BRIVIS DUCTED INVERTER SERVICE MANUAL DRCi

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George Moody
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1 BRIVIS DUCTED INVERTER SERVICE MANUAL DRCi 1

2 TABLE OF CONTENTS TABLE OF CONTENTS... 2 IMPORTANT NOTE... 3 FAULT FINDING AND DIAGNOSTICS... 3 ABBREVIATIONS... 3 PCB S... 4 OUTDOOR MAIN PCB... 4 INDOOR PCB... 5 IPM (OUTDOOR UNIT)... 6 PFC MODULE (OUTDOOR UNIT)... 6 BRIVIS INVERTER CHECK BUTTON FUNCTIONS... 7 POWER TRANSFORM CHART... 8 INDOOR UNIT FAULT CODES... 9 INDOOR RECEIVER LED FAULT CODE DIAGNOSIS... 9 OUTDOOR UNIT FAULT CODES DIAGNOSIS AND RECTIFICATION STEPS INDOOR ROOM TEMPERATURE SENSOR READING INCORRECT EVAPORATOR TEMPERATURE SENSOR READING INCORRECT CONDENSER TEMPERATURE SENSOR READING INCORRECT OUTDOOR UNIT MALFUNCTION EEPROM FAILURE DRAIN FAILURE OUTDOOR FAN MOTOR FAILURE EEPROM MALFUNCTION INDOOR PCB TO OUTDOOR PCB COMMUNICATIONS FAILURE OUTDOOR PCB TO DSP COMMUNICATIONS FAILURE OUTDOOR / AMBIANT TEMPERATURE SENSOR MALFUNCTION COMPRESSOR VOLTAGE PROTECTION PFC MODULE PROTECTION HIGH PRESSURE PROTECTION LOW PRESSURE PROTECTION COMPRESSOR CURRENT PROTECTION COMPRESSOR DISCHARGE TEMPERATURE PROTECTION CONDENSER HIGH TEMPERATURE PROTECTION MODULE PROTECTION P6 LED SUPPLEMENT FAULT CODES EVAPORATOR HIGH TEMPERATURE PROTECTION GENERAL COMPONENT TESTING HP/LP SWITCHES REVERSING VALVE REVERSING VALVE TESTING TABLE SENSOR RESISTANCE VALUE TABLE SENSOR RESISTANCE VALUE GRAPH

3 IMPORTANT NOTE ANY COMPONENTS DEEMD TO BE FAULTY AND REPLACED ON ANY UNIT UNDER BRIVIS WARRANTY ARE TO BE RETURNED TO BRIVIS. FAILURE TO RETURN FAULTY COMPONENTS TO BRIVIS MAY EFFECT THE PROCESSING OF A WARRANTY INVOICE CLAIM. FAULT FINDING AND DIAGNOSTICS ABBREVIATIONS PCB DSP PSB IPM T1 T2 T2B T3 T4 Printed Circuit Board Display Board Power Source Board Inverter Protection Module Room Temperature Sensor (R/A) Indoor unit s Middle Pipe Temperature Sensor Indoor unit s Outer Pipe Temperature Sensor Outdoor unit Defrost Temperature Sensor Outdoor Unit Ambient Temperature Sensor 3

4 PCB S OUTDOOR MAIN PCB Defrost & ambient temp sensors HP & LP Discharge temp sensor LED Display Check Button for accessing parameters 4

5 INDOOR PCB Room and middle coil Temp sensors Coil temp sensor EEPROM Chip 5

6 IPM (OUTDOOR UNIT) IPM Diagnostic LED s PFC MODULE (OUTDOOR UNIT) 6

BRIVIS INVERTER CHECK BUTTON FUNCTIONS On the main outdoor PCB there is a LCD 2 digit display, on the right hand side of this display is a press button marked SW1.

In forced cooling the system will hold the indoor fan at a high speed, disable any response to the remote control, all of the safeties are still active during the forced cool mode.

7 BRIVIS INVERTER CHECK BUTTON FUNCTIONS On the main outdoor PCB there is a LCD 2 digit display, on the right hand side of this display is a press button marked SW1. SW1 SW1 has two functions; Forced cool mode. Current condition display. Forced cooling: Press and hold the SW1 for 10 seconds and the unit will enter a forced cooling mode. In forced cooling the system will hold the indoor fan at a high speed, disable any response to the remote control, all of the safeties are still active during the forced cool mode. Current condition display; By pressing SW1 for a second will move through the displayed current operating status / outputs or inputs that are currently occurring within the system. Each press of SW1 will move to the next reading. Display number What is being LED display interpretation displayed 00 rmal home screen Displays the inverter running frequency 01 Capacity request of indoor unit 02 Corrected capacity 03 Target running Hz 04 Target Hz when Hz limit occurs 05 Target Hz to IR Middle pipe sensor Evap If no call will read 0 07 Defrost sensor 08 Ambient sensor 09 TP 10 Current AD Hex display 11 Voltage AD Hex display 12 Indoor mode 0=off, 1- fan, 2 cool, 3 heat, 4 forced cool 13 Outdoor mode 0=off, 1- fan, 2 cool, 3 heat, 4 forced cool 14 EX valve steps Multiply by 4 for the ex valve steps open. If above 99 decimal place is displayed between digits 15 Signs of frequency limit 16 DC motor speed Speed of compressor 17 Heat sink temperature If greater than 99 decimal place is displayed between digits 7

8 POWER TRANSFORM CHART 240V (1PH) 50 Hz 240V (1PH) 50 Hz POWER SUPPLY OUTDOOR UNIT 240V (1PH) 50 Hz OUTDOOR PCB CONTROL POWER SUPPLY INDOOR UNIT 240V (1PH) 50 Hz POWER FILTER MODULE IPM 6 Part Motor Winding Drive Signals COMPRESSOR 240V (1PH) 50 Hz 3 PH AC V RECTIFIER, PFC, FILTER & CAPACITOR 380V DC IPM CHANGES INTO AC When the compressor is running the voltage will be lower (around 200 V) 8

9 INDOOR UNIT FAULT CODES INDOOR RECEIVER LED FAULT CODE DIAGNOSIS Infar-red receiver Temporary button Operation Light Timer Indicator Pre-Defrost Indicator Alarm Indicator Fault Operation indicator Timer indicator Defrost indicator Alarm indicator Wall Controller Display Indoor to outdoor X O X X E1 communication Room Temp sensor O X X X E2 T1 Middle Pipe Temp O X X X E3 sensor T2 End Pipe Temp O X X X E4 sensor T2B Drain X X X O EE EEPROM X X O X E7 Indoor Fan speed X X O O E8 Outdoor Unit X X X O Ed X = Off O = Flashing 9

10 OUTDOOR UNIT FAULT CODES Error Code Fault - (E) Error (P) Protection Diagnosis on Page E0 EEPROM Malfunction 18 E2 Indoor PCB to Outdoor PCB 19 communication failure E3 Outdoor PCB to DSP communication 20 failure E4 Outdoor Temperature or Ambient 22 sensor failure E5 Compressor Voltage Protection 24 E6 PFC module protection 25 P1 High Pressure fault 26 P2 Low Pressure fault 28 P3 Compressor Current protection 30 P4 Discharge Temperature protection 31 P5 Condenser High Temperature 32 protection P6 Module protection 34 P7 Evaporator High Temperature protection 36 10

11 DIAGNOSIS AND RECTIFICATION STEPS INDOOR ROOM TEMPERATURE SENSOR READING INCORRECT Test the resistance of the room temperature sensor T1. Resistances in K ohms values on Sensor resistance value table and graph. Replace the room temp. sensor Test room temp. sensor output from PCB for voltage. Test between the two sensor leads for a DC voltage between 2 and 5 Volts. Replace indoor PCB Visual inspection of sensor wiring from Indoor PCB to sensor and connection on PCB. Terminal T1 CN6 White wires Replace sensor wiring or reconnect onto PCB Test between the two white wires for a DC voltage or between 2 and 5 volts DC. 11

12 EVAPORATOR TEMPERATURE SENSOR READING INCORRECT Test the resistance of the evaporator temperature sensor T2. Resistances in K ohms values on Sensor resistance value table and graph. Replace the Evap temp. sensor Test room Evap. sensor output from PCB for voltage Test between the two sensor leads for a DC voltage between 2 and 5 Volts. Replace indoor PCB Visual inspection of sensor wiring from the indoor PCB to sensor and connection on PCB Terminals T2 CN6 Black wire and terminal T2B CN7 Black wire. Replace sensor wiring or reconnect onto PCB Test between the two Black sensor leads for a DC voltage between 2 and 5 Volts. 12

13 CONDENSER TEMPERATURE SENSOR READING INCORRECT Test the resistance of the condenser temperature sensor. Resistances in K ohms values on Sensor resistance value table and graph. Replace the Cond. temp. sensor Test room Cond. sensor output from PCB for voltage Test between the two sensor leads for a DC voltage between 2 and 5 Volts. Replace indoor PCB Visual inspection of sensor wiring from PCB to sensor and connection on outdoor PCB Terminal T3 CN36 Black wires Replace sensor wiring or reconnect onto PCB Test between the two black wires T3 CN36 for between 2 and 5 volts DC 13

OUTDOOR UNIT MALFUNCTION Is there power at the outdoor unit supply terminals? Check isolator and circuit breaker then re-test system. Test the voltage of the communication cable.

14 OUTDOOR UNIT MALFUNCTION Is there power at the outdoor unit supply terminals? Check isolator and circuit breaker then re-test system. Test the voltage of the communication cable. Red to Black +5 volts is expected Replace outdoor PCB Check terminal CN5 on the indoor PCB is correctly fitted. Refit CN5 connection and re-test run the system Replace the main PCB Communication cable 14

15 EEPROM FAILURE Check if EEPROM chip is broken or misfitted Refit or replace chip Check if main chip (9177) is broken or misfitted Refit or replace chip Check main PCB or replace main control board EEPROM chip Indoor PCB 15

16 DRAIN FAILURE THIS FUNCTION IS NOT USED ON THE BRIVIS INVERTER DUCTED UNIT. SO ENSURE THAT TERMINAL CN5 ON THE INDOOR UNIT HAS A JUMPER WIRE FITTED INTO THE BOARDS TERMINALS. CN5 Jumper Wire 16

17 OUTDOOR FAN MOTOR FAILURE Isolate power for 5 seconds re-power and test run. Does the unit operate correctly? ISOLATE THE POWER Spin the outdoor fan by hand, does it spin freely Remove the fan blade from the fan motor and recheck the motor bearing. If the bearing is faulty replace fan motor. Is the fan supply connection firmly fitted onto the PCB, if not refit and re-test run the system? Is there power from the PCB to the fan motor Replace the fan motor Replace the PCB 17

18 EEPROM MALFUNCTION E0 Check if the EEPROM chip is correctly and firmly fitted onto the PCB with no bent or misfitted pins Carefully remove and then re-insert the EEPROM chip onto the PCB Replace the PCB EEPROM Chip Indoor PCB 18

19 INDOOR PCB TO OUTDOOR PCB COMMUNICATIONS FAILURE E2 Does the indoor unit have power? Is the signal cable shielded and is the shield earthed? Turn on the power to the indoor unit Replace the communication cable with shielded cable / earth the shield Are there crossed wires in the shielded cable between the indoor and outdoor PCB s? Correct the crossed over wires Test if the signal wiring between the indoor unit and outdoor unit is broken. Replace the broken communication cable The indoor or outdoor PCB has failed, replace the outdoor main PCB Replace the indoor PCB 19

20 OUTDOOR PCB TO DSP COMMUNICATIONS FAILURE E3 Is LED 1 or LED 2 on the outdoor main PCB flashing? Is the interconnecting loom between the IPM and terminal CN4 on the outdoor main PCB loose or unplugged Disconnect the interconnecting loom between the IPM and terminal CN4 on the outdoor main PCB. Test for 5 volts between pin 3 and 4 on terminal CN1 of the IPM. Pin is 5 volts + Replace the outdoor main PCB Reconnect the interconnecting loom Replace the outdoor main PCB Check the transformer output voltage and connection onto terminal CN4 Either reconnect the connection from the transformer to connection CN4 / replace the transformer Check interconnecting wires between the IPM and connectioncn12 & CN13 on the power source board has a good connection Reconnect the interconnecting loom Test between connections CN12 and CN13 on the PSB Expected voltage is between 277 v 345v Replace the IPM Replace the PSB 20

21 Test for 5 volts between pin 3 and 4 on terminal CN1 of the IPM. Pin is 5 volts + 21

22 OUTDOOR / AMBIENT TEMPERATURE SENSOR MALFUNCTION E4 Check the connection of Defrost Temperature Sensor (T3) connection CN36 Black wires Good Test the resistance of the defrost temperature sensor. Resistances in K ohms values on Sensor resistance value table and graph. Good Check the connection of Ambient Temperature Sensor (T4) connection CN36 White wires Good Bad Bad Bad Reconnect the defrost temperature sensor Replace the Defrost temperature sensor Reconnect the Ambient temperature sensor Replace the Ambient temperature sensor Test the resistance of the Ambient temperature sensor. Resistances in K ohms values on Sensor resistance value table and graph. Good Test the output voltage to the Defrost and Ambient sensors Test between the two sensor leads for a DC voltage between 2 and 5 Volts. Replace the outdoor main PCB 22

23 Test the output voltage to the Defrost and Ambient sensors. Test between the two black wires for each sensor voltage is expected to be between 2 and 5 Volts DC. 23

24 COMPRESSOR VOLTAGE PROTECTION E5 Test the power supply voltage. Is the voltage between 172 volts volts Check the power supply Replace the PSB, re-test run the system. Is the system now operating correctly? Replace the main outdoor PCB 24

25 PFC MODULE PROTECTION E6 Check the interconnecting loom between the main PCB and the PFC module is connected properly Check if the voltage between the P and N connections on the IPM is between 380 volts 390 volts DC Reconnect the loom into the connections, re-test has this fixed the problem? Replace the outdoor main PCB Replace the PFC module Check if the voltage between the P and N 25

26 HIGH PRESSURE PROTECTION P1 Bad Check the HP wiring connection onto the Reconnect the plug termination main PCB Connection CN30 GY Yellow wires Good Connect gauges and test the refrigerant pressures whilst the unit is operating. Is the ambient temperature too high (above maximum rated operating temperature) Turn the controller off for the system. Is there obstructions preventing the condenser air from escaping from the condenser? Remove the obstruction preventing free air flow or creating the recirculation of air Good Is the outdoor coil blocked or dirty Clean the outdoor coil. Test if the pressure switch is broken or faulty. Bypass the HP switch for testing. Does the system now run without HP fault? Replace the HP switch Check if pipe work is blocked Replace the outdoor PCB Reclaim the refrigerant, use nitrogen to blow through the pipe work. Vac and re-charge the system and test run 26

27 Test HP (Yellow wires) For continuity. 27

28 LOW PRESSURE PROTECTION P2 Bad Check the LP wiring connection onto the Reconnect the plug termination main PCB Connection CN30 DY Red wires Good Connect gauges and test the refrigerant pressures whilst the unit is operating. Ok Is the ambient temperature too low (below minimum rated operating temperature) Low Complete a leak test on the system to find the leak and then rectify. Turn the controller off for the system. Test if the pressure switch is broken or faulty. Bypass the LP switch for testing. Does the system now run without LP fault? Replace the LP switch Is the indoor coil or filters blocked or dirty Check if pipe work is blocked Replace the outdoor PCB Clean the indoor coil or filters. Reclaim the refrigerant, use nitrogen to blow through the pipe work. Vac and re-charge the system and test run 28

29 Test LP (Red wires) For continuity. 29

30 COMPRESSOR CURRENT PROTECTION P3 Check if the power supply cable is adequate of the units current draw Upgrade the power supply to be sized for the units current draw Is the refrigerant system and pressures ok Rectify the refrigeration issue and retest the system Is the ambient temperature too high Isolate the unit at the controller Is the condenser air recirculating or unable to escape from the condenser Remove the obstruction creating the recirculating issue. Is the condenser coil blocked Clean the coil Is refrigeration pipe work blocked Replace the main outdoor PCB 30

31 COMPRESSOR DISCHARGE TEMPERATURE PROTECTION P4 If the compressor discharge temperature exceeds 115 degrees C the unit will shut down and then restart when the discharge temperature drops below 90 degrees C. Test the compressor discharge temperature. Is it above 115 degrees C Test the refrigeration system for low gas pressures is low find, repair leak and recharge system Check the connection of Compressor discharge Temperature Sensor connection CN38 Black wires Reconnect the Compressor temperature sensor Test the resistance of the Compressor discharge temperature sensor. Resistances in K ohms values on Sensor resistance value table and graph. Bad Replace the Compressor discharge temperature sensor Good Test the output voltage to the Compressor discharge temperature sensor Test between the two sensor leads for a DC voltage between 2 and 5 Volts. Discharge sensor Replace the main outdoor PCB 31

32 CONDENSER HIGH TEMPERATURE PROTECTION P5 Test the condenser temperature. Is it more than 65 degrees C Is the ambient temperature above the operating range of the unit Check the connection of Condenser Temperature Sensor connection CN36 Black wires Turn unit off Good Bad Reconnect the Condenser temperature sensor Test the resistance of the Condenser temperature sensor. Resistances in K ohms values on Sensor resistance value table and graph. Bad Replace the Compressor discharge temperature sensor Good Is the condenser coil blocked? Test the output voltage to the Compressor discharge temperature sensor Test between the two sensor leads for a DC voltage between 2 and 5 Volts. Clean coil Replace the main outdoor PCB Check if pipe work is blocked Replace the outdoor PCB Reclaim the refrigerant, use nitrogen to blow through the pipe work. Vac and re-charge the system and test run 32

33 Test between the two black wires (CN36) for DC voltage. 33

34 MODULE PROTECTION P6 Also refer to P6 LED supplementary fault codes Check voltage range of the module s P&N terminals. DC v for smaller units DC v for larger units. Is the power supply between v 50 Hz Rectify power supply issues Check the communication line between the main PCB and the IPM is correctly fitted and are tight. Is power supply connected correctly and tight? Rectify power supply connections Check the compressor terminal connections are correctly fitted and are tight Are the E-part box connected correctly and tight? Rectify connections Replace the IPM, test run the system. Replace the Main PCB, test run the system. Check single phase bridge. Measure resistance between each of the two terminals. Is the value 0 Ohms? Check the connecting line of each reactor. Is the value infinite Ohms? Replace the single phase bridge Replace the connecting lines Replace the compressor. Check the fuse on the PSB. Replace the fuse Good Bad Replace the PSB. 34

35 P6 LED SUPPLEMENT FAULT CODES The IPM has a secondary fault identification aid. This is displayed by the 3 LED s on the IPM module illuminating in different sequences dependant on the unit / modules status. LED 3 is always illuminated. This LED is a power indicator LED. FAULT LED 2 GREEN LED 1 RED rmal operation in standby. ON OFF rmal operation running. OFF ON DC voltage too high or low ON ON Or IR 341 chip fault. EEPROM for IR341 chip faulty. ON FLASH Losing compressor speed. OFF FLASH Dropped a phase, no speed protection or FLASH ON Synchronisation fault. Over current of IGBT. FLASH OFF Communication fault ( comm. s received from main PCB for 1 minute) FLASH FLASH LED Diagnostic lights 35

36 EVAPORATOR HIGH TEMPERATURE PROTECTION P7 Does the compressor operate correctly? Check compressor connections Check if evaporator coil or filter is blocked and if the indoor fan is operating correctly. Check the Evaporator sensor resistances as per the sensor resistance table or graph. Replace the Compressor discharge temperature sensor Clean filters / coil or rectify the indoor fan issue. Ok Test the output voltage to the Evaporator Coil temperature sensor Test between the two sensor leads for a DC voltage between 2 and 5 Volts. Replace the indoor PCB Evap temp sensors 36

37 GENERAL COMPONENT TESTING HP/LP SWITCHES The HP and LP switches need to be tested whilst also testing the refrigerant pressures. Connect your gauges to the system (both HP and LP). Test run the system and watch your gauges for a HP or LP trip. If the pressures are correct when the HP or LP s trip, proceed by bypassing the HP or LP and retest run the system. Bypassing the HP or LP is completed by removing the two female lugs of the switch and using a small length of wire with two male lugs fitted on the ends, connect the unit s two wires off the HP or LP switch using the jumper wire. AT THE COMPLETION OF TESTING THIS BRIDGE MUST BE REMOVED. SERIOUS DAMAGE MAY RESULT IF THIS BRIDGE IS NOT REMOVED. 37

38 REVERSING VALVE A Reversing Valve can be tested to prove correct operation by using the following table on page 39 and the steps below. Step 1 Check if power is being applied to the Reversing valves solenoid from the PCB (In the heating mode). Step 2 Fit your gauges to the system (both HP and LP). Step 3 Run the system and take the 6 temperature readings of the pipe work from around the Reversing Valve using a digital thermometer. Step 4 Look through the table (on the next page) that describes the symptoms that the system is displaying for a correct diagnosis of the Reversing Valves status. 1 Compressor discharge line 2 Compressor suction line 3 Line to indoor coil 4 Line to outdoor coil 5 Left capillary line 6 6 Right capillary line 38

39 REVERSING VALVE TESTING TABLE Valves operating condition Possible cause Correction Jammed in cooling. Check electrical circuit and coil of reversing valve power to Test output from PCB coil Faulty coil Replace coil Check refrigerant charge Low gas charge Repair leak and re-gas system Pressure differential too high Recheck system Hot Cool As cool as 2 As hot as 1 Temp of RV body Hot Blockage in 1 breather hole. Disconnect RV raise head and re-energise Replace RV Piston cup leak Test drive RV with compressor off Replace Starts to shift but not complete. Warm As warm as 1 Temp of RV body Clogged pilot tube Hot Hot Both pilot ports open Temp of RV body Hot Warm Warm Hot Temp of RV body Apparent leak in Hot Cool As hot as 1 Jammed in heating Hot Cool As hot as 1 Warm Hot Hot Hot Hot Temp of RV body As warm as 1 As cool as 2 As cool as 2 Hot Temp of RV body Warmer than RV body Temp of RV body Hot Warmer Warm Hot Defective compressor t enough pressure differential RV body damage Both pilot ports open RV Disconnect RV raise head and re-energise Replace RV Disconnect RV raise head and re-energise Replace RV Test compressor by pumping system down Replace compressor. Check unit pressures, lift head and test replace RV Replace RV Hot Body Damage Replace RV RV jammed mid stroke Warmer than RV body Temp of RV body Both pilot ports open Piston needle leaking. Pilot and piston needles leaking. Pressure differential too high Pilot tube blockage Bleeder hole blockage Piston cup leak Hot Defective pilot Replace RV Temp Defective of RV compressor body Disconnect RV raise head and re-energise Replace RV Disconnect RV raise head and re-energise Replace RV Disconnect RV raise head and re-energise Replace RV Operate RV several times replace RV Operate RV several times replace RV Turn off balance pressures restart retest RV Check operating pressures Disconnect RV raise head and re-energise Replace RV Disconnect RV raise head and re-energise Replace RV Turn off balance pressures restart in cool then retest RV Replace RV Test compressor by pumping system down Replace compressor. 39

40 SENSOR RESISTANCE VALUE TABLE Acceptable tolerance of the sensors is + or 3 degrees C, if the reading is out of the 3 degrees C tolerance range replace the sensor. Degrees C K Ohms Degrees C K Ohms Degrees C K Ohms Degrees C K Ohms

41 K OHM RESISTANCE SENSOR RESISTANCE VALUE GRAPH DEGREES C Series1 41

LIGHT COMMERCIAL. Troublesooting

LIGHT COMMERCIAL. Troublesooting LIGHT COMMERCIAL Troublesooting 2. 2.1 Display board 2.1.1 Icon explanation on indoor display board (Super slim cassette 24K). 2.1.2 Icon explanation on indoor display board (Compact cassette 12K, 18K).