Service Manual. 9. Maintenance. 9.1 Precautions before Maintenance. discharge resistance or plug of soldering iron. Installation and Maintenance

Transcription

1 9. Maintenance 9.1 Precautions before Maintenance Service Manual pacitor after power off. - discharge resistance or plug of soldering iron A B A B - nance safely. 40

2 9.2 Error Code List O Malfunction ame High pressure protection of system Antifreezing protection High discharge temperature protection of compressor Overcurrent protection Communication Malfunction High temperature resistant protection PG motor (indoor fan motor) does not operate Malfunction protection of jumper cap Indoor ambient temperature sensor is open/short circuited Display Method of Outdoor Unit Display Method of Indoor Unit (Indicator has 3 kinds of display status and they will be displayed circularly every 5s.) A/C status Possible Causes Indicator Display (during OFF Dual-8 blinking, O 0.5s and OFF 0.5s) Illuminated Blink Code Operation Cool Heating D5 D6 D16 D30 Display Indicator Indicator Indicator (D40) (D41) (D42) (D43) E1 E2 E4 E5 E6 E8 H6 C5 F1 OFF 3s once twice 4 times 5 times 6 times 8 times 11 times 15 times once operation, except indoor fan operates, all loads stop complete unit stops. operation, compressor and outdoor fan stop while indoor fan operates. operation, compressor and outdoor fan stop while indoor fan operates. During heating operation, all loads stop. operation, compressor and outdoor fan stop while indoor fan operates. During heating operation, all loads stop. Possible reasons: 1. Refrigerant was superabundant; 2. Poor heat exchange (including and bad radiating environment ); Ambient temperature is too high. 1. Poor air-return in indoor unit; 2. Fan speed is abnormal; 3. Evaporator is dirty. Please refer to the malfunction analysis (discharge protection, overload). 1. Supply voltage is unstable; 2. Supply voltage is too low and load is too high; 3. Evaporator is dirty. During cooling operation, compressor stops while indoor Refer to the corresponding malfunction analysis. fan motor operates. During heating operation, the complete unit stops. During cooling operation: Refer to the malfunction analysis compressor will stop while (overload, high temperature indoor fan will operate. During resistant). heating operation, the complete unit stops. Indoor fan, outdoor fan, 1. The feedback terminal of PG compressor and electric heat motor is not connected tightly. tube stop Horizontal 2. The control terminal of PG motor louver stops at the current isnot connected tightly.3. Fan blade position. rotates unsmoothly. 4. Malfunctionof moto.r 5. Controller is damaged. Operation of remote controller 1. There's not jumper cap on the or control panel is available, but controller. the unit won't act. 2. Jumper cap is not inserted properly and tightly 3. Jumper cap is damaged. 4. Controller is damaged. operation, indoor unit operates while other loads will stop; during heating operation, the 1. The wiring terminal between indoor ambient temperature sensor and controller is loosened or poorly contacted; 2. There's short circuit due to tripover of the parts on controller;3. Indoor ambient temperature sensor is damaged(please check it by referring to the resistance table for temperature sensor) 4. Main board is broken. 41

3 O Malfunction ame Indoor evaporator temperature sensor is open/short circuited Outdoor ambient temperature sensor is open/short circuited Outdoor condenser temperature sensor is open/short circuited Outdoor discharge temperature sensor is open/short circuited Limit/ decrease frequency due to overload Decrease frequency due to overcurrent Decrease frequency due to high air discharge Voltage for DC bus-bar is too high Malfunction of complete units current detection Overcurrent protection of phase current for compressor Dual-8 Code Display F2 F3 F4 F5 F6 F8 F9 PH U5 P5 Display Method of Indoor Unit Indicator Display (during blinking, O 0.5s and OFF 0.5s) Operation Indicator Cool Heating Indicator Indicator and blink twice and blink 3 times Display Method of Outdoor Unit (Indicator has 3 kinds of display status and they will be displayed circularly every 5s.) A/C status Possible Causes OFF Illuminated Blink D5 (D40) D6 (D41) D16 (D42) D30 (D43) and blink 4 times and blink 5 times and blink for 6 times and blink 8 times and blink 9 times and blink 11 times and blink 13 times and blink 15 times The unit will stop operation 1. The wiring terminal between as it reaches the temperature indoor evaporator temperature point. sensor and controller is loosened operation, except indoor fan or poorly contacted; operates, other loads stop 2. There's short circuit due to the operation; During heating trip-over of the parts on controller; operation, the complete unit 3.Indoor evaporator temperature stops sensor is damaged (Please check it by referring to the resistance table for temperature sensor) 4. Main board is broken. Outdoor temperature sensor operating, compressor stops hasnt been connected well or while indoor fan operates; is damaged. Please check it by referring to the resistance table for operation temperature sensor) operation, compressor stops During heating operation, the Outdoor temperature sensor hasnt been connected well or is damaged. Please check it by referring to the resistance table for temperature sensor) 1.Outdoor temperature sensor operation, compressor will sop hasnt been connected well or is after operating for about 3 mins, damaged. Please check it by referring to the resistance table for temperature sensor) after 2.The head of temperature sensor operating for about 3 mins. hasnt been inserted into the copper tube All loads operate normally, while operation frequency for compressor is decreased All loads operate normally, while operation frequency for compressor is decreased All loads operate normally, while operation frequency for compressor is decreased operation, the compressor will stop During heating operating, the Refer to the malfunction analysis (overload, high temperature resistant) The input supply voltage is too low; System pressure is too high and overload Overload or temperature is too high; Malfunction of electric expansion valve (EKV) 1. Measure the voltage of position L and on wiring board (XT), if the voltage is higher than 265VAC, turn on the unit after the supply voltage is increased to the normal range. 2.If the AC input is normal, measure the voltage of electrolytic capacitor C on control panel (AP1), if its normal, theres malfunction for the circuit, please replace the control panel (AP1) Theres circuit malfunction on outdoor units control panel AP1, please replace the outdoor units control panel AP1. Refer to the malfunction analysis (IPM protection, loss of synchronism protection and overcurrent protection of phase current for compressor. 42

4 O. Malfunction ame Dual-8 Code Display Display Method of Indoor Unit Indicator Display (during OFF blinking, O 0.5s and OFF 0.5s) Illuminated Blink Operation Indicator Cool Indicator Heating Indicator Display Method of Outdoor Unit (Indicator has 3 kinds of display status and they will be displayed circularly every 5s.) A/C status Possible Causes D5 (D40) D6 (D41) D16 (D42) D30 (D43) 20 Defrosting H1 once Defrosting will occur in heating mode. Compressor will operate while indoor fan will stop Its the normal state 21 Overload protection for compressor H3 3 times 1. Wiring terminal OVC-COMP is loosened. In normal state, the resistance for this terminal should be less than 1ohm. 2.Refer to the malfunction analysis ( discharge protection, overload) 22 IPM protection H5 5 times Refer to the malfunction analysis (IPM protection, loss of synchronism protection and overcurrent protection of phase current for compressor. 23 PFC protection HC 6 times Refer to the malfunction analysis 24 Desynchronizing of compressor H7 7 times Refer to the malfunction analysis (IPM protection, loss of synchronism protection and overcurrent protection of phase current for compressor. 25 Failure startup LC 11 times Refer to the malfunction analysis 26 Malfunction of phase current detection circuit for compressor U1 13 times Replace outdoor control panel AP1 43

5 O. 27 Malfunction ame EEPROM malfunction Dual-8 Code Display EE Display Method of Indoor Unit Indicator Display (during blinking, O 0.5s and OFF 0.5s) Operation Indicator Cool Indicator Heating Indicator 15 times Display Method of Outdoor Unit (Indicator has 3 kinds of display status and they will be displayed circularly every 5s.) A/C status Possible Causes OFF Illuminated Blink D5 (D40) D6 (D41) D16 (D42) D30 (D43) Replace outdoor control panel AP1 28 Charging malfunction of capacitor PU 17 times Refer to the part three charging malfunction analysis of capacitor 29 Malfunction of module temperature sensor circuit P7 18 times Replace outdoor control panel AP Module high temperature protection Malfunction of voltage dropping for DC bus-bar P8 U3 19 times 20 times During cooling operation, After the complete unit is deenergized for 20mins, check compressor will stop while indoor fan will operate; During whether the thermal grease on heating operation, the complete IPM Module of outdoor control unit will stop whether the radiator is inserted tightly. If its no use, please replace control panel AP1. Supply voltage is unstable Voltage of DC bus-bar is too low Limit/ decrease frequency due to high temperature of module PL 21 times EU All loads operate normally, while operation frequency for compressor is decreased 1. Measure the voltage of position L and on wiring board (XT), if the voltage is higher than 150VAC, turn on the unit after the supply voltage is increased to the normal range. 2.If the AC input is normal, measure the voltage of electrolytic capacitor C on control panel (AP1), if its normal, theres malfunction for the circuit, please replace the control panel (AP1) Discharging after the complete unit is de-energized for 20mins, check whether the thermal grease on IPM Module of outdoor control whether the radiator is inserted tightly. If its no use, please replace control panel AP1. 34 The four-way valve is abnormal U7 If this malfunction occurs during heating operation, the complete unit will stop 1.Supply 4V. voltage is lower than AC175V; 2.Wiring terminal 4V is loosened or broken; 3.4V is damaged, please replace 35 Limit/ decrease frequency due to antifreezing FH All loads operate normally, while operation frequency for compressor is decreased Poor air-return in indoor unit or fan speed is too low 44

6 9.3 Troubleshooting for Main Malfunction 1. Malfunction of Temperature Sensor F1, F2 Troubleshooting for F1,F2 malfunction Is the wiring terminal between the temperature sensor and the controller loosened or poorly contacted? yes Insert the temperature sensor tightly no no Is malfunction eliminated Is there short circuit due to trip - over of the parts? yes Make the parts upright no no Is malfunction eliminated yes Is the temperature sensor normal according to the Resistance Table? no Replace it with a temperature sensor with the same model yes no Is malfunction removed yes Replace the mainboard with the same model. yes 45

7 2. Malfunction of Blocked Protection of IDU Fan Motor H6 interface terminal 1 and 2 within interface terminal 2 and 3 is 15VDC 46

8 3. Malfunction of Protection of Jumper Cap C5 Troubleshooting for C5 malfunction Is there jumper cap on the mainboard? yes no no Assemble the jumper cap with the same model Is malfunction eliminated Appearance of the jumper cap Is the jumper cap inserted correctly and tightly? no Insert the jumper cap tightly yes no Is malfunction eliminated yes Replace the jumper cap with the same model yes Is malfunction eliminated yes no Replace the mainboard with the same model. 47

9 4. Communication malfunction E6 Start Cut off power, check if the wire between indoor unit and outdoor unit, and the wire inside electric box are connected correctly Connected correctly? o Reconnect the wire according to wiring diagram Malfunction is eliminated es o Is there incorrect match between the mainboard and the display panel or between the indoor and outdoor mainboards? o Match them according to the requirement Malfunction is eliminated es es o Communication wire connection is broken? es Replace the wire Malfunction is eliminated o o Replace indoor mainboard es Malfunction is eliminated o Replace outdoor mainboard es 48

10 1.Key detection point Test9 Test3 Test4 Test2 C B Test1 L E A D F G K J I H Test5 Test8 Tset7 Test6 Test10 Test12 T S M Test11 Test O Test point Corresponding component condition Test 1 Between A and C 160V~265V Test 2 Between B and C 160V~265V Test 3 Between D and E DC 180V~380V Test 4 Electrolytic capacitor of power DC 180V~380V Test 5 Two ends of diode D15 DC 14.5V~15.6V Test 6 Two ends of electrolytic capacitor C715 DC 12V~13V Test 7 Two ends of electrolytic capacitor C710 DC 5V Test 8 Two ends of electrolytic capacitor C226 DC 3.3V Test 9 C912 DC 15V~18V Test 10 Between M to GD Test 11 Between to GD Test 12 Between S and T DC 56V 49

11 2.Capacity charging malfunction (outdoor unit malfunction) (AP1 below is control board of outdoor unit) Main detection point: Turn on the unit and wait 1 minute Use DC voltmeter to measure the voltage on the two ends of electrolytic capacitor Voltage higher than 200V? Fault with the voltage testing circuit on control panel AP1 Replace the control panel AP1 Measure the AC voltage between terminall and on wiring board XT(power supply) Voltage within 210VAC~250VAC? Shut down the power and repair the power supply to restore the range 210VAC~250VAC power on and restart the unit If the fault is eliminated? Shut down the power and wait 20 nutes; mi or use DC voltmeter to measure the voltage on the two ends of capacitor (test3), until the voltage is lower than 20V Check the connection of reactor (L in the Electrical Wiring Diagram) If the wiring of reactor Lis normal? Connect the reactor Laccording to Electrical Wiring Diagram correctly Re-energize and turn on the unit If the fault is eliminated? Replace the control panel AP1 50

12 3.IPM protection, desynchronizing malfunction, phase current of compressor is overcurrent (AP1 below is control board of outdoor unit) Main detection point: 51

13 Energize and switch on IPM protection occurs after the machine has run for a period of time? Use AC voltmeter to measure the voltage between terminal L and on the wiring board XT) If the voltage between terminal L and on wiring board XT is within 210VAC~250VAC? Check the supply voltage and restore it to 210VAC~250VAC Refer to the Electrical Wiring Diagram and check if the connection between AP1 and COMP is loose and if the connection order is correct. Please confirm: 1. If the indoor and outdoor heat exchangers are dirty? If they are obstructed by other objects which affect the heat exchange of indoor and outdoor unit. 2. If the indoor and outdoor fans are working normally? 3. If the environment temperature is too high, resulting in that the system pressure is too high and exceeds the permissible range? 4. If the charge volume of refrigerant is too much, resulting in that the system pressure is too high? 5. Other conditions resulting in that the system pressure becomes too high. Voltage between the two ends of celectrolytic capacitor (test3) is higher than 250V Stop the unit and disconnect the power supply. Then, check the connection of capacitor C2 according to Electrical Wiring Diagram. Remove the wires on the two ends of capacitor C2. Then, use capacitance meter to measure the capacitor C2. Verify as per the Parameters Sheet. If capacitor C2 is failed? If there is any abnormality described above? Restart theunit. Before protection occurs, use DC voltmeter to measure the voltage between the two ends of electrolytic capacitor on control panel AP1 (test3) The connection of capacitor C2 is loose. Stop the unit and disconnect the power supply. Wait 20 minutes, or use DC voltmeter to measure the voltage between the two ends of capacitor C2, until the voltage is lower than 20V Replace the capacitor C2. Then, energize and start the unit. Replace the control panel AP1 Take corrective actions according to Technical Service Manual, and then energize and start the unit. Replace the control panel AP1 If the unit can work normally? Reconnect the capacitor C2 according to Electrical Wiring Diagram. Then, Restart the unit. If the unit can work normallv? If the unit can work normally? If the unit can worknormally? If the connection between AP1 and COMP is unsecure or the connection order is wrong? Connect the control panel AP1 and compressor COMP correctly according to the Electrical Wiring Diagram. Then, energize and start the unit. If the unit can work normally? Use ohmmeter to measure the resistance between the three terminals on compressor COMP, and compare the measurements with the compressor resistance on Service Manual. Use ohmmeter to measure the resistance between the two terminals of compressor COMP and copper tube. If the resistance is normal? Resistance higher than 500MΩ? Replace the compressor COMP Replace the control panel AP1 ED 52

14 4.Diagnosis for anti-high temperature, overload protection (AP1 below is control board of outdoor unit) Main detection point: Anti-high temperature, overload protection If the outdoor ambient temperature is higher than 53 ºC? ormal protection, please use it after improve the outdoor ambient temperature After the unit deenergized for 20min If the radiating of outdoor and indoor unit is well? Improve the radiating environment of unit If the indoor and outdoor fan work well? 1. Check if fan terminal OFA is connected well 2. Test if resistance value of any two terminals is less than 1k with ohmic meter Replace control board AP1 Replace fan capacitor C1 Replace outdoor fan 53

15 5.Diagnosis for failure start up malfunction (AP1 below is control board of outdoor unit) Main detection point: Energize the unit and start it If the stop time of compressor is more than 3min? If the stop time is not enough and the high and low pressure of system is not balance, please start it after 3min If the compressor wire COMP(UVW) is well connected and connection sequence is correct Improve the connection situation of control board AP1 and compressor COMP, connect it with wiring diagram If the refrigerant charging is too much? Does the unit start up normally? Charge the refrigerant according to service manual Does the unit start up normally? Replace control board AP1 If malfunction is removed? Replace the compressor 54

16 6. Diagnosis for compressor synchronism (AP1 below is control board of outdoor unit) Main detection point: Synchronism after energize the unit and start it Synchronism occurred during operation If the stop time of compressor is more than 3min If the outdoor fan works normally? Check if the fan terminal OFA is connected well Replace fan capacitor C1 If the compressor wire COMP(UVW) is well connected, the connection sequence forwards to clockwise direction? If the radiating of unit is well? Improve the radiating of unit (clean heat exchanger and increase ventilation) Replace outdoor fan Connect wire well If the input voltage of unit is normal? Start to run until the power resume normal voltage Replace control board AP1 If the refrigerant is too much? Charge the refrigerant with service manual Remove malfunction? Replace compressor Replace control board AP1 Remove malfunction? Replace compressor 55

17 7.Diagnosis for overload and discharge malfunction (AP1 below is control board of outdoor unit) Main detection point: After the unit de-energized for 20min If the overload protector SAT is well connected? Under ambient temperature, test the resistance of overload protector with ohmic If the wiring terminal FA of electron expansion is well connected? Connect wire well with wiring diagram The resistance value of firs t 4 l ead fo ot an d th e fif th lead foot is similar, less than 100 Replace overload protector SAT Replace EKV coil of electron expansion valve Remove malfunction? Check refrigerant, if there is leakage, please refer to specification Remove malfunction? Replace control board AP1 56

18 8.PFC (correction for power factor) malfunction (outdoor unit malfunction) (AP1 below is control board of outdoor unit) Main detection point: Start Check the connection wire of reactor (L) of outdoor unit and PFC capacity If there is damaged short circuit Replace connection wire with circuit diagram If the malfunction is removed? Remove PFC capacity and test resistance of two terminals If the resistance value is 0 Capacity is short circuit and replace it Re-energize the unit and start it If the malfunction is removed? Cut the terminal of reactor, test the resistance between two terminals of reactor with ohmic meter If there is damaged short circuit Replace the reactor Reenergize the unit and start it If the malfunction is removed? Replace control board AP1 57

19 9.Communication malfunction (AP1 below is control board of outdoor unit) Main detection point: aged Start If the unit is operation normal before malfunction Check connection wire of indoor and outdoor unit with circuit diagram Check builtin wiring of indoor and outdoor unit Connection correct? Malfunction of circuit is detected with control board AP1 voltage If the wiring is damaged? Check connection wire of indoor and outdoor unit with circuit diagram If the malfunction is removed? Check communication circuit of outdoor unit If the malfunction is removed? Problem of communication circuit Replace outdoor mainboard AP11 Replace indoor board If the malfunction is removed? 58

20 10.Diagnosis process for outdoor communication circuit Start Test voltage value with Test 10 position in diagram with voltage meter umber jumping Test voltage value with Test 13 position in diagram with voltage meter umber jumping Test voltage value with Test 11 position in diagram with voltage meter Outdoor unit malfunction umber jumping Test voltage value with Test 12 position in diagram with voltage meter umber jumping The circuit of outdoor unit communication is normal 59

21 9.4 Troubleshooting for ormal Malfunction 1. Air conditioner can't be started up Wrong wire connection between or poor connection for wiring terminals 2. Poor cooling (heating) for air conditioner motor is set too low Small wind blow conditioner Add refrigerant. range Compressor can't operate Service Manual connected well. reliably correctly once improper Replace batteries for remote controller Repair or replace remote controller details details details 3. Horizontal louver can't swing Wrong wire connection, or poor connection diagram Connect wires according to wiring diagram to Stepping motor is damaged Stepping motor can't operate Repair or replace stepping motor Main board is damaged can't operate 60

22 4. ODU fan motor can't operate Wrong wire connection, or poor connection 5. Compressor can't operate Wrong wire connection, or poor connection 6. Air conditioner is leaking pipe Replace drain pipe 7. Abnormal sound and vibration conditioner coil compressor diagram diagram Connect wires according to wiring diagram to damaged fan capacitor. is bad and ODU compressor generates a lot of Connect wires according to wiring diagram to Capacity of compressor is damaged fan capacitor. Repair or replace compressor between compressor terminals and it's 0 Compressor can't operate Repair or replace compressor damping plaster between connected parts Replace magnetic coil 61