4) Defrost stop The red OPERATION lamp ( ), the green SELF
CLEAN lamp ( ) and the blue PLASMACLUSTER
When defrosting time exceeds 13 minutes or when the temperature
lamp on the unit will light up.
of the outdoor heat exchanger rises above approximately 10qC -
The unit will stop operation after forty minutes.
15qC, defrost stop is determined by either of the above conditions,
and the compressor is stopped. At the same time, the outdoor fan TO CANCEL
go ON. The compressor is reactivated in the heating cycle 1 minute
Press the SELF CLEAN button.
after it was stopped, and normal control resumes.
Or, turn the unit off by pressing the ON/OFF button.
1.14. Plasmacluster operation The red OPERATION lamp ( ), the green SELF
The Plasmacluster ion generator inside the air conditioner will release CLEAN lamp ( ) and the blue PLASMACLUSTER
positive and negative Plasmacluster ions into the room. Approximately lamp on the unit will turn off.
the same numbers of positive and negative ions released into the air NOTE:
will reduce some airborne mold. You cannot set the temperature, fan speed, air flow direc-
tion or timer setting during the SELFCLEAN operation.

2–9
ESD24HRA
1.16. Airflow control
More than More than More than
Press the PROGRESSIVE AIRFLOW button during cooling or dry 20 min. 20 min. 20 min.
operation when you do not want to feel cold air. Vertical adjustment
louvre is set obliquely upward to deliver cool air to the ceiling.
Press the button during heating operation. Vertical adjustment louvre
is set downward to deliver the warm air down to the floor and warm
you. Heating
operation
start
Defrosting Defrosting
Max. 11 min. Max. 11 min.

3) During defrosting
When defrosting begins, the compressor stops. Approximately 1
AM
minute later, the compressor reactivates in the refrigeration cycle,
and the outdoor heat exchanger is defrosted.
Each mode is as follows:
The outdoor fan is stopped
The operating frequency is 50Hz The indoor fan is stopped.

1
DISPLAY
The 4-way valve is OFF.

2.2. Overheat or Freezing Prevention Control

2.2.1 Indoor heat exchanger (Frequency Control)


1 During operation, press the PROGRESSIVE
AIRFLOW button. 1) 1 Level down of Compressor Frequency

• The remote control will display . If the temperature of indoor heat exchanger exceeds the over heat
prevention line 1 during heating operation, the operating frequency
is lowered by approximately 5Hz. After that, the frequency is low-
TO CANCEL
ered by approximately 5Hz once every 60 seconds. When the tem-
Press the PROGRESSIVE AIRFLOW button. perature of indoor heat exchanger goes below the overheat
prevention line 1, the frequency is raised by approximately 5Hz
NOTES: once every 60seconds, and normal operation is restored.
• The PROGRESSIVE AIRFLOW setting is cancelled when
you press FULL POWER button while PROGRESSIVE 2) 2 Level down of Compressor Frequency
AIRFLOW is set. If the temperature of indoor heat exchanger exceeds the overheat
• POWER mode, press PROGRESSIVE AIRFLOW button prevention line 2 during heating operation, the operating frequency
during FULL POWER operation. is lowered by approximately 10Hz. After that, the frequency is low-
If you want PROGRESSIVE AIRFLOW operation in FULL ered by approximately 10Hz once every 90 seconds. When the
temperature of indoor heat exchanger goes below the overheat
prevention line 1, the frequency is raised by approximately 5Hz
1.17. TEST RUN
once every 60 seconds, and normal operation is restored.
If the "AUX" button on the unit is pressed for 5 seconds or more during
3) Compressor Stop by Minimum Frequency
operation, cool test operation starts. The operation LED (Red) flickers
during test run. If the frequency is lowered to minimum frequency without the tem-
perature of indoor heat exchanger decreasing and this condition
To put the system in the heating test run mode, start the cooling opera-
lasts for 1 minute, the compressor will be stopped.
tion and select the heating mode on the remote control. In cool and
heat mode continuous compressor on operation is performed. In dry
Temperature (ºC)

mode the operation is in dehumidifying zone. 58ºC

2. OUTDOOR UNIT
55ºC overheat prevention line 2
2.1. Defrost operation
51ºC 51ºC
1) Overview overheat prevention line 1
Defrosting begins during heating if the conditions for compressor 48ºC 48ºC
operation time and outdoor heat exchanger temperature are met.
When defrosting begins, the indoor and outdoor fans stop.
2) Defrosting 15 37 103 130
If the compressor operation time is more than 20minutes in the Frequency (Hz)
heating mode and the outdoor air temperature and outdoor heat
exchange temperature satisfy the defrosting conditions, the 2.2.2 Outdoor unit overheat prevention control
defrosting operation is started.
During cooling operation, if the temperature of the outdoor unit heat
When the outdoor heat-exchanger temperature reaches approx. exchanger exceeds the outdoor unit heat exchanger overheat preven-
12qC or above or when the defrosting time exceeds 11 minutes, the tion temperature (about 55qC), the operating frequency is decreased
defrosting operation is quit. about 4 to 15 Hz. Then, this operation is repeated every 60 seconds
until the temperature of the outdoor unit heat exchanger drops to about
54qC or lower.

2 – 10
ESD24HRA
Once the temperature of the outdoor unit heat exchanger drops to 2.3. Compressor overheat prevention control
about 54qC or lower, the operating frequency is increased about 4 to
If the temperature of the compressor exceeds the compressor over-
10 Hz every 60 seconds until the normal operation condition resumes.
heat prevention temperature (110qC), the operation frequency is
If the temperature of the outdoor unit heat exchanger exceeds the out- decreased about 4 to 10 Hz. Then, this operation is repeated every 60
door unit heat exchanger overheat protection temperature for (120 seconds until the temperature of the compressor drops below the
sec.: outdoor temperature t 40qC x 60 sec.: outdoor temperature < overheat protection temperature (109qC). Once the temperature of the
40qC) at minimum operating frequency, the compressor stops operat- compressor drops below the overheat protection temperature, the
ing and then restarts after about 180 seconds, and the above-men- operating frequency is increased about 4 to 10 Hz every 60 seconds
tioned control is repeated. until the normal operation condition resumes. If the temperature of the
compressor exceeds the overheat protection temperature (for 120
2.2.3 Discharge overheating (Frequency Control) seconds in cooling operation or 60 seconds in heating operation) at
1) Level down of Compressor Frequency minimum operating frequency, the compressor stops operating and
then restarts after about 180 seconds, and the above-mentioned con-
If the discharge temperature exceeds approximately 110qC during trol is repeated.
compressor operation, the operating frequency is lowered by
approximately 5Hz. After that, the frequency is lowered by approxi- 2.4. Control by Current
mately 5Hz once every 60 seconds. When the discharge tempera-
ture goes below approximately 109qC, the frequency is raised by 1) AC current peak control
approximately 5Hz once every 60 seconds, and normal operation is As the AC current does not exceed maximum current the frequency
restored. of the compressor is controlled.
2) Compressor Stop by Minimum Frequency 2) AC over current detection
If the frequency is lowered to minimum frequency without the dis- If AC current exceeds approximately 20A or “AC current peak con-
charge temperature decreasing and this condition lasts for 1 trol” is performed at minimum frequency, compressor is stopped. In
minute, the compressor will be stopped. this case, the outdoor fan doesn't stop, and 3 minutes after opera-
tion stopped, another try will be made. Three retries are allowed.
2.2.4 Compressor protector (Compressor ON/OFF) On the 4th try, a complete stop request signal is sent to the indoor
If the discharge temperature exceeds approximately 114qC, the com- unit, and outdoor unit will remain stopped until reset is performed.
pressor is stopped. In this case, the outdoor fan doesn't stop, and At this time, the 3 minutes delay for control of the outdoor unit will
when the discharge temperature decreases to 100qC 3 minutes after not function; therefore, do not cancel by removing the plug and cut-
operation stopped, another try will be made. Three retries are allowed. ting the power.
On the 4th try, a complete stop request signal is sent to the indoor unit, 3) DC over current detection
and outdoor unit will remain stopped until reset is performed. At this
If DC current exceeds approximately 32A (ESD24HRA)/ 48A
time, the 3 minutes delay for control of the outdoor unit will not func-
(ESD30HRA), compressor is stopped. In this case, the outdoor fan
tion; therefore, do not cancel by removing the plug and cutting the
power. doesn't stop, and 3minutes after operation stopped, another try will
be made. Three retries are allowed. On the 4th try, a complete stop
2.2.5 Heat-sink overheating (Frequency Control) request signal is sent to the indoor unit, and outdoor unit will remain
stopped until reset is performed. At this time, the 3 minutes delay
1) Level down of Compressor Frequency for control of the outdoor unit will not function; therefore, do not
If the heat-sink temperature exceeds approximately 94qC during cancel by removing the plug and cutting the power.
compressor operation, the operating frequency is lowered by
approximately 5Hz. After that, the frequency is lowered by approxi- 2.5. Abnormal Rotation of Compressor
mately 5Hz once every 60 seconds. When the heat-sink tempera- If the position detection cannot be performed during feedback opera-
ture goes below approximately 89qC, the frequency is raised by tion of compressor operation, operation of the compressor stopped. In
approximately 5Hz once every 60seconds, and normal operation is this case, the outdoor fan doesn't stop, and 3 minutes after operation
restored. is stopped, another try will be made. Seventh retries are allowed. On
2) Compressor Stop by Minimum Frequency the eighth retry, a complete stop request signal is sent to the indoor
unit, and outdoor unit will remain stopped until reset is performed. At
If the frequency is lowered to minimum frequency without the heat-
this time, the 3 minutes delay for control of the outdoor unit will not
sink temperature decreasing and this condition lasts for 1 minute,
function; therefore, do not cancel by removing the plug and cutting the
the compressor will be stopped. power.
2.2.6 Indoor heat exchanger freezing (Frequency Control 2.6. Power transistor module protector
and Compressor ON/OFF)
If the temperature of the heat-sink exceeds 99qC, the compressor is
1) Level down of Compressor Frequency stopped. In this case, the outdoor fan does not stop, and when the
If the temperature of indoor heat exchanger goes below approxi- temperature of the heat-sink decreases to 89qC 180 seconds after
mately 5qC during cooling operation, the operating frequency is operation is stopped, another try will be made. Three retries are
lowered by approximately 5Hz. After that, the frequency is lowered allowed. On the fourth retry, a complete stop request signal is sent to
by approximately 5Hz once every 60seconds. When the tempera- the indoor unit, and the outdoor unit will remain stopped until reset is
ture rises above approximately 5qC, the frequency is raised by performed. At this time, the 3-minutes delay for control of the outdoor
approximately 5Hz once every 60seconds, and normal operation is unit will not function; therefore, do not cancel by removing the plug and
restored. cutting the power.
2) Compressor Stop
If the temperature of the heat exchanger goes below approximately
0qC and this condition continues for 4 minutes, the compressor is
stopped.

2 – 11
ESD24HRA
2.7. Power factor module 2.8. Serial signals
If a voltage error over 450V is detected at power factor module output 1) Serial signals consist of all 96-bit signals
voltage, 3minutes the compressor is stopped. In this case, the outdoor
2) If the outdoor unit does not receive a serial signal, it will stop
fan does not stop, and 3 minutes after operation is stopped, another approximately 30 seconds later. Note that this is true only of normal
try will be made. Three retries are allowed. On the fourth retry, a com-
operation; in test mode, it does not stop and operation takes place
plete stop request signal is sent to the indoor unit, and the outdoor unit
based on the test mode commands.
will remain stopped until reset is performed. At this time, the 3 minute
delay for control of the outdoor unit will not function; therefore, do not
cancel by removing the plug and cutting the power.

2.9. Active Filter Circuit


This circuit uses active filter and IPM as the figure below for the high efficiency operation of compressor.

Choke coil Active filter

Rectifica-
tion circuit
Noise filter + Comp
AC IPM
circuit ressor

Positional
detection
Voltage raise
Sine wave current
ON/OFF signal IPM
Compressor
Control
Driving signal source
Control
source
IC1

2.9.1 Active Filter


In the case the direct current is obtained by the diode bridge and smooth capacitor from the commercial power source, the current wave shape will be
the pulse shape at the peak of the voltage wave shape as shown in the figure below. For this reason, the harmonic current will be generated and at
the same time the power factor will be deteriorated. While monitoring the AC input voltage in the control circuit, in order to be the same phase and
wave shape as this voltage wave shape, IGBT is made ON/OFF by the carrier frequency of approximately 20 kHz. By adoption of this active filter, the
current wave shape can be made to the sine wave synchronized to the commercial power source and the power factor can be made to almost 99%.
As a result of this, reactor can be disused. Active filter works for the improvement of power factor and as the countermeasures for the harmonic cur-
rent.

Power-supply voltage
(50/60 Hz)

Current waveform
(Before)

Current waveform
(Active filter)

2.9.2 Active Filter Voltage Raise Circuit


The IGBT in the figure below is the switching transistor of the active filter. By adding ON signal to the gate of IGBT from the control IC, IGBT turns ON
and the collector current Ic flows. This current flows from the + side of the diode bridge DB to the Choke coil, the - side of the diode bridge DB through
IGBT from the Choke coil L. At this time, energy is stored in the choke coil L. Next, when gate signal of IGBT turned OFF, IGBT will be turned OFF
and the energy stored in L during the ON time of IGBT will be discharged through the diode D, electrolytic capacitor C, load, primary side and the +
side of DB. Assuming the input voltage of active filter (voltage between + and - of DB) as Ei, the output voltage (voltage at the both ends of smooth
capacitor) as Vo, switching cycle of IGBT as T and ON time of IGBT as ton, the voltage between collector emitter of IGBT Vs will be as follows;
Vs= 0 (during ON of IGBT: ton)
Vs= Vo (during OFF of IGBT: T-ton)
Here, assuming no loss in L and IGBT, average value of Vs turns equal to Ei,
Ei=(T-ton)/T x Vo

2 – 12
ESD24HRA
Therefore
Vo=T/(T-ton) x Ei
As ton is a smaller value than T, output voltage Vo will be higher than input voltage Ei.

DB +
D

Control +
Ei Vs Vo RL
IC C

IGBT
-

L1 L2
(+) P

(-)

Io
PFC control

1 2 3 4 5 6

BCN13

Active Filter Circuit

2.9.3 Active Filter Driving Electronics Circuit


At the operation of compressor, the microcomputer (IC1), as the 50th pin gets “H”, will turn the transistor Q4 ON through the transistor Q3. By this,
18V is supplied to the 3rd pin of connector BCN13 of the active filter and the active filter will be turned ON.

2.9.4 Protection Circuit of Active Filter


18V
In order to prevent from the destruction of active filter due to the
excessive over or under output voltage of active filter, the active filter
R36 R35 R33
will be turned OFF immediately at the abnormal output voltage by 270KF
1M 34.8KF
monitoring the output voltage. At the same time, the operation of com- R32
pressor will be stopped. Detection circuit of the abnormal voltage 3 4 270KF DC
2 - Voltage
detects the abnormal voltage by inputting the output voltage of active 52
IC1 + 5
filter to the 2nd and 5th pins of comparator IC (IC5) at the divided volt- 12 C33 R31
R34 0.1u 4.64KF
age by the resistors (R31, R32 and R33) and comparing with refer- 9.53KF 50V
ence voltage. When the output voltage of active filter reaches 450V or 0V
C32
higher, the 4th pin of IC10 will be higher than the reference voltage at 0V 0.1u
the 5th pin, the output of comparator will be reversed (H-L), the L sig- 50V 0V
nal will be entered at the 52nd pin of microcomputer (IC1) and the
operation of the active filter will be stopped. 0V

2.10. Explanation of IPM drive circuit


The IPM for compressor drive is made by Mitsubishi Electric.
The power supply for the IPM drive, and the shunt resistance for over current detection, etc., are provided out of the IPM (in control PCB).

2.10.1 IPM drive power supply circuit


The power supply for driving the upper-phase IGBT (HU, HV, HW) drive employs a bootstrap system.

2 – 13
ESD24HRA
The 15-V power supply for the lower-phase IC is provided by the control printed circuit board (PCB).
1) Brief explanation of bootstrap system (single power drive system)
To supply power to the upper-phase IC, the microcomputer (IC1) turns ON the lower-phase IGBT (LU, LV, LW).
It results in a charging current that flows through the electrolytic capacitor in each upper-phase IC input and charges the bootstrap capacitor up to 15-
V voltage.
The power supply for the subsequent stages is stored when the lower-phase IGBT is ON in common drive control of the compressor.

Initial charge period P(Vcc)


Charging current group
Bootstrap capacitor

(HU,HV,HW)

VDB
HVIC
U,V,W,
High-voltage-withstanding,
high-speed recovery diode

N-side

VD
(LU,LV,LW) IGBT

LVIC
VCIN(n)
N(GND)

Bootstrap circuit

2) DC overcurrent detection circuit


When a current about 32A (ESD24HRA)/48A (ESD30HRA) or higher flows through the shunt resistance (R100) on the control printed circuit board
(PCB), the voltage on this resistance is input to IPM CIN pin (16). Then, the gate voltage of the lower-phase IGBT (LU, LV, LW) inside the IPM turns
OFF to cut the overcurrent off. At the same time, an L output which lasts about 1.8 ms is generated from IPM Fo pin (18), and it results in an L level
input to overcurrent detection input pin (53) of the microcomputer (IC1) and then turns OFF the PWM signal output (IC1 from pins (65) to (70)) to the
IGBT gate.

SET
Protection circuit status RESET

(Lower phase)
Internal IGBT gate

About 32A (ESD24HRA)


About 48A (ESD30HRA)
SC

a1

Output current Ic (A)

SC reference voltage

Sense voltage relative


to shunt resistance

Delay by CR time constant circuit

About 1.8 ms
Error output Fo

2 – 14
ESD24HRA

Shunt resistance
Overcurrent
R100 (R101)

N 5V

IC1

53

IPM overcurrent CiN


detection circuit 16

FO
18 0V

65 70

2.11. 120q energizing control (digital position detection control)


This control system detects the digital position detection signal and adjusts the rate of acceleration/deceleration accordingly.
The motor's induced voltage waveform is input to the comparator in the form of PWM-switched pulse, and a position detection signal is generated as
a reference voltage which is equal to 1/2 of 370 VDC. However, since there is no induced voltage waveform when the PWM waveform is OFF, the
microcomputer works in an internal processing so that detection is enabled only when it is ON. Based on the position signal detected, actual PWM
waveform output timing is determined. Since it does not use a filter circuit, the accuracy of detection.
The microcomputer works in an internal processing to eliminate spiky voltage during the regenerative process.
Furthermore, even if the induced voltage is low, position detection is still possible, and it allows sensor-less operation at low rotation speed in the ini-
tial stage of operation. These reduce the starting current and improve reliability of IPM.

Terminal voltage waveform

Reference voltage
(1/2 of DC voltage)

Spiky voltage Comparator output waveform


(cancelled) (Position signal waveform)

2 – 15
ESD24HRA
2.12. 180q energizing control
This is the control system to moderate the speed by the current phase difference for higher efficiency and lower noise of the compressor. The current
phase difference control is the control system paid attention to the interrelation between efficiency and phase gap generated by the applied voltage of
motor and current in the coil of motor as shown in the figure below.

Motor voltage

Motor current

Efficiency
Best timing Ჷ(
Ტ Difference of current
and voltage peak Უ Voltage /Current
phase difference

Concept chart of the current phase difference control

This control is the forced magnetization system independent of the location of rotor, detecting the phase difference between driving voltage phase and
line current phase flowing in motor coil, and controls the modulation rate data to get the phase difference at the best efficiency.

2.13. DC Current Detection Sensor Circuit


Control of current phase difference is made by reading in the phase difference generated at the both edges of shunt register (R100) by the compres-
sor electrifying current on the PWB through the op-amp (IC9) to the microcomputer. This is a control to modulate up to the phase with the best effi-
ciency by comparing the phase of this input current, so called compressor electrifying current, with the compressor driving voltage. In the case that
phase difference between motor voltage and current is large (current delay is large), the control will be made by lowering the compressor modulation
rate data (compressor effective value).

IPM
FUSE 101 P U
250V 20A
FC1
C121
TU
TV
TW

V W
R201
100KF
CIN N
5V
Z D20 15V R202
R113 18KF
8 20KF
R100 2
C119
(R101) IC1 1 - Y
ZD101 R200 + 3 Z
4 R203
C80 1K IC9 2KF
Y
1000P C81
0.1μ
5V
R204
0V 200KF

R205
200KF
Inverter current detection circuit
0V

2 – 16
ESD24HRA
ESD24HRA
CHAPTER 3. FUNCTION AND OPERATION
Service Manual
OF PROTECTIVE PROCEDURES
[1] TROUBLESHOOTING GUIDE
1. SELF-DIAGNOSIS FUNCTION AND DISPLAY MODE
1) To call out the content of the self-diagnosis memory, hold down the emergency operation button for more than five seconds when the indoor unit is
not operating.
a) According to the content of the self-diagnosis memory, the Operation LED (main category) and the Plasmacluster Ion LEDs (sub-category)
flash in sync with the Timer LED on the indoor unit.
b) In the event a complete shutdown occurs due to a malfunction, the Operation LED (red), Timer LED (yellow) and Plasmacluster Ion LED (blue)
flash to indicate the general information of the generated malfunction.
c) If the power cord is unplugged from the AC outlet or the circuit breaker is turned off, the self-diagnosis memory loses the stored data.
2) Display of detailed self-diagnosis result with main category and sub-category indications
When malfunction information is called out, the main category and sub-category of the self-diagnosis result are indicated by the Operation, Timer,
and Plasmacluster Ion LEDs on the indoor unit.
* 1:Example of self-diagnosis result displayed on indoor unit: Suction thermistor open-circuit error
Main category Sub-category
*1: Example of self-diagnosis result displayed on indoor unit: Suction thermistor open-circuit error Malfunction No.
Basic flashing cycle due to error 1 sec 1 sec 1 sec 5 sec
ON
Timer LED [yellow]
OFF
Figures in ( ) indicate numbers (binary notation) assigned based on the flashing sequence.
ON
Operation LED [red] Flashing for main category indication
OFF

Plasmacluster Ion LED [blue] Flashing for sub-category indication

* 2:The self-diagnosis display function of the outdoor unit indicates the error information by flashing LED1 on the outdoor unit according to the
content of self-diagnosis.
The self-diagnosis display function of the outdoor unit is active only for about 3 to 10 minutes after self-diagnosis is performed during operation,
and the display returns to normal condition after this display period.
The content of self-diagnosis cannot be called out by the self-diagnosis display function of the outdoor unit.

Example of self-diagnosis display on outdoor unit : Compressor high-temperature abnormality


1 sec 1 sec 0.6 sec 1 sec 0.6 sec 1 sec 1 sec 1 sec 0.6 sec 1 sec 0.6 sec 1 sec 1 sec
ON
OFF

* 3:The content of diagnosis is transferred to the indoor unit via serial communication, but it does not trigger a complete shutdown operation.

3–1
Malfunction diagnosis indications, descriptions, inspection methods and remedies
: Flashes in 2-sec intervals (normal) : On : Off : Flashes 3 times in 0.2-sec intervals
2. CHART
Indication Indication by operation lamp on indoor unit
Status of Malfunction No. Content of diagnosis
ESD24HRA

by LED on
indoor/ Lighting pattern at the time of timer lamp lighting Inspection location/method Remedy
outdoor Main Sub
outdoor units unit Main category Sub-category
Off for 5 seconds category category
Indoor/ Normal Normal
0 0
outdoor units flashing
in operation
Indoor/ 1 time Operation lamp 1 0 Outdoor unit ther- Heat exchanger ther- (1) Measure resistance of the outdoor unit (1) Replace the outdoor unit thermistor
outdoor units Cluster lamp mistor short-circuit mistor short-circuit error thermistor. assembly.
in complete (2) Check the lead wire of the outdoor unit (2) Replace the outdoor unit thermistor
shutdown Operation lamp 1 Outdoor temperature ther- thermistor for torn sheath and short-cir- assembly.
Cluster lamp mistor short-circuit error cuit.
Operation lamp 2 Suction thermistor short (3) No abnormality found in above inspec- (3) Replace the outdoor unit control
Cluster lamp circuit error tions (1) and (2). PWB assembly.

Operation lamp 4 Heatsink thermistor (1) Measure resistance of the heatsink ther- (1) Replace the heatsink thermistor.
Cluster lamp short-circuit error mistor.
(2) Check the lead wire of the heatsink ther- (2) Replace the heatsink thermistor.
mistor for torn sheath and short-circuit.
(3) No abnormality found in above inspec- (3) Replace the outdoor unit control
tions (1) and (2). PWB assembly.

Indoor/ 2 times Operation lamp 2 0 Cycle tempera- Compressor high tem- (1) Check the outdoor unit air outlet for (1) Ensure unobstructed air flow from
outdoor units Cluster lamp ture perature error blockage. the outdoor unit air outlet.
in complete (2) Check if the power supply voltage is 216 (2) Connect power supply of proper
shutdown V or higher at full power. voltage.
(3) Check the pipe connections for refriger- (3) Charge the specified amount of re-

3–2
ant leaks. frigerant.
(4) Measure resistance of the outdoor com- (4) Replace the outdoor unit compres-
pressor thermistor. sor thermistor assembly.
(TH1: Approx. 53 k½ at 25¼C) (5) Replace the expansion valve coil,
(5) Check the expansion valve for proper expansion valve or outdoor unit
operation. control PWB assembly.

Indoor unit in Operation lamp 1 Temporary stop due to (Temporary stop for cycle protection)
operation Cluster lamp compressor discharge
Outdoor unit overheat *3
in temporary
stop Operation lamp 2 Temporary stop due to (Temporary stop for cycle protection)
Cluster lamp outdoor unit heat ex-
changer overheat *3

Operation lamp 3 Temporary stop due to (Temporary stop for cycle protection)
Cluster lamp indoor unit heat ex-
changer overheat *3

Operation lamp 4 Temporary stop due to (Temporary stop for parts protection)
Cluster lamp IPM overheat *3

Operation lamp 5 IPM high temperature (1) Measure resistance of the heat (1) Replace the heat sink
Cluster lamp error sink thermistor. thermistor.

3 times Operation lamp 3 0 Dry operation Temporary stop due to de- (Temporary stop for cycle protection)
Cluster lamp humidifying operation *3

*3: The content of diagnosis is transferred to the indoor unit via serial communication, but it does not trigger a complete shutdown operation. Number of repetition °: No complete shutdown
: Flashes in 2-sec intervals (normal) : On : Off : Flashes 3 times in 0.2-sec intervals

Indication Indication by operation lamp on indoor unit Content of diagnosis


Status of by LED on Malfunction No.
indoor/ Lighting pattern at the time of timer lamp lighting Inspection location/method Remedy
outdoor Main Sub
outdoor units unit Main category Sub-category
Off for 5 seconds category category
Indoor/ 5 times Operation lamp 5 0 Outdoor unit Heat exchanger thermis- (1) Check the connector of the outdoor unit (1) Correct the installation.
outdoor units Cluster lamp thermistor tor open-circuit error thermistor for secure installation.
in complete open-circuit (2) Measure resistance of the outdoor ther- (2) Replace the outdoor unit thermistor
shutdown Operation lamp 1 Outdoor temperature ther- mistor. assembly.
Cluster lamp mistor open circuit error (3) Check the lead wire of the outdoor unit (3) Replace the outdoor unit thermistor
Operation lamp 2 Suction thermistor open- thermistor. assembly.
Cluster lamp circuit error (4) No abnormality found in above inspec- (4) Replace the outdoor unit control
tions (1) through (3). PWB assembly.
Operation lamp 4 Discharge thermistor open
Cluster lamp circuit error
Operation lamp 5 Heatsink thermistor (1) Check the connector CN8B of the heat- (1) Correct the installation.
Cluster lamp open-circuit error sink thermistor for secure installation.
(2) Measure resistance of the heatsink thermistor. (2) Replace the heatsink thermistor.
(3) Check the lead wire of the heatsink thermistor. (3) Replace the heatsink thermistor.
(4) No abnormality found in above inspec- (4) Replace the outdoor unit control
tions (1) through (3). PWB assembly.

6 times Operation lamp 6 0 Outdoor unit DC DC overcurrent error (1) IPM continuity check (1) Replace the outdoor unit control
Cluster lamp PWB assembly.
(2) Check the IPM and heat sink for secure (2) Correct the installation (tighten the
installation. screws). Apply silicon grease.
(3) Check the outdoor unit fan motor for (3) Replace the outdoor unit fan motor.
proper rotation.
(4) No abnormality found in above inspec- (4) Replace the outdoor unit control
tions (1) through (3). PWB assembly.
(5) No abnormality found in above inspec- (5) Replace the compressor.
tions (1) through (4).
Operation lamp 1 IPM pin level error Check the IPM is attached correctly to the Replace the outdoor unit IPM PWB.

3–3
Cluster lamp outdoor unit control PWB.
7 times Operation lamp 7 0 Outdoor unit AC AC overcurrent error (1) Check the outdoor unit air outlet for (1) Ensure unobstructed air flow from
Cluster lamp blockage. the outdoor unit air outlet.
(2) Check the outdoor unit fan for proper rotation. (2) Check the outdoor unit fan motor.
Operation lamp 1 AC overcurrent error in (1) IPM continuity check. Replace the outdoor unit IPM PCB.
Cluster lamp OFF status.
Operation lamp 2 AC maximum current (1) Check the outdoor unit air outlet for (1) Ensure unobstructed air flow from
Cluster lamp error blockage. the outdoor unit air outlet.
(2) Check the outdoor unit fan for proper rotation. (2) Check the outdoor unit fan motor.
Operation lamp 3 AC current deficiency (1) Check if there is an open-circuit in the (1) Replace the outdoor unit control
Cluster lamp error secondary winding of the current trans- PWB assembly.
former of the outdoor unit control PWB.
(2) Check if the refrigerant volume is abnor- (2) Charge the specified amount of refriger-
mally low. ant.
(3) Check if the refrigerant flows properly. (3) Correct refrigerant clogs. (2-way valve,
3-way valve, pipe, expansion valve)
9 times Operation lamp 9 4 Outdoor unit cool- Gas leakage error (1) Check if the refrigerant volume is abnor- (1) Charge the specified amount of re-
Cluster lamp ing/heating switch mally low. frigerant.
over (2) Check the indoor unit thermistor TH2 (heat ex- (2) Correct the installation of TH2.
changer) for secure installation. (3) Check the gas leakage
11 times Operation lamp 11 0 Outdoor unit DC Outdoor unit DC fan ro- (1) Check the connector CN3 of the outdoor (1) Correct the installation.
Cluster lamp fan tation error. unit DC fan motor for secure installation.
(2) Check outdoor unit DC fan motor for (2) Replace the outdoor unit fan motor.
proper rotation.
(3) Check fuse FU3. (3) Replace the outdoor unit control
PCB assembly.
(4) Outdoor unit control PCB. (4) Replace the outdoor unit control
PCB assembly.

*3: The content of diagnosis is transferred to the indoor unit via serial communication, but it does not trigger a complete shutdown operation. Number of repetition °: No complete shutdown
ESD24HRA
: Flashes in 2-sec intervals (normal) : On : Off : Flashes 3 times in 0.2-sec intervals

Indication Indication by operation lamp on indoor unit Content of diagnosis


Status of by LED on Malfunction No.
indoor/ Lighting pattern at the time of timer lamp lighting Inspection location/method Remedy
outdoor Main Sub
outdoor units unit Main category Sub-category
Off for 5 seconds category category
ESD24HRA

Indoor/ 13 times Operation lamp 13 0 DC compressor Compressor start (1) Check the colors (red, white, orange) of (1) Correct the installation.
outdoor units Cluster lamp up error the compressor cords for proper connec- (U: Red, V: White, W: Orange)
in complete tion. (PWB side, compressor side)
shutdown Operation lamp 1 Compressor rota-
(2) Check if the IPM terminal resistance val- (2) Replace the outdoor unit control
Cluster lamp tion error. (at 120º
ues are uniform. PWB assembly.
energizing)
(3) Check if outdoor main relay (MRY1) turns (3) Replace the outdoor unit control
Operation lamp 2 Compressor rota- on and the voltage of both end of the PWB assembly.
Cluster lamp tion error. (at 180º condenser (C10) has become DC380V. (4) Replace the outdoor unit control
energizing) (4) No abnormality found in above inspec- PWB assembly.
tions (1) and (3). (5) Replace the compressor.
(5) No abnormality found in above inspec-
tions (1) through (4).

Operation lamp 3 Detection error of (1) Check the circuit of detection of inverter (1) Replace the outdoor unit control
Cluster lamp inverter current. current. PCB assembly.

14 times Operation lamp 14 2 Outdoor active Over voltage error (1) Check the connector of the active filter (1) Connect the connector.
Cluster lamp filter for disconnection.
(2) No abnormality found in above inspection (1). (2) Replace the active filter.

Operation lamp 3 Clock error (1) Check the voltage of power supply. (1) Connect stable power supply.
Cluster lamp (2) Check if the clock is input.
(2)Replace the outdoor unit control PCB
assembly.

Indoor unit in Operation lamp 17 0 Wires between Serial open circuit (1) Check the wires between units. (1) Connect stable power supply.
operation Cluster lamp units (2) Check voltage between Nos. 1 and 2 on (2) Replace the outdoor unit control
the indoor/outdoor unit terminal boards. PWB assembly.

3–4
Outdoor unit
in temporary
stop Operation lamp Outdoor unit does (1) Check the wires between units. (1) Correct the wiring.
Cluster lamp not turn on due to (2) Check the outdoor unit fuse. (2) Replace the fuse or outdoor unit
erroneous wiring control PWB assembly.
(3) Check 15-V, 13-V and 5-V voltages on (3) Replace the outdoor unit control
the PWB. PWB assembly.
Check resistance between IPM terminals.
(4) Check pins No. 5 and 7 of connector CN3 of (4) Replace the outdoor unit fan motor.
the outdoor unit fan motor for short-circuit. (5) Replace the outdoor unit control
(5) Outdoor unit control PWB PWB assembly.

Indoor unit in Operation lamp 18 0 Wires between Serial short circuit (1) Check the wires between units. (1) Correct the wiring.
operation Cluster lamp units
Outdoor unit
in temporary Operation lamp 1 Erroneous serial (1) Check the wires between units. (1) Correct the wiring.
stop Cluster lamp wiring

Indoor/ Operation lamp 19 0 Indoor unit fan Indoor unit fan er- (1) Check the indoor unit fan motor for proper (1) Replace the indoor unit fan motor.
outdoor units Cluster lamp ror rotating operation. (Check for fan lock.)
in complete (2) Check the lead wire of the indoor unit fan (2) Replace the indoor unit fan motor.
shutdown motor for open-circuit.
(3) Check CN1 of the indoor unit fan motor (3) Correct the installation of CN1 of
for secure installation. the indoor unit fan motor.
(4) No abnormality found in above inspec- (4) Replace the indoor unit control
tions (1) through (3). PWB.

Indoor/ Operation lamp 20 0 Indoor unit EEPROM data (1) Error in data read from the indoor unit (1) Replace the indoor unit control
outdoor units Cluster lamp control PWB error EEPROM PCB.
in operation

*3: The content of diagnosis is transferred to the indoor unit via serial communication, but it does not trigger a complete shutdown operation. Number of repetition °: No complete shutdown
ESD24HRA
3. CHECK METHOD (OUTDOOR)
3.1. CAUTION IN CHECKING PRINTED CIRCUIT BOARDS (PWB)

3.1.1 Non-insulated control circuit


The GND terminals of the low-voltage circuits (control circuits for microcomputer and thermistors and drive circuits for expansion valve and relays) on
the control printed circuit board (PWB) are connected to the compressor drive power supply (370-VDC negative terminal). Therefore, exercise utmost
caution to prevent electric shock.
If a measuring instrument used for the test is grounded, its chassis (ground) has the same electric potential as the 0-V probe. Since non-insulated cir-
cuits have the following voltage potential difference from the ground, connection of the grounding wire results in a short-circuit between the 0-V line
and the ground, thus allowing an excessive current to flow to the tester to cause damage.
If the sheaths of the thermistor lead wires or expansion valve lead wires inside the outdoor unit become damaged due to pinching by the front panel
or other metal parts or contacting a pipe, a high voltage can flow and destroy the circuits. To prevent these problems, carefully conduct assembly
work.

Outdoor unit circuits


Terminal board
Reactor Point (E)
2
Do not touch the
AC220 + cabinet or bring metal
- 240V - IPM M parts into contact with
the cabinet. Danger!!
1 Do not connect
Compressor the grounding
0-V line Point (F) motor wire.
Ground

Reason
The oscilloscope (chassis ground) has the same electric potential as the 0-V
probe. The entire electronic control section of the outdoor unit has a voltage
potential difference from the ground as shown in the above diagram. When the
oscilloscope is set up, the 0-V line and the ground voltage (ground) will be short-
circuited, resulting in an excessive current flow to cause damage to the
oscilloscope or indoor electric circuits.

3.2. Procedure for determining defective expansion valve

(tool) LED Measure resistance in expansion valve coil.


(red)
Checker

Normal resistance between red


NO
terminal of expansion valve lead wire and
each terminal: about 46 (at 20ºC)

5.6K 5.6K 5.6K 5.6K


YES

Insert checker shown at left into connector (CN12) on


6 5 4 3 2 1 control PWB, and operate air conditioner.
CN12
Connector
J.S.T. XAP-06V-1
Terminal
SXA-001T-P0.6 NO Do LEDs on checker light in orderly sequence
Replace control PWB. (lighting of 1 LED => lighting of 2 LEDs)

YES

If frost accumulates on 2- Thermistors in


way valve after 10 to 20 minutes of normal condition
cooling operation, then thermistors with yellow and black
lead wires may be defective. Check
these thermistors.

Defective thermistor
Replace expansion
valve assembly.
Replace thermistor assembly.

3–5
ESD24HRA
3.3. Diode bridge check method
Turn off the power and let the inverter electrolytic capacitor (C16A, C16B) discharge completely. Then use a tester and check continuity.
When using a digital tester, the (+) and (-) tester lead wires in the table must be reversed.

Needle-type tester Normal resistance value

(several M )

Value in ( ) is for digital tester.

3.4. Inverter electrolytic capacitor (C16A, C16B) check method


Turn off the power, let the inverter electrolytic capacitor (C16A, C16B) discharge completely, and remove the lead wire from the capacitor. First, check
the case for cracks, deformation and other damages. Then, using a needle-type tester, check continuity.

Determination of normal condition


The tester needle should move on the scale and slowly returns to the original position. The tester needle should move
in the same way when polarities are reversed. (When measurement is taken with the polarities reversed, the tester
needle exceeds the scale range. Therefore, let the capacitor discharge before measurement.)

3.5. IPM check method


Turn off the power, let the large capacity electrolytic capacitor (C16A, C16B) discharge completely, and dismount the IPM. Then, using a tester, check
leak current between C and E.
When using a digital tester, the (+) and (-) tester lead wires in the table must be reversed.

Needle-type tester Needle-type tester


Normal resistance value Normal resistance value
(-) (+) (-) (+)
P N U
f
U f V N
(several M:)
V (several M:) W
W Values in ( ) are for digital tester.

Values in ( ) are for digital tester.

3.5.1 IPM internal circuit diagram

VN0
W
U

N
P

V
22

23

24

25

20

26
DIP-IPM

16

CIN
17

CFO
UOUT

VOUT

WOUT

VNO

CIN

CFO
VB

HO

VS

VB

HO

VS

VB

HO

VS

LVIC
HVIC1

HVIC2

HVIC3
COM

COM

COM

GND
VCC

VCC

VCC

VCC

WN
IN

IN

IN

UN

Fo
VN
20

21
12

13

10

14

19

18

15
3

9
VUFB

VUFS

VP1

UP

VVFB

VVFS

VP1

VP

VWFB

VWFS

VP1

WP

VN1

UN

VN

WN

FO

VNC

3–6
ESD24HRA
3.6. Active filter check method
Turn off the power, let the large capacity electrolytic capacitor discharge completely. Then, using a tester and check continuity.

Needle-type tester Normal resistance value


(+) (-)
L2 P f
L2 Io (several M:)

[2] THERMISTOR TEMPERATURE CHARACTERISTIC


1. Figure 1 Temperature properties of indoor thermistors

Thermistor Signal Color


Room temperature TH1 Yellow 100
Heat exchanger TH2 Orange
Pipe temperature TH3 Black
To measure the resistance, first remove the connector 80 Heat exchange thermistor
as shown at right. TH2 (Orange), TH3 (Black)
Room temperature 25ºC resistance 4.431 k
thermistor TH1 (CN6 3 - 4 ) 60
Heat exchanger CN6 Resistance (k )
thermistor TH2 (CN6 1 - 2 ) 1 6
Room temperature
Pipe temperature
40 thermistor TH1 (Yellow)
thermistor TH3 (CN6 5 - 6 )
25ºC resistance 10 k

Tester 20

0
-10 0 10 20 30 40
Temperature (ºC)

2. Figure 2 Temperature properties of outdoor heatsink thermistors

500
Thermistor Signal Color

Heatsink CN8B Black


400
To measure the resistance, first remove the
Resistance (k )

connector as shown at right. 1 3


300
Heatsink thermistor
TH5 (black)
25ºC resistance 50k
200 Tester

6.14k
100
12.3k 3.25k

0
-20 0 20 40 60 80 100
Temperature (ºC)

3–7
ESD24HRA
3. Figure 3 Temperature properties of outdoor thermistors

TH1 compressor thermistor TH2 Heat exchange thermistor


TH3 Outdoor temp. thermistor

Resistance ( )
500K TH4 Suction pipe temp. thermistor
Resistance ( )
40K
400K Connector 0ºC resistance Connector
CN8 30K 14.5 K CN8
1 8 1 8
300K 25ºC resistance 25ºC resistance
45 K 4.431 K
20K
200K
5.78K 3.06K TH2,TH3, TH4
100K 4.17K 2.28K Tester 10K
1.72K
0 0 Tester
-20 0 20 60 80 100 120 -20 0 20 40 60
Temperature (ºC) Temperature (ºC)

Thermistor No. Connector Color To measure the resistance, first remove the
Compressor thermistor TH1 No. 1 to 2 Red connector from the board.
Heat exchanger pipe thermistor TH2 No. 3 to 4 Orange
Outdoor temp. thermistor TH3 No. 5 to 6 Green
Suction pipe temp. thermistor TH4 No. 7 to 8 Black

[3] HOW TO OPERATE THE OUTDOOR UNIT INDEPENDENTLY


1. Cautions when attaching or removing the board
When operating only the outdoor unit (cooling 40 Hz fixed mode) To make only the outdoor unit run in cooling mode, short the places marked with
arrows below with an adaptor, and apply a voltage of 220 ~ 240 V AC to 1 and N on the terminal board. (Avoid operating the outdoor unit alone for
long periods of time.)

Microcomputer Input
terminal signal JPT Adaptor
Pin No. 61 0
Pin No. 60 1
(GND)
0 ------ Low input
1 ------ High input

3–8
ESD24HRA
ESD24HRA
5GTXKEG/CPWCN


CHAPTER 4. REFRIGERATION CYCLE


[1] REFRIGERATION CYCLE
1. FLOW OF REFRIGERANT

Indoor unit

Evaporator
(3)

Flare coupling Flare coupling

Outdoor unit
3-way valve 3-way valve
(GAS) Receiver (LIQUID)
tank Heating Cooling
Muffler
s Strainer

Accumulator
(4) Expansion
(1) valve

Comp-
ressor

Sub Muffler s Strainer


Accumu-
lator
Coil
Condenser
C

Reverse valve (2)

2. STANDARD CONDITION

Indoor side Outdoor side


Dry-bulb Temperature Relative humidity Dry-bulb Temperature(qC) Relative humidity
Cooling 27qC 47% 35qC 40%
Heating 20qC – 7qC 87%

3. TEMPEATURE AT EACH PART AND PRESSURE IN 3-WAY VALVE

MODEL ESD24HRA ESD30HRA


Max. Test Mode Max. Test Mode
Operation Mode
Cooling Heating Cooling Heating Cooling Heating Cooling Heating
Indoor Fan Speed High High High High High High High High
Compressor (rpm) 6200 6200 2500 2500 5600 5000 2500 2500
(1) 82 95 68 60 88 97 68 67
(2) 40 2 42 2 42 2 41 2
(3) 15 39 15 31 17 46 15 34
(4) 5 2 14 6 4 1 13 5
3-way valve pressure
0.78 3.42 1.06 2.05 0.76 3.50 1.08 2.45
(GAS) Mpa (gauge)

4–1
ESD24HRA
[2] PERFORMANCE CURVES
NOTE: 1) Indoor fan speed: High
2) Vertical adjustment louver “45q“, Horizontal adjustment louver “front”
3) Indoor air temp.: Cooling 27qC, Heating 20qC
4) Power source: 230V, 50Hz

1. ESD24HRA
1.1. At cooling 1.2. At heating

(Compressor rotation: 5200rpm) (Compressor rotation: 5400rpm)

2600 2800
Input(W)

Input(W)
2400
2600

Outlet air temp.((ºC)


2200
2400

Outlet air temp.(ºC)


2000
2200
1800 14
2000 50
12
10 45

Heating capacity(kW)
9.0 40
Cooling capacity(kW)

7.5 8.0
7.0 7.0
6.5
6.0
6.0
5.0
25 30 35 40
Outside air temp.(ºC) -5 0 5 7 10
Outside air temp.(ºC)

2. ESD30HRA
2.1. At cooling 2.2. At heating

(Compressor rotation: 4875rpm) (Compressor rotation: 4175rpm)

3400 3000
Input(W)
Input(W)

3200 2800

Outlet air temp.((ºC)


3000 2600
Outlet air temp.(ºC)

2800
2400
2600 14
2200 50
12
45
10
Heating capacity(kW)

9.0
Cooling capacity(kW)

8.5
40

8.0 8.0

7.5 7.0
7.0 6.0

25 30 35 40
5.0
Outside air temp.(ºC)
-5 0 5 7 10
Outside air temp.(ºC)

[3] REFRIGERANT PIPE INSTALLATION WORKS


Refrigerant pipe length and level difference between the indoor and outdoor units.

MODEL PIPE SIZE STANDARD PERMISSIBLE PERMISSIBLE LEVEL CHARGE LESS ADDITIONAL
GAS LIQUID LENGTH DIFERENCE LENGTH CHARGE
ESD24HRA 5/8" 3/8" 30m 10m 20m 15g
ESD30HRA 5/8" 3/8" 30m 10m 20m 15g

4–2
ESD24HRA
ESD24HRA
5GTXKEG/CPWCN


CHAPTER 5. DISASSEMBLING PROCEDURE


[1] INDOOR UNIT
CAUTION: DISCONNECT THE UNIT FROM THE POWER SUPPLY BEFORE ANY SERVICING.

1. Disassembling procedure of the indoor unit 5) Close the open panel. Push the hook of the cabinet, and lift the
front panel up.
1) Remove two air filters.
(1) Open the open panel
(2) Push the air filters up slightly to unlock them.
(3) Pull the air filters down to remove them.

(1)
(2) (3)
2) Remove the 2 screws fixing the cover L and cover R.

6) Remove the unit-to-unit wiring from the Terminal board.

Screw Screw
Cover L Cover R
Pull the covers toward you to release the lock.

Cover

3) Remove the 6 screws fixing the front panel.

7) Remove the screw fixing the control box cover.

4) Remove the screw fixing the Cord holder.

5–1
ESD24HRA
12)Remove the LED guide.

8) Cut the fixing band and remove the cover.


13)Remove the thermistor of the evaporator.

14)Cut the fixing band.

9) Remove the screw fixing the ground wire.

15)Disconnect the connector and remove the 2 screws fixing the con-
trol box assembly.
10)Remove the 2 screws fixing the cluster holder.

Cluster holder

Screw 16)Remove the control box assembly.

11)Remove the LED guide.

Control box assembly

5–2
ESD24HRA
17)Remove the 4 screws fixing the drain pan and pull drain pan toward 20)Remove the 2 screws fixing the side coder L.
you.

Left side
21)Remove the 4 screws fixing the side cover R and remove the and
remove the evaporator from the cabinet.

Right side

22)Loose the screw fixing cross flow fan.


18)Remove the drain cover from the evaporator.

19)Remove the 3 screws fixing the evaporator.


2. ELECTRIC CONTROL BOX
1) Remove the screw fixing the receiving filter.

5–3
ESD24HRA
2) Remove the photo detector unit.

3) Remove the screw fixing the cord holder. 3. The louver and related
1) Remove the2 screws fixing the louver motor.

4) Remove the screw fixing the cord holder and the 2 screws fixing
2) Open the horizontal louver to remove it from the holders.
the terminal board.

5) Remove the 2 screws fixing the transformer and pull the control 3) Remove the holders.
board unit.

Holder

5–4
ESD24HRA
4) Tilt the hooks of vertical louvers inside, and pull them up. 2) Take off the high voltage unit assembly from the holder.

High voltage unit

3) Remove the connector of high voltage unit assembly.

4. How to remove the display cover


1) Push the center of the front panel under the display cover to
release the lock.

Connector

2) Slide the display cover to one side.

Display cover

5. How to remove the high voltage unit.


1) Remove the 2 screws fixing holder.

5–5
ESD24HRA
[2] OUTDOOR UNIT
CAUTION: DISCONNECT THE UNIT FROM THE POWER SUPPLY BEFORE ANY SERVICING
(The illustrations are for ESD24HRA. Construction of ESD30HRA may differ slightly from the illustration.)
1) Remove 3 screws fixing the Front panel R.
And slide the Front panel R down.

6) Remove 6 screws fixing the Rear guard.

2) Remove 10 screws fixing the Top cover.

7) Remove 10 screws fixing the Side cabinet R.

3) Remove 6 screws fixing the Front panel L.

8) Remove 6 screws fixing the Side cabinet L.

4) Remove 1 screw fixing the Front panel bottom.


5) Remove 4 screws fixing the Side cabinet bottom.

5–6
ESD24HRA
9) Cut the Insulators.

Cut

12)Cut the fixing bands.

10)Remove 2 screws fixing the Control box cover.

13)Remove 4 screws fixing the Flare coupling sub.


Caution: Discharge electrolytic capacitor before touching this
capacitor or other components or wirings.
11)Cut the fixing band.
Disconnect 4 connectors.
• Reverse valve
• Thermistor
• Expansion valve
• Fan motor

Cut

14)Remove the Compressor covers.

5–7
ESD24HRA
15)Remove the Terminal cover and disconnect 3 terminals. 18)Remove 3 screws fixing the Bulkhead.

Note: Caution to the connectors' position when re-installing.

19)Remove the nut fixing the Propeller fan.

Thermistor (Red)
White (C)
Compressor

Red (S)

Orange (R)

16)Remove 5 screws fixing the control box assembly. Loose

20)Remove 2 screws fixing the Motor angle.

17)Cut the insulator.

21)Cut the fixing bands.

5–8
ESD24HRA
22)Remove 4 screws fixing the Fan motor.

Orange

2. How to disassemble the Control box assembly


1) Remove 2 screws fixing the PWB.
2) Unlock the Spacer's lock.

1. Position of the Thermistors


NOTE: Caution to the position when re-installing.

Green

Black

Orange

Black

5–9