SERVICE Manual AIR CONDITIONER INDOOR UNIT OUTDOOR UNIT US12A2VC US09A2VA US07A2VA AS12A2VC AS09A2VA AS07A2VA. 1. Installation

Transcription

1 ROOM AIR CONDITIONER INDOOR UNIT ASAVC AS09AVA AS07AVA OUTDOOR UNIT USAVC US09AVA US07AVA SERVICE Manual AIR CONDITIONER CONTENTS. Installation. Disassembly and Reassembly. Troubleshooting 4. Exploded Views and Parts List 5. Refrigerating Cycle Block Diagrams 6. Wiring Diagrams 7. Schematic Diagrams E DB A()

2 . Installation Refrigerant Refill Procedure Refill an airconditioner with refrigerant when refrigerant has been leaked at installing or using. Purge air(for new installation only).. Turn the way valve clockwise to close, connect the pressure gauge(low pressure side) to the service valve, and open the way valve again. Suspension hook. Connect the tank to refill with Refrigerant 4. Set the unit to cool operation mode. 5. Check the pressure indicated by the pressure gauge(low pressure side). * Standard pressure is should be 64~78kg/cm in a reqular, high operation mode. Compound gauge For mounting other and of hose when not in use High pressure gauge Hand wheel Finger tight fittings Connected to high pressure side Charging line 6. Open the refrigerant tank and fill with refrigerant until the rated pressure is reached. * It is recommended not to pour the refrigerant in too quickly, but gradually while operating a pressure valve. R 7. Stop operation of the air conditioner. 8. Close the way valve, disconnect the pressure gauge, and open the way valve again. 9. Close the cap of each valve.

3 Pump down Procedure Pump down' shall be carried out when an evaporator is replaced or when the unit is relocated in another area.. Remove the caps from the way valve and the way valve. Turn the way valve clockwise to close and connect a pressure gauge(low pressure side) to the service valve, and open the way valve again.. Set the unit to cool operation mode (Check if the compressor is operating.) Way Valve 4. Turn the way valve clockwise to close. 5 When the pressure gauge indicates "0" turn the way valve clockwise to close. Way Valve 6. Stop operation of the air conditioner. 7. Close the cap of each valve. 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 cable.. 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 locatioon. 8. Remove the mounting plate for the indoor unit and move it to a new location.

4 . Disassembly and Reassembly Stop operation of the air conditioner and remove the power cable before repairing the unit. Indoor Unit No Parts Procedure Remark Front Grille ) Stop the air conditioner operation and block the main power. ) Seperate tape of front panel upper. ) 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) 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.

5 No Parts Procedure Remark Ass y Tray Drain. ) Do, above. Separate the drain hose from the extension drain hose. ) Take the display PCB out. (Center of indoor unit) ) Loosen three fixing screws of left and right 4) Pull tray drain out from the back body. Electrical Parts (Main PCB) ) Do,, above ) Take all the connector of PCB upper side out. ) 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 Heat Exchanger ) Do and,, above ) Loosen two fixing earth screws of right side. ) Separate the connection pipe. 4) Separate the bush body at the upper side and holder at the rearside. 5) Loosen the two fixing screws of left side. 6) Lifting the heat exchanger up a little to push the up side for separation from the indoor unit. 4

6 No Parts Procedure Remark 5 Fan Motor and Cross Fan ) Do 4, above. ) Loosen the fixing three screws and separate the motor holder. ) Loosen the fixing screw of fan motor. (By use of M wrench) 4) Separate the fan motor from the fan. 5) Separate the fan from the left holder bearing. 5

7 Outdoor Unit No Parts Procedure Remark Common Work ) Loosen the fixing screw and separate the cover Eparts. ) Separate the connection wire from the terminal block. ) Loosen three fixing screws and separate the upper cabinet. 4) Loosen the two fixing screws of Ass'y Epart. 5) Loosen seven fixing screws and separate the side cabinet. Fan and Motor ) Do, above. ) Loosen two fixing screw, of the front cabinet. ) Push the brackets of the outer cover to separate the protection mesh from the rear side of front cabinet. 6

8 No Parts Procedure Remark 4) Remove the nut flange (Turn to the right to remove, as it is a left hand screw) 5) Separate the fan. 6) Loosen four fixing screws to separate the motor. Heat Exchanger ) Do, above. ) Loosen three fixing screws of left and right side. ) Disassemble the inlet and outlet pipe by welding. 4) Separate the heat exchanger. 4 Compressor ) Do, above. ) Open the terminal cover of compressor and unscrew the connection terminal. ) Disassemble the inlet and outlet pipe of compressor by welding. 4) Disassemble the inlet and outlet pipe of condenser by welding 5) Loosen the three bolts of the lower part. 6) separate the compressor. 7

9 . Troubleshooting Items to be checked first ) Is the voltage of the power correct? The input voltage shall be the rating vlotage ±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. ) 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. Fan speed setting is not allowed in AUTO or DR mode. 4 Compressor stops operation intermittently in DR 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 DR 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 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 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 DR mode. Fan speed is 4 steps is selected automatically in AUTO mode. Compressor operation is controlled automatically in DR 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) OPERATING and TIMER LED blinking (Hz) 4 FAN LEA 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 spead is Below 8Orpm) 8

10 Fault Diagnosis by Symptom No Power(completely dead)initial diagnosis ) Checklist : () Is input voltage normal? (the rating voltage ±0% range.) () Is AC power linked correctly? () Are connections between primary side, secondary side of the power transformer and PCB good. (4) Is output voltage of DC regulator IC KA78 (IC0) normal? (VDC.5VDC) (5) Is output voltage of DC regulator IC KA7805 (IC0) normal? (4.5VDC5.5VDC) ) Troubleshooting procedure Remove power cord and plug in again in approx. 5 seconds Replace PCB display Is DC voltage of PCB display normal? Is the rating voltage ±0% range applied to the primary side of the power transformer? Check linkage between power cord and terminal tap Check fuse Is 4~8VAC appear in the secondary side of the power transformer? Replace power transformer Replace resonator (X50) Is operation normal? OK Is operation lamp blinking? 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? Are voltages of #6 (compressor), #60(4 way valve) and #6 (outdoor fan) of the micom normal? 5VDC Is voltage of #6 (indoor fan) of the micom normal? DC5V 0ms Is voltage at # 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? Replace micom 0ms Are voltage at #0 and # of the micom normal? 00ns Normal Refer to remote control unit fault diagnosis OK Replace PCB module. Are voltages at R7(Compressor) R7(4way valve) and S7(outdoor fan) normal? DCV Is voltage at SS7(indoor fan) Check connections compressor 4way valve, outdoor fan and indoor fan. Is output voltage of ICO normal? Check PCB pattern. Replace main PCB. Is voltage output terminal of D0~D05(IN4007) normal? Replace R7, R7, R7 and SS7 Replace ICO Replace IN4007 9

11 When the Indoor Unit Fan Does Not Operate. (Initial Diagnosis) ) Checklist : () Is the indoor unit fan motor properly connected with the connector (CN7)? () Is the AC voltage correct? () Is HALL IC in indoor fan motor properly connected with the connector (CN4)? (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 power parts Refer tp page 5. 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 CN7 Test rod location Condition Normal voltage Fan operate AC 80V MFC is out of order Replace MFC Fan motor is out of order. Fan motor should be replaced. 0

12 When the Outdoor Unit Does Not Operate. (Initial Diagnosis) ) Checklist : () Is input voltage normal?(the rating voltage ±0% range) () Is the set temperature of the remote control higher than room temperature in COOL mode? () Is the set temperature of the remote control lower than room temperature in HEAT mode? (4) Is the POWER IN connector (terminaltab) linked correctly? (5) Is the outdoor unit properly connected with the TERMINAL BLOCK connector(5p)? ) Troubleshooting procedure 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 5. Room temperature sensor is out of order PCB should be checked. Is the power relay R7 operated by adjusting the room temperature? Microcomputer is out of order. Test rod location Normal + Condition Voltage IC Pin No.6 GND R7 ON DC 4.8V PCB should be checked. Is the rating voltage ±0% range applied relay between Terminal Tap(TB7) and R 7 terminal No. Power relay is out of order Power relay should be replaced. Outdoor unit is out of order. Is the room sensor normal register? 0 C 0 C 0 C 7.96k Ω.09k Ω 8.k Ω

13 4 When the UP/DOWN Louver Motor Does Not Operate. (Initial Diagnosis) ) Checklist : () Is input voltage normal? (the rating voltage ±0% range) () 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? Voltage at pin ##6 of micom (ICO4) change?(squarewave) Volatge at pin #0, #, #, # of IC05 (KID6500) change?(squarewave) UP/DOWN louver motor is faulty. N N N Check as in the procedure "No Power parts". Refer to page 8. Normal Micom (IC04) is faulty. Driver IC05 (KID6500) is faulty.

14 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? sound heard from the indoor unit when ON/OFF button on the remote control unit pushed? N Check as in the procedure Power parts. Refer to page 5. Normal N Voltage of battery less than.5v (Remote Control Unit)? N LCD display status of REMOCON normal? N Replace battery. LCD is faulty. Transmission display lamp ( ) blinking when ON/OFF button on the remote control unit pushed? N Replace button. Voltage at PIN #0 of Remocon Micom change? Voltage at collecter of Q60 or Q60 change? N N Micom is faulty. Q60(C475) or Q60(C6) is faulty. IR LED(CLL5EU) is faulty. Voltage at pin #6 of micom (IC04) change (INDOOR UNIT)? Micom (IC04) is faulty. N Receiver module is faulty.

15 4. Exploded Views and Parts List 4 Indoor Unit

16 Parts List No. CODE Q T Description Specification Remark ASAVC AS09AVA AS07AVA DB64040A GRILLE AIR INLET ABS DB647007A PANEL CENTER DISPLA PC DB60A GUARD AIR FILTER PP * DB74009A FILTER CLEANER/CARBON () () () 4 DB6047B COVER TERMINAL HIPS 5 DB970075E FRONT PANEL 6 DB90560C PCB DISPLA 6 DB609A CASE CENTER PCB PC 6 DB60494A COVERDISPLA PC 7 DB940088B TRA DRAIN 7 DB9508A STEP MOTOR U/D DCV.600GR 7 DB6605A BLADEH HIPS 8 DB754009B EVAP DB B 9 DB670058C SPACER EVAP PVC 0 DB64094A HOLDER MOTOR DB0078H MOTOR FAN IN AMPFS040WTVB DB056A AMPFS07ZREA DB9404A CFFAN Ø mm DB944007A BEARING 4 PDSAV0 PDQAV04 MAIN PCB PDQAV0 5 DB0008D THERMISTOR 6 DB A TERMINAL BLOCK 7 DB605A CASE CONTROL ABS 8 DB66009A BODBUSH HIPS 9 DB94000D BACK BOD 0 DB64047A HOLDER PIPE HIPS DB70068A PLATE HANGER SGCCM DB9005L ASS REMOCON ARC06 * : Option 5

17 4 Outdoor Unit

18 Parts List No CODE DB60004A DB600004A DB675006A DB0058C DB0058G DB90000X DB90000 DB94000X DB94000 DB B DB750560B DB90094A DB90094C DB90094D DB A DB9058A DB47000G DB470066E DB47000V DB676000A DB750566A DB750558A DB75057A DB75056A DB750567A 48A5IVEG 44H09HWE6 44A07HWEB DB70004A DB60008A DB6000A DB6065B DB60008A DB96009A DB9600A DB96000A DB664B DB960579A DB96059A DB960694B DB9605C DB96057B DB C DB96005B DB75056A DB90004H DB6044C DB960086V DB900006A DB60000A DB60000B DB60000C Q T Description Specification Remark USAVC US09AVA US07AVA GUARD FAN NUT FLANGE PROPELLERFAN MOTOR FAN OUT FRAME PARTITION CABINET UPPER INSU CABI UPPER E PARTS. CAPACITOR TERMINAL BLOCK COMP & MOTOR WIRE O.L.P. O.L.P SPRING CLOTH COMP BOTTOM CLOTH COMP SIDE CLOTH COMP UPPER COMPRESSOR GROMMETISOLATOR NUTWASHER GASKET COVER TERMINAL NUTFLANGE TUBEDISCHARGE TUBESUCTION ASSCAPI TUBE ASSCOND INSUL CABISIDE ASSCABI SIDE ASSCOVER E, PARTS ASSCABLE BOX CONNECTORCABLE FLARENUT ABS C SM0C M6 NTR AS+G/F Ø405 AMASS00WTVA AMASS00ZREA SECCP FOAMPE+FOAMPU.5/5µF 450VAC 4/45µF 70VAC 4/5µF 70VAC 5P MRA00900 MRA09007 MRA STS04 FELT RUB+FELT FELT EVA+FOPU FELT 48A5IVE5 44B09HWE6 44A07HWE EPDM M8 EPDM TL M5. SM0C ASS ASS ASS ASS ASS FOAMPE+FOAM PU SECCP ASS AWG # 4 /4 /8 / 7

19 4 PCB Box 4 4 Parts List No CODE Description Specification Q T Remark ASAVC AS09AVA AS07AVA DB605A CASECONTROL DB906A Ass'y main PCB DB9064A Ass'y main PCB DB906A Ass'y main PCB DE6054A Transpower AC0V DC7V 00mA DE6066A TransPower AC5V DC7V 00mA Cfilm CFS 99N 450VAC 55K Cfilm 00VAC 4µF Powerrelay DIU DCV 4 DE007A Fuse T, 50V.5A Fuse T, 5V,.5A DB90560A Ass'ydisplay and Module PCB EDGE 4 DB0008D ThermistorEVAP 0AT 40/40 8

20 5. Refrigerating Cycle Block Diagram INDOOR UNIT OUTDOOR UNIT Capillary tube T way valve Liquid side Heat exchanger (Evaporator) Cross fan Heat exchanger (Condenser) Propeller fan T Gas side way valve Compressor Cooling Gas leak check point Refrigerating cycle temperature and pressure Operating Condition STD Pressure Piping Temp( F) Use Temp. Condition( F) (psi) Indoor Outdoor T T Way Valve DB WB DB WB Standard 64~78 50~54 50~ Cooling Max over load 6~64 6~ Low temp 4~9 4~

21 6. Wiring Diagrams 6 Indoor Unit ASAVC AS09AVA, AS07AVA 0

22 6 Outdoor Unit

23 7. Schematic Diagrams 7 Indoor Unit ASAVC

24 AS09AVA/AS07AVA 4 5

25 ELECTRONICS