SERVICE Manual AIR CONDITIONER OUTDOOR UNIT UM26A1C2 UM18A1C2 INDOOR UNIT AM26A1C13 AM18A1C Installation. 2. Disassembly and Reassembly

Transcription

1 ROOM AIR CONDITIONER INDOOR UNIT AM6AC3 AM8AC09 OUTDOOR UNIT UM6AC UM8AC SERVICE Manual AIR CONDITIONER. Installation CONTENTS. Disassembly and Reassembly 3. Troubleshooting 4. Exploded Views and Parts List 5. Refrigerating Cycle Block Diagrams 6. Wiring Diagrams 7. Schematic Diagrams E DB A(5)

2 . Installation - Refrigerant Refill Procedure If connecting pipe of more than 0 metres is installed, additional refrigerant should be charged by extra metre. You don t have to charge additional refrigerant up to 0 metres of connecting pipe.. Remove the valve stem cap and service port of 3-way valve.. Connect the charging hose of low pressure side of Manifold gauge to the packed valve having a charging port(/ó Packed valve) as shown at the right figure. Piping length and the height AM6AC3 AM8AC09 Pipe Size LIQUID GAS Max.piping length A Max height B A-UNIT /4Ó /Ó 5m(49ft 3in) 3m(9ft 0in) B-UNIT /4Ó /Ó 5m(49ft 3in) 3m(9ft 0in) A-UNIT /4Ó 3/8Ó 5m(49ft 3in) 3m(9ft 0in) B-UNIT /4Ó 3/8Ó 5m(49ft 3in) 3m(9ft 0in) 3. Operate the unit at the cooling mode. 4. Slowly open the valve of the low pressure side of Manifold gauge counterclockwise until the low pressure of manifold gauge indicates 4.8 to 5.5 kg/cm (68 a 78psi) at the high cool operation (-unit operation) and the standard temperature. Additional refrigerant charge (R,g) When length of the pipe is over 5u by the unit, you should charge the refrigerant Formulas A-UNIT : 0gx(La-0)/m B-UNIT : 0gx(Lb-0)/m (La:the length of A-unit s pipe Lb:the length of B-unit s pipe) INDOOR UNIT B A OUTDOOR UNIT It is recommend that refrigerant should be slowly put in. If the refrigerant is put in too quickly, compressor will be damaged. 5. Stop operation of the air conditioner. 6. Disconnect the charge hose of manifold gauge. INDOOR A-UNIT 7. Close the cap of each valve. INDOOR B-UNIT

3 - ÒPump downó Procedure. Confirm that both the -way and 3-way valves are set to the open position. () Remove the valve stem caps. () Be sure to use a hexagonal wrench to operate the Gas side valve stems.. Operate the unit for 0 to 5 minutes. -Way Valve 3. Stop operation and wait for 3 minutes, then connect the charge set to the service port of the 3-way valve. () Connect the charge hose with the push pin to the service port. Cap 4. Air purging of the charge hose. () Open the low-pressure valve on the charge set slightly to air purge from the charge hose. 3-Way Valve 5. Set the liquid side -way valve to the closed position. 6. Operate the air conditioner at the cooling cycle and stop operation immediately after setting the 3-way valve to the closed position when the gauge indicates 0 kg/cm G. If the unit can not be operated at the Cooling Mode(weather is rather cool), operate the unit at the Trubo Mode. So that the unit can be operated. 7. Disconnect the charge set, and mount the both 3-way valve s stem nuts and the service port cap. Relocation of the air conditioner Refer to this procedure when the unit is relocated.. Carry out the pump down procedure (refer to the details of pump down ).. Remove the power cord. 3. Disconnect the assembly cable from the indoor and outdoor units. 4. Remove the flare nut connecting the indoor unit and the pipe. At this time, cover the pipe of the indoor unit and the other pipe using a cap or vinyl plug to avoid foreign material entering. 5. Disconnect the pipe connected to the outdoor unit. At this time, cover the valve of the outdoor unit and the other pipe using a cap or vinyl plug to avoid foreign material entering. 6. Make sure you do not bend the connection pipes in the middle and store together with the cables. 7. Move the indoor and outdoor units to a new location. 8. Remove the mounting plate for the indoor unit and move it to a new location.

4 . Disassembly and Reassembly Stop operation of the airconditioner and remove the power plug from the wall outlet before repairing the unit - Indoor Unit No Parts Procedure Remark Front Grille ) Stop the air conditioner operation and block the main power. ) Seperate the tape of front. Panel upper. 3) Contract the second finger to the left and right handle and pull to open the inlet grille. 4) Take the left and right filter out. 5) Loosen one of the right fixing screw and seperate the terminal cover. 6) Open the cover screw and loosen three fixing screws of front grille. 7) Pull the upper left and right of discharge softly for the outside cover to be pulled out. 8) Pull softly the lower part of discharge and push it up Caution: Assemble the front panel and fix the hooks of left and right. 3

5 No Parts Procedure Remark Filter Frame ) Loosen the left and right screw of the Holder Filter, and Separate the Holder Filter. 3 Ass'y Tray Drain ) Do, above. Separate the holder at the rear side of Indoor unit. ) Take the display PCB out. (Center of indoor unit). 3) Loosen three fixing screws of left and right. 4) Pull tray drain out from the back body. 4 Main PCB ) Do " ", above ) Take all the connector of PCB upper side out. 3) Separate the outdoor unit connection wire from the terminal block. 4) If pulling the Main PCB up, it will be taken out. (Separate the TRANS hook, it before). 4

6 No Parts Procedure Remark 5 Heat Exchanger ) Do " 3 4 ", above. ) Loosen the left screws of the heat exchanger. Lifting the heat exchanger up a little to push the up side for separation from the indoor unit 6 Fan Motor and Cross Fan ) Do " ", above. ) Loosen the fixing two screws and separate the motor holder. 3) Loosen the fixing screw of motor fan. (By use of M3 wrench) Separate the motor from the fan. Separate the fan motor the left holder bearing. 5

7 - Outdoor Unit No Parts Procedure Remark Cabinet ) Turn off the unit and remove the power cable ) Remove the top cover. 3) Remove the control box cover. 4) Unplug the ass'y cable. 5) Remove the cabi-side. 6) Remove the cabi-front. <AM6AC> * When you assemble the parts, check if the each parts and electric connectors are fixed firmly. <AM8AC> Fan Motor & Propeller Fan ) Do Procedure above. ) Remove the nut flange. (Turn to the right to remove as it is a left turned screw) 3) Disassemble the propeller fan. <AM6AC> <AM8AC> 6

8 3. Troubleshooting 3- Items to be checked first ) Is the voltage of the power correct? The input voltage shall be rating voltage ±0% range. The airconditioner may not operate properly if the voltage is out of this range. ) Is the link cable linking the indoor unit and the outdoor unit linked properly? The indoor unit and the outdoor unit shall be linked by 5 cables. Check the terminals if the indoor unit and outdoor unit are properly linked by the same number of cables. Otherwise the airconditioner may not operate properly. 3) When a problem occurs due to the contents illustrated in the table below it is a symptom not related to the malfunction of the airconditioner. Operation of air conditioner Explanation The COOL operation indication LED (Green) blinks when a power plug of the indoor unit is plugged in for the first time. In a COOL operation mode, the compressor does not operate at a room temperature higher than the setting temperature that the IN DOOR FAN should operate. 3 Fan speed setting is not allowed in AUTO or DRY mode. 4 Compressor stops operation intermittently in DRY mode. 5 Timer LED only of the indoor unit lights up and the air conditioner does not operate. 6 The compressor stops intermittently in a COOL mode or DRY mode, and fan speed of the indoor unit decreases. It indicates power is on. The LED stops blinking if the operation ON/OFF button on the remote control unit is pushed. In happens after a delay of 3 minutes when the compressor is reoperated. The same phenomenon occurs when a power is on. As a phenomenon that the compressor is reoperated after a delay of 3 minutes, the indoor fan is adjusted automatically with reference to a temperature of the air blew The speed of the indoor fan is set to LL in DRY mode. Fan speed is 5 steps is selected automatically in AUTO mode. Compressor operation is controlled automatically in DRY mode depending on the room temperature and humidity. Timer is being activated and the unit is in ready mode. The unit operates normally if the timer operation is cancelled. The compressor stops intermittently or the fan speed of the indoor unit decreases to prevent inside/outside air frozen depending on the inside/outside air temperature. 4) Indoor unit observes operation condition of the air conditioner, and displays self diagnosis details on the display panel. Display Self Diagnosis Operating LED blinking (Hz) TIMER LED blinking (Hz) 3 OPERATING and TIMER LED blinking (Hz) 4 FAN LED blinking (Hz) Restore from power failure (input initial power) Indoor unit Room sensor Error (open or short) Indoor unit heat exchanger temperature sensor Error (open or short) Indoor fan malfunctioning (for speed is Below 38Orpm) 7

9 3- Fault Diagnosis by Symptom 3-- No Power(completely dead)-initial diagnosis ) Checklist : () Is input voltage normal? () Is AC power linked correctly? (3) Is output voltage of DC regulator IC KA78(IC0) normal? (.5VDC-.5VDC) (4) Is output voltage of DC regulator IC KA7805(IC0) normal? (4.5VDC-5.5VDC) ) Troubleshooting procedure Remove power cord and plug in again in approx. 5 seconds Is operation lamp blinking? Replace PCB display Is DC voltage of PCB display normal? Is rating voltage ±0% range applied to the primary side of the power transformer? Check linkage between power cord and terminal tap Check fuse Does operation start when run/stop button on the remote controller unit pushed? Is transmission display of the remote controller unit blinking? Is "beep"sound heard from the main unit? Is DC voltage of the PCB module normal? Normal Refer to remote control unit fault diagnosis Replace PCB module. Is 4~8VAC appear in the secondary side of the power transformer? Are voltages of #6 (compressor), #6 (outdoor fan) of the micom normal? 5VDC Is voltage of #63 (indoor fan) of the micom normal? DC5V 0ms Are voltages at RY7(Compressor) RY7(outdoor fan) normal? DCV Is voltage at SS7(indoor fan) Replace power transformer Is voltage at #3 terminal of the Micom normal? 0VDC Is voltage at #64 terminal of the Micom normal? 5VDC Is voltage at #5 terminal of the micom normal? Check connections compressor, outdoor fan and indoor fan. Is output voltage of ICO normal? Replace RY7, RY73, RY7 and SS7 0ms Are voltage at #30 and #3 of the micom normal? Check PCB pattern. Replace main PCB. Replace ICO Is voltage output terminal of D0~D05(IN4007) normal? Replace resonator (X50) Is operation normal? Replace micom 00ns OK Replace IN4007 OK 8

10 3-- When the Indoor Unit Fan Does Not Operate. (Initial Diagnosis) ) Checklist : () Is the indoor unit fan motor properly connected with the connector (CN73)(CN43)? () Is the AC voltage correct? (3) Is HALL IC in indoor fan motor properly connected with the connector (CN43)? (4) Is the running capacitor properly connected with the terminal? ) Troubleshooting procedure After unplugging out the power cord should be reconnected within five seconds. Does the operating lamp(green) blink? Check as in the procedur Ò power partsó Refer tp page 8. Does the Solid State Relay(SS7) work properly? + Test rod location - Normal Voltage Microcomputer is out of order. SS7- SS7- V Is the supply voltage of the fan motor sufficient? PCB is out of order. PCB should be replaced. PCB CN73 Test rod location Condition Normal voltage Fan operate AC 80V MF-C is out of order Replace MFC Fan motor is out of order. Fan motor should be replaced. 9

11 3--3 When the Outdoor Unit Does Not Operate. (Initial Diagnosis) ) Checklist : () Is input voltage normal? () Is the set temperature of the remote control higher than room temperature in COOL mode? (3) Is the POWER IN connector (terminal-tab) linked correctly? (4) Is the outdoor unit properly connected with the TERMINAL BLOCK connector(5p)? ) Troubleshooting procedure () Checking procedures for the indoor unit. After unplugging out the power cord should be reconnected within five seconds. Does the operating lamp blink Does the timer lamp blink during operation? Check as in the procedure "No Power parts" Refer to page 8. Room temperature sensor is out of order PCB should be checked. Is the power relay RY7 operated by adjusting the room temperature? Test rod location Normal 3 Microcomputer is out of order. + - Condition Voltage IC04 Pin No.63 GND RY73 ON DC 4.8V PCB should be checked. IC04 Pin No.6 GND RY7 ON DC 4.8V ) Is AC 98-64V applied relay between Terminal Tap(TB7) and RY 7 terminal No. 3 ) Is AC 98-64V applied relay between Terminal Tap(TB7) andcn 7 terminal No. Power relay is out of order Power relay should be replaced. A Room operation ÒAÓCompreessor or outdoor fan-motor replaced Is the room sensor normal register? 0 C 0 C 30 C 7.96k ½.09k ½ 8.3k ½ 3 B Room or C Room operating Proceed to the checking points for the outdoor unit. 0

12 3--4 When the UP/DOWN Louver Motor Does Not Operate. (Initial Diagnosis) ) Checklist : () Is input voltage normal? () Is the UP/DOWN louver motor properly connected with the connector (CN6)? ) Troubleshooting procedure Remove power cord and plug in again in approx. 5 seconds. Is operating lamp blinking? Does operation start when swing button of the remote control unit pushed? Y N Y Y Check as in the procedure "No Power parts". Refer to page 8. Normal Voltage at pin #33-#36 of micom (ICO4) change?(squarewave) N Micom (IC04) is faulty. Y Volatge at pin #0, #, #, #3 of IC05 (KID65003) change?(squarewave) N Driver IC05 (KID65003) is faulty. Y UP/DOWN louver motor is faulty.

13 3--5 If Operation By Remote Control Unit Is Impossible. (Initial Diagnosis) ) Troubleshooting procedure Remove power cord and plug in again approx. 5 Seconds Is operation lamp blinking? Y N Check as in the procedure Ò Power partsó. Refer to page 8. Ò Ò sound heard from the indoor unit when ON/OFF button on the remote control unit pushed? Y Normal N Voltage of battery less than.5v (Remote Control Unit)? N LCD display status of REMOCON normal? Y Y N Replace battery. LCD is faulty. Transmission display lamp ( ) blinking when ON/OFF button on the remote control unit pushed? N Replace button. Y Voltage at PIN #30 of Remocon Micom change? Y Voltage at collecter of Q60 or Q60 change? Y N N Micom is faulty. Q60(C4375Y) or Q60(C63Y) is faulty. IR LED(CL-L5EU) is faulty. Voltage at pin #6 of micom (IC04) change (INDOOR UNIT)? Y Micom (IC04) is faulty. N Receiver module is faulty.

14 MEMO 3

15 4. Exploded Views and Parts List 4- Indoor Unit (AM6AC3, AM8AC09)

16 Parts List QÕTY No. CODE Description Specification Remark AM6AC3 AM8AC09 DB64-040A GRILLE AIR INLET ABS - DB A PANEL CENTER DISPLAY PC DB63-303A GUARD AIR FILTER PP 3 DB63-047B COVER TERMINAL HIPS 4 DB E ASS«Y FRONT PANEL ASS«Y 5 DB B ASS«Y DISPLAY PCB ASS«Y(EDGE) 6 DB B ASS«Y TRAY DRAIN ASS«Y 6- DB95-038A ASS«Y STEP MOTOR U/D DCV.600GR 6- DB A BLADE-H HIPS 7 DB A ASS«Y EVAP ASS«Y - DB B ASS«Y EVAP ASS«Y - 8 DB C SPACER EVAP PVC 9 DB6-000B HOLDER MOTOR ASS«Y ASS«Y 9- DB A ASS«Y TERMINAL BLOCK ASS«Y 0 DB3-0078H MOTOR FAN IN AMPFS040WTVB DB94-304A ASS«Y-C-F-FAN 95 X 69.4mm DB A ASS«Y BEARING ASS«Y 3 DB93-066B ASS«Y MAIN PCB ASS«Y - DB93-066A ASSÕY MAIN PCB ASSÕY - 4 DB3-0008D THERMISTOR ASS«Y ASS«Y 5 DB6-05A CASE-CONTROL ABS(94-5V) 6 DB A BODY-BUSH HIPS 7 DB C ASS«Y BACK BODY ASS«Y 8 DB6-4047A HOLDER PIPE HIPS 9 DB70-068A PLATE HANGER SGCC-M 5

17 4- Outdoor Unit 4-- UM6AC (-~-) 5 0(0-~0-6) 3(3-~3-5) 5(5-) (6-~6-) (-) 6

18 Parts List No. CODE QÕTY Description Specification Remark UM6AC DB90-063D ASS'Y-WELD FRONT SC-90073T - DB7-5050A INSUL FRONT OUT Foam pu + Foam pe DB A FAN-PROPELLER AS+G/F0% 3 DB B MOTOR-FAN OUT OSM-738SRC 4 DB6-0094A BASE-MOTOR SGCC-M 5 DB B CABINET-SIDE SECC-P 5- DB A INSUL SIDE CABI FOAM PU + FOAM PE 6 DB90-400A ASS'Y COVER VALVE ASS'Y 6- DB A COVER-CONTROL p.p 6- DB A COVER-VALVE P.P 7 DB90-007A ASS'Y-BASE OUT UM6AC 8 DB99-074A ASS'Y-VALVE - 8- DB6-400A VALVE-PACKED /" /Ó 8- DB A VALVE-PACKED /4" /4Ó 8-3 DB6-3965A TUBE CAPI (C) ID.7 x DB C GUARD-COND SC-90073T 0 DB A ASS'Y CONTROL OUT UM6AC 0- DB6-099A CASE CONTROL OUT SGCC-M 0- DB65-005A CLIP-CAPACITOR SGCC-M C-OIL 5µF x 450V 0-4 DB B TERMINAL BLOCK 8P C-OIL 4.0µF x 450V 0-6 DB47-000A TERMOSTAT BU-A38 DB A ASSÕY PARTITION ASSÕY - DB A INSUL PARTITION FOAM PU + FOAM PE - DB A PARTITION SGCC-M DB90-066A ASSÕY CABI UPPER ASSÕY 3 DB95-006W ASS'Y-COMP 48A35VE5 3- DB A GROMMET-ISOLATOR EPDM 6 3- DB A NUT-WASHER M DB A NUT-FLANGE P DB63-065B COVER-TERMINAL RYL 3-5 DB47-000G OLP MRA DB A CONDENSER ASS'Y 5 DB63-300J SCREEN-GUARD P.E.H 00% 7

19 4-- UM8AC (3-~3-5) 8-9 0(0~0-6) (-) 5(5-) 8 8

20 Parts List No. CODE QÕTY Description Specification Remark UM8AC DB90-053J ASS'Y-WELD FRONT SC-90073J - DB A INSUL FRONT FOAM-PU DB A FAN-PROPELLER AS+G/F0% 3 DB3-0000A MOTOR-FAN OUT IC-9630SLF6J 4 DB6-0008C BASE-MOTOR SGCC-M 5 DB90-065B ASSÕY CABINET-SIDE ASSÕY 5- DB A CABI SIDE - 6 DB B ASSÕY-COVER-TERMINAL 94-5V 7 DB90-0A ASS'Y-BASE OUT ASHM-807ER 8 DB A ASS'Y-VALVE UM8AC 8- DB A VALVE-PACKED 3/8" 3/8Ó 8- DB A VALVE-PACKED /4" /4Ó 8-3 DB6-3368A TUBE CAPI. C ID.5 x DB D GUARD-COND SC-90073T 0 DB A ASS'Y CONTROL OUT - 0- DB6-099A CASE-CONTROL SGCC-M 0- DB65-005A CLIP-CAPACITOR SGCC-M C-OIL 0µF x 450V 0-4 DB B TERMINAL BLOCK 8P C-OIL.5µF x 450V 0-6 DB47-000A THERMOSTAT BU-A38 DB B PARTITION SGCC-P - DB B INSUL PARTITION Foam pu + Foam pe DB63-00A COVER-TOP SECC-P 3 DB C ASS'Y-COMP 44B09WE5 3- DB A GROMMET-ISOLATOR EPDM 6 3- DB A NUT-WASHER M DB A NUT-FLANGE P DB63-065B COVER-TERMINAL RYL 3-5 DB47-000A OLP MRA DB A CONDENSER ASS'Y 5 DB B SCREEN-GUARD P.E.H 00% 9

21 4-3 Romote Control & PCB Box 4-3- Remote Control Parts List No CODE Description Specification QÕTY Remark DB6-044A DB6-045A DB A DB A DB A DB73-00B DB B DB A DB A PH-M DB A DB A DB A 90 x 50 DB B DB6-4043A DB L DB N CASE UP CASE LOW DOOR REMOCON COVER BATTERY FILTER REMOCON RUBBER REMOCON INLAY LCD INLAY REMOCON LABEL REMOCON LABEL DOOR SCREW TAP SPRING BATTERY SPRING BATTERY SPRING BATTERY PE BAG ASSÕY PCB REMOCON HOLDER REMOCON ASSÕY REMOCON REMOCON + HOLDER ABS ABS ABS ABS PC SILICON PC PC ART 90 ART 90 PH-M SUS 304 SUS 304 SUS x 50 ABS Cooling Only Cooling Only 6 0

22 4-3- PCB Box Parts List No CODE Description Specification QÕTY AM6AC3 AM8AC09 Remark DB6-05A CASE-CONTROL ABS(94-5V) DB93-066A ASS'Y MAIN PCB - - DB93-066BA ASSÕY MAIN PCB - - DB09-049A IC-MCY MB89635R DB3-0008D THERMISTOR-ASSÕY 03AT -3 DE6-054A TRANS-POWER AC30V DC7V 300mA C-FILM CFS 99N 450VAC 55K POWER-RELAY DIU DCV -6 DE3-0037A FUSE 50V 3.5A 3 DB B ASSÕY DISPLAY PCB EDGE

23 4-3-3 AssÕy Display & Module DB B Parts List No Description CODE- Specification QÕTY PCB - DISPLAY LED - LAMP LED - LAMP LED - LAMP LED - LAMP MODULE REMOCON C - CERAMIC R - CARBON CONNECTOR WAFER C - CERAMIC DIODE SWITCHING C/W DIS & MODULE CASE-CENTER PCB UP CASE-CENTER PCB LOW SEAL DISPLAY UPP SEAL CASE DISPLAY ÒAÓ DB4-004B DB3-5007A DB A DB6-009A DB A DB7-033A DB7-00F - FR- T.6 W0 L70 LTL-30EHJ(ORG/GRN) SY55 (YEL) SM55 (GRN) SO55 (ORG) PNA46M XD CA OA 50V 04Z RD /8TP -J YWLA00-09P CA OA 50V 0Z N448 UL007 AWG#6/9 PC,BLUE ABS,BLK FOAM-PE,BLK 30FOAM-PE DCR00H(BROWN)

24 5. Refrigerating Cycle Block Diagram (UM6AC/UM8AC) INDOOR UNIT OUTDOOR UNIT T -way valve Capillary tube (A) (B) Liquid side Cross fan Cross fan Heat exchanger (Condenser) Propeller fan Compressor-B Heat exchanger (Evaporator) T Gas side 3-way valve Compressor-A Cooling Gas leak check point Refrigerating cycle temperature and pressure Operating Condition STD Pressure (psi) 3-WAY V/V Piping Temp.(ûF) T T DB Use Temp. Condition (ûf) Indoor Outdoor WB DB WB Standard 64~78 50~54 50~ Cooling Max over load - 6~64 6~ Low temp - 34~39 34~

25 6. Wiring Diagrams 6- Indoor Unit 4

26 6- Outdoor Unit ENGLISH ESPAL FRANCAIS ITALIA BLK NEGRO IR NERO RED ROJO ROUGE ROSSO 3 WHT BLANCO BLANC BIANCO 4 YEL AMARILLO JAUNE GIALLO UM6AC CAPACITOR FAN MOTOR : 3.5µF/450VAC COMP MOTOR : 5µF/450VAC UM8AC CAPACITOR FAN MOTOR :.5µF/450VAC COMP MOTOR : 0µF/450VAC 5

27 7. Schematic Diagrams 7- Indoor Unit 6 7

28 ELECTRONICS