Multi Zone Air Conditioner
SVC MANUAL(General)
CAUTION
Before Servicing the unit, read the safety
precautions in General SVC manual.
Only for authorized service personnel.
960-914-07
Air Conditioner Service Manual
CONTENTS
Part 1 General Information.........................................................................................................2
1. Safety Precautions........................................................................................................3
2. Model Line Up................................................................................................................6
Part 2 Functions & Controls ......................................................................................................9
1. List of Functions & Controls......................................................................................10
2. Air Flow .......................................................................................................................12
3. Installation Functions .................................................................................................14
4. Reliability .....................................................................................................................16
5. Convenience Functions & Controls .........................................................................17
Part 3 Control logic....................................................................................................................22
1. Compressor .................................................................................................................23
2. Step(frequency) control..............................................................................................24
3. Reversing valve operaton ..........................................................................................25
4. Discharge pipe control ...............................................................................................26
5. Input Current Control..................................................................................................27
6. Outdoor Fan Control...................................................................................................28
7. Defrost Control............................................................................................................29
8. EEV Control .................................................................................................................30
9. Oil restoration operation ............................................................................................32
10. Compressor warm-up control logic ........................................................................32
11. Heat sink control .......................................................................................................33
Part 4 Test Run ..........................................................................................................................34
1. Check before Test Run ..............................................................................................35
2. Test Run Flow chart ...................................................................................................36
3. Test Runing..................................................................................................................37
Part 5 Trouble Shooting Guide ...............................................................................................38
1. Self-diagnosis Function ......................................................................................39
2. Pump Down ..........................................................................................................41
3. Evacuation............................................................................................................42
4. Gas Charging .......................................................................................................43
5. Cycle Part .............................................................................................................44
6. Electronic Parts....................................................................................................45
Only for training and service purposes
-1-
Part 1 General Information
1. Safety Precautions ............................................................................................................3
2. Model Line Up .....................................................................................................................6
Only for training and service purposes
-2-
Part 1 General Information
1. Safety Precautions
To prevent injury to the user or other people and property damage, the following instructions must be followed.
n Incorrect operation due to ignoring instruction will cause harm or damage. The seriousness is classified by the following indications.
This symbol indicates the possibility of death or serious injury.
This symbol indicates the possibility of injury or damage to properties only.
n Meanings of symbols used in this manual are as shown below.
Be sure not to do.
Be sure to follow the instruction.
Dangerous Voltage
1.1 Safety Precautions in Repair
Be sure to disconnect all remote electric power supplies before servicing. Internal
components and circuit boards are at main potential when the equipment is connected to the power cables. This voltage is extremely dangerous and may cause
death or severe injury if come in contact with it.
Do not touch the discharging refrigerant gas during the repair work.
The refrigerant gas can cause frostbite.
Release the refrigerant gas completely at a well-ventilated place first.
Otherwise, when the pipe is disconnected, refrigerant gas or refrigerating
machine oil discharges and it can cause injury.
When the refrigerant gas leaks during work, execute ventilation. If the refrigerant
gas touches to a fire, poisonous gas generates. A case of leakage of the refrigerant and the closed room full with gas is dangerous because a shortage of oxygen
occurs. Be sure to execute ventilation.
When removing the front panel or cabinet, execute short-circuit and discharge
between high voltage capacitor terminals. If discharge is not executed, an electric
shock is caused by high voltage resulted in a death or injury.
Be sure to provide the grounding when repairing the equipment in a humid or
wet place, to avoid electrical shocks.
Only for training and service purposes
-3-
Part 1 General Information
Do not use a defective or underrated circuit breaker. Use the correctly rated
breaker and fuse. Otherwise there is a risk of fire or electric shock.
Install the panel and the cover of control box securely. Otherwise there is risk of
fire or electric shock due to dust, water etc.
Indoor/outdoor wiring connections must be secured tightly and the cable should
be routed properly so that there is no force pulling the cable from the connection
terminals. Improper or loose connections can cause heat generation or fire.
Do not touch, operate, or repaire the product with wet hands. Hoding the plug by
hand when taking out. Otherwise there is risk of electric shock or fire.
Use a vacuum pump or Inert (nitrogen) gas when doing leakage test or air
purge. Do not compress air or Oxygen and Do not use Flammable gases.
Otherwise, it may cause fire or explosion.
- There is the risk of death, injury, fire or explosion.
Do not turn on the breaker or power under condition that front panel, cabinet, top
cover, control box cover are removed or opened.
Otherwise, it may cause fire, electric shock, explosion or death.
Be sure to earth the air conditioner with an earthing conductor connected to the
earthing terminal.
Conduct repair works after checking that the refrigerating cycle section has
cooled down sufficiently. Otherwise, working on the unit, the hot refrigerating
cycle section can cause burns.
Do not tilt the unit when removing panels. Otherwise, the water inside the unit
can spill and wet floor.
Do not use the welder in a well-ventilated place. Using the welder in an enclosed
room can cause oxygen deficiency.
Be sure to turn off power switch before connect or disconnect connector, or parts
damage may be occurred.
Only for training and service purposes
-4-
Part 1 General Information
1.2 Inspections after Repair
Check to see if the terminal block is not dirty or loose. If terminal block is dust or
loose it can cause an electrical shock or fire.
Do not use a joined power cable or extension cable, or share the same power
outlet with other electrical appliances. otherwise, it can cause an electrical shock,
excessive heat generation or fire.
Do not insert hands or other objects through the air inlet or outlet while the product is operating. There are sharp and moving parts that could cause personal
injury.
Do not block the inlet or outlet of air flow. It may cause product failure
Check to see if the parts are mounted correctly and wires are connected.
Improper installation and connections can cause an electric shock or an injury.
Check the installation platform or frame has corroded. Corroded installation platform or frame can cause the unit to fall, resulting in injury.
Be sure to check the earth wire is correctly connected.
After the work has finished, be sure to do an insulation tset to check the resistance is 2[Mohm] or more between the charge section and the non-charge metal
section (Earth position). If the resistance value is low, a disaster such as a leak or
electric shock is caused at user’s side.
Check the drainage of the indoor unit after the repair. If drainage is faulty the
water to enter the room and wet floor.
Only for training and service purposes
-5-
Part 1 General Information
2. Model Line Up
2.1 Indoor units
Category
Chassis
2.6 (9)
TR
Ceiling
cassette
Model names
Capacity, kW(kBtu/h Class)
3.5 (12)
5.3 (18)
MC12Y3JM
4-way
TQ
Low
Ceiling
static
concealed pressure
duct
(Slim)
Only for training and service purposes
L1
MC18Y3JM
MD09Y3JM
L2
MD12Y3JMA
-6-
MD18Y3JMA
Part 1 General Information
2.2 Outdoor units
Multiple Piping Type
Model Name
No. of connectable indoor units (Min. ~ Max.)
Total capacity index of connectable indoor units
Power supply
MR24DY3JMA
MR36TQY3JMA
2~3
2~4
33
48
208/230V, 1Ø, 60Hz
208/230V, 1Ø, 60Hz
Chassis
Branch Distribution type
Model Name
MR48DEY3JM
No. of connectable indoor units (Min. ~ Max.)
2~8
Total capacity index of connectable indoor units
65
Power supply
208/230V, 1Ø, 60Hz
Chassis
Only for training and service purposes
-7-
Part 1 General Information
2.3 BD(Branch distributor) units
No. of connectable indoor units(Min. ~ Max.)
Model name
Connectable indoor unit capacity kBtu/h
1~4
PMBD3640
9 ~ 24
BD unit
2.4 Branches
Specifications
Branch No. of BD Accessory Applicable
Type
Units Model Name Model
YBranch
Gas
To ODU
Ø 3/4
2
Liquid
To BD unit Ø 3/4
To ODU
Ø 3/8
To BD unit Ø 3/8
PMBL5620 MULTI F MAX
Ø 3/4
Only for training and service purposes
-8-
Ø 3/8
Part 2 Functions & Controls
1. List of Functions & Controls ........................................................................................10
1.1 List of Function (Indoor) ..............................................................................................10
1.2 List of Function (Outdoor)............................................................................................11
2. Air flow ............................................................................................................................12
2.1 Auto swing (left & right) ...............................................................................................12
2.2 Auto swing (up & down) ..............................................................................................12
2.3 Chaos swing (up/down)...............................................................................................12
2.4 Air flow step.................................................................................................................13
2.5 Chaos wind (auto wind)...............................................................................................13
2.6 SURGE Mode Operation.............................................................................................13
2.7 Swirl wind Swing .........................................................................................................13
3. Installation Functions ....................................................................................................14
3.1 How to Set E.S.P. on the remote controller?...............................................................14
3.2 High Ceiling operation.................................................................................................15
4. Reliability ........................................................................................................................16
4.1 Hot start.......................................................................................................................16
4.2 Self-diagnosis Function...............................................................................................16
4.3 Soft dry operation........................................................................................................16
5. Convenience Functions & Controls .............................................................................17
5.1 Auto cleaning operation ..............................................................................................17
5.2 Auto Operation (Fuzzy Operation) ..............................................................................18
5.3 Auto restart Opeartion.................................................................................................19
5.4 Child Lock Function.....................................................................................................20
5.5 Forced operation .........................................................................................................20
5.6 Sleep Timer Operation ................................................................................................21
5.7 Timer(On/Off) ..............................................................................................................21
5.8 Defrost Control (Heating) ............................................................................................21
Only for training and service purposes
-9-
Part 2 Functions & Controls
1. List of Functions & Controls
1.1 List of Function (Indoor)
Category
MC12Y3JM
MC18Y3JM
Functions
Air supply outlet
Airflow direction control (left & right)
Airflow direction control (up & down)
Auto swing (left & right)
Air flow
Auto swing (up & down)
Airflow steps (fan/cool/heat)
Chaos wind(auto wind)
Surge (cool/heat)
Swirl wind
Deodorizing filter
Plasma air purifier
Air purifying
Allergy Safe filter
Prefilter(washable / anti-fungus)
Drain pump
E.S.P. control*
Installation
Electric heater
High ceiling operation
Hot start
Reliability
Self diagnosis
Soft dry operation
Auto changeover
Auto cleaning
Auto operation(artificial intelligence)
Auto Restart
Child lock*
Convenience
Forced operation
Group control*
Sleep mode
Timer(on/off)
Timer(weekly)*
Two thermistor control*
Wired remote controller
Deluxe wired remote controller
Individual conSimple wired remote controller
troller
Simple Wired remote controller(for hotel use)
Wireless remote controller
Dry contact
Network
Solution
PI 485(for Indoor Unit)
Zone controller
Special function
CTI(Communication transfer interface)
kit
Electronic thermostat
Remote temperature sensor
Group control wire
Others
Telecom shelter controller
Connector for water level sensor
Only for training and service purposes
4
X
Auto
X
O
4/5/4
O
O/X
O
X
X
X
O
O
X
X
O
O
O
O
X
X
O
O
O
O
O
O
O
O
O
DWC1
X
X
X
O
O
X
X
X
X
X
X
X
X
- 10 -
MD09Y3JM
MD12Y3JMA
MD18Y3JMA
1
X
X
X
X
3/3/3
X
X/X
X
X
X
X
O
O
O
X
X
O
O
O
X
X
O
O
O
X
O
O
O
O
O
DWC1
X
X
X
O
O
X
X
X
X
X
X
X
X
Part 2 Functions & Controls
1.2 List of Function (Outdoor)
Category
Functions
Remark
Defrost / Deicing
O
High pressure switch
X
Low pressure switch
X
Phase protection
X
Restart delay (3-minutes)
O
Self diagnosis
O
Soft start
O
Test function
X
Night Silent Operation
O
Network solution(LGAP)
O
Reliability
Convenience
Network function
[Note]
○ : Applied, × : Not applied
* Option : Model name & price are different according to options, and assembled in factory with main unit.
Accessory model name : Installed at field, ordered and purchased separately by the corresponding model name, supplied with separate package.
Only for training and service purposes
- 11 -
Part 2 Functions & Controls
2. Air flow
2.1 Auto swing (left & right)
• By the horizontal airflow direction control key input, the left/right louver automatically operates with the auto swing or it
is fixed to the desired direction.
Left
Right
110° ~ 120°
2.2 Auto swing (up & down)
• By the auto swing key input, the upper/lower vane automatically operates with the auto swing or it is fixed to the
desired direction.
Close
110° ~ 120°
Open
2.3 Chaos swing (up/down)
• By the Chaos swing key input, the upper/lower vane automatically operates with the chaos swing or it is fixed to the
desired direction.
CLOSED
110~120°
Mode9
Mode8
Mode7
Mode6
Mode5
Mode4
Mode3
7~8°
Mode2
OPEN
NOTE: Some Models are different by swing width and swing pattern.
Only for training and service purposes
- 12 -
Part 2 Functions & Controls
2.4 Air flow step
• Indoor fan motor control have 6 steps.
• Air volume is controlled "SH", "H", "Med", Low" by remote controller.
• "LL" step is selected automatically in Hot start operation.
Step
Discription
LL
Very low, In heating mode
L
M
H
Low
Med
High
SH
Auto
Super high
Chaos wind
2.5 Chaos wind (auto wind)
• When "Auto" step selected and then operated, the high, medium, or low speed of the airflow mode is operated for
2~15 sec. randomly by the Chaos Simulation
2.6 SURGE Mode Operation
• While in heating mode or Fuzzy operation, the Jet Cool key cannot be input.
When it is input while in the other mode operation (cooling, dehumidification, ventilation), the Jet Cool mode is operated.
• In the Jet Cool mode, the indoor fan is operated at super-high speed for 30 min. at cooling mode operation.
• In the Jet Cool mode operation, the room temperature is controlled to the setting temperature, 64.4℉.
• When the sleep timer mode is input while in the Jet Cool mode operation, the Jet Cool mode has the priority.
• When the Jet Cool key is input, the upper/lower vanes are reset to those of the initial cooling mode and then operated
in order that the air outflow could reach further.
2.7 Swirl wind Swing
Vane 2
• It is the function for comfort cooling/heating operation.
• The diagonal two louvers are opened the more larger
than the other louvers. After one minute, it is opposite.
Vane 1
Vane 3
Vane 4
• Comparison of Air Flow Types
4-Open (conventional)
Only for training and service purposes
Swirl Swing (New)
- 13 -
Part 2 Functions & Controls
3. Installation Functions
3.1 How to Set E.S.P. on the remote controller?
This is the function that decides the strength of the wind for each wind level and because this function is to make the installation easier.
• If you set ESP incorrectly, the air conditioner may malfunction.
• This setting must be carried out by a certificated-technician.
1
OPER
When pressing the
button and MODE
button simultaneously for more than 3
seconds, the system will be entered into the
installer setting mode.
* E.S.P code value : 03
the desired air flow rate with
2 Select
the
button. Whenever pressing
FAN
SPEED
FAN
the SPEED
button, [SLo→Lo→Med→Hi→Po] will
be indicated.
FAN
SPEED
the desired air flow rate value with
3 Select
the temperature up(s), down(t) button.
TEMP
* E.S.P value range : 0~255
- E.S.P value will be indicated at the upper
right section of the display window.
OPER
MODE
pressing the
button, currently
4 When
established E.S.P value will be set up.
5
OPER
When pressing the
button and MODE
button
simultaneously for more than 3 seconds after the
setting has been completed, the setting mode will
be released.
- If there isn’t any button input for more than
25 seconds, the installer setting mode will
also be released.
• Precaution shall be taken not to alter the E.S.P value corresponded to each air flow section.
• E.S.P value can be varied according to the products.
• In the case of going to the next air flow rate stage by pressing the fan-speed button during the setup of the E.S.P value,
the E.S.P value of previous air flow rate will be maintained by remembering the E.S.P value prior to the shift.
Only for training and service purposes
- 14 -
Part 2 Functions & Controls
3.2 High Ceiling operation
Function to Control the Air Volume by Ceiling Height Control of the air intensity has been made possible by employing a
height-control algorithm for the interior fan.
According to the height of the installation, it provides variability of indoor fan motor rpm. If the height of installation is low
then you can adjust low rpm of indoor fan motor. On the other hand if the height of the installation is high you can adjust
high rpm of indoor fan motor. Selection of speed can be done by slide switch at the back of the LCD wired remote.
installation on the
higher ceiling
(ft)
Installation on the
8.86 normal-height ceiling
(ft)
10.50
9.84
7.87
6.56
6.56
3.28
3.28
(ft) 13.12 9.84
Only for training and service purposes
6.56
3.28
0
- 15 -
3.28
6.56
(ft)
9.84 13.12
Part 2 Functions & Controls
4. Reliability
4.1 Hot start
• When heating is started, the indoor fan is stopped or very slow to prevent the cold air carry out
• When the temp. of heat exchanger reach 86℉(model by model), indoor fan is started.
4.2 Self-diagnosis Function
• The air conditioner installed can self-diagnosed its error status and then transmits the result to the central control.
Therefore, a rapid countermeasure against failure of the air conditioner allows easy management and increases the
usage life of air conditioner.
• Refer to trouble shooting guide.
4.3 Soft dry operation
• When the dehumidification operation input by the remote control is received, the intake air temperature is detected and
the setting temp is automatically set according to the intake air temperature.
Intake air Temp.
78°F ≤ intake air temp.
76°F ≤ intake air temp.< 78°F
72°F ≤ intake air temp. < 76°F
64°F ≤ intake air temp. < 72°F
intake air temp. < 64°F
Setting Temp.
77°F
intake air temp. -2°F(
intake air temp. 1°F
intake air temp.
64°F
• While compressor off, the indoor fan repeats low airflow speed and stop.
• While the intake air temp is between compressor on temp. and compressor off temp., 10-min dehumidification operation and 4-min compressor off repeat.
Compressor ON Temp. ‘ Setting Temp+1°F
Compressor OFF Temp. ‘ Setting Temp-1°F
• In 10-min dehumidification operation, the indoor fan operates with the low airflow speed.
Only for training and service purposes
- 16 -
Part 2 Functions & Controls
5. Convenience Functions & Controls
5.1 Auto cleaning operation
• Function used to perform Self Cleaning to prevent the Unit from Fungus and bad odor.
• Used after the Cooling Operation before turning the unit off, clean the Evaporator and keep it dry for the next operation.
• The function is easy to operate as it is accessed through the Remote controller.
Unit
Operation
(Heat Pump)
ON
OFF
ON
Indoor
Fan
OFF
Setting step
L Low
OFF
ON
Comp.
OFF
Setting step
Unit
Operation
13~14 minutes
1 minute
2~3 minutes
(Cooling Only)
ON
OFF
ON
Indoor
Fan
OFF
Setting step
L Low
ON
Comp.
OFF
Setting step
Only for training and service purposes
- 17 -
OFF
Part 2 Functions & Controls
5.2 Auto Operation (Fuzzy Operation)
• When any of operation mode is not selected like the moment of the power on or when 3 hrs has passed since the
operation off, the operation mode is selected.
• When determining the operation mode, the compressor, the outdoor fan, and the 4 way valve are off and only the
indoor fan is operated for 15 seconds. Then an operation mode is selected according to the intake air temp at that
moment as follows.
76°F ≤ Inatake Air Temp
‘ Fuzzy Operation for Cooling
70°F ≤ Inatake Air Temp < 76°F ‘ Fuzzy Operation for Dehumidification
Inatake Air Temp < 70°F
‘ Fuzzy Operation for Heating
• If any of the operation modes among cooling / dehumidification / heating mode operations is carried out for 10 sec or
longer before Fuzzy operation, the mode before Fuzzy operation is operated.
5.2.1 Fuzzy Operation for Cooling
• According to the setting temperature selected by Fuzzy rule, when the intake air temp is 1℉ or more below the setting
temp, the compressor is turned off. When 1℉ or more above the setting temp, the compressor is turned on.
Compressor ON Temp ‘ Setting Temp + 1°F
Compressor OFF Temp ‘ Setting Temp + 1°F
• At the beginning of Fuzzy mode operation, the setting temperature is automatically selected according to the intake air
temp at that time.
78°F ≤ Intake Air Temp
‘ 76°F
76°F≤ Intake Air Temp<78°F ‘ Intake Air Temp + 2°F
72°F≤ Intake Air Temp<76°F ‘ Intake Air Temp + 1°F
64°F≤ Intake Air Temp<72°F ‘ Intake Air Temp
Intake Air Temp<64°F
‘ 64°F
• When the Fuzzy key (Temperature Control key) is input after the initial setting temperature is selected, the Fuzzy key
value and the intake air temperature at that time are compared to select the setting temperature automatically according to the Fuzzy rule.
• While in Fuzzy operation, the airflow speed of the indoor fan is automatically selected according to the temperature.
5.2.2 Fuzzy Operation for Dehumidification
• According to the setting temperature selected by Fuzzy rule, when the intake air temp is 1°F or more below the setting
temp, the compressor is turned off. When 1°F or more above the setting temp, the compressor is turned on.
Compressor ON Temp ‘ Setting Temp + 1°F
Compressor OFF Temp ‘ Setting Temp+1°F
• At the beginning of Fuzzy mode operation, the setting temperature is automatically selected according to the intake air
temp at that time.
78°F ≤ Intake Air Temp
‘ 76°F
76° ≤ Intake Air Temp<78°F
‘ Intake Air Temp+2°F
72°F ≤ Intake Air Temp<76°F ‘ Intake Air Temp+1°F
64°F ≤ Intake Air Temp<72°F ‘ Intake Air Temp
Intake Air Temp<64°F
‘ 64°F
• When the Fuzzy key (Temperature Control key) is input after the initial setting temperature is selected, the Fuzzy key
value and the intake air temperature at that time are compared to select the setting temperature automatically according to the Fuzzy rule.
• While in Fuzzy operation, the airflow speed of the indoor fan repeats the low airflow speed or pause as in dehumidification operation.
Only for training and service purposes
- 18 -
Part 2 Functions & Controls
5.2.3 Fuzzy Operation for Heating
• According to the setting temperature selected by Fuzzy rule, when the intake air temp is 3.5°F or more above the setting temp, the compressor is turned off. When below the setting temp, the compressor is turned on.
Compressor ON Temp ‘ Setting Temp
Compressor OFF Temp ‘ Setting Temp + 3.5°F
• At the beginning of Fuzzy mode operation, the setting temperature is automatically selected according to the intake air
temp at that time.
68°F≤Intake Air Temp ‘ Intake Air Temp + 1°F
Intake Air Temp<68°F ‘ 68°F
• When the Fuzzy key (Temperature Control key) is input after the initial setting temperature is selected, the Fuzzy key
value and the intake air temperature at that time are compared to select the setting temperature automatically according to the Fuzzy rule.
• While in Fuzzy operation, the airflow speed of the indoor fan is set to the high or the medium according to the intake air
temperature and the setting temperature.
Notes: The Temp. of Comp. Turn ON and OFF is different in heating mode and fuzzy operation for heating. Please,
refer page 11
5.3 Auto restart Operation
• Whenever there is electricity failure to the unit, and after resumption of the power, unit will start in the same mode prior
to the power failure. Memorized condition are on / off condition, operating mode (cooling/ heating), set temperature and
fan speed. The unit will memorize the above conditions and start with same memorized condition.
Only for training and service purposes
- 19 -
Part 2 Functions & Controls
5.4 Child Lock Function
It is the function to use preventing children or others from careless using.
the operation, when pressing the
1 During
button and
button for approx. 3 seconds,
FAN
SPEED
the ‘Child Lock’ Function can be used.
- At the time of initial setting of the ‘Child Lock’,
the ‘CL’ Will be indicated approx. 3 seconds
at the temperature Display section before
resuming to the previous mode.
After the setting of the ‘CL’, if another button
is setup, the button can not be recognized as
the ‘CL’ is indicated at the temperature
display section for approx. 3 seconds.
FAN
SPEED
the ‘CL’ function is wanted to be used
2 Ifunder
the operation standby state, press the
TEMP
OPER
MODE
FAN
SPEED
button and
Button for approx.
3 seconds under the standby mode state and
the system will be the ‘CL’ state.
releasing method, when pressing
3 Asthefor theButton
and
button for approx. 3
FAN
SPEED
seconds, the ‘CL’ function can be released.
5.5 Forced operation
• To operate the appliance by force in case when the remote control is lost, the forced operation selection switch is on
the main unit of the appliance, and operate the appliance in the standard conditions.
• The operating condition is set according to the outdoor temp. and intake air temperature as follows.
Indoor temp.
Operating Mode
Setting temp.
over 76°F
Cooling
72°F
70~76°F
Healthy Dehumidification
72°F
below 70°F
Heating
72°F
• The unit select the last operation mode in 3 hours.
• Operating procedures when the remote control can't be used is as follows :
- The operation will be started if the ON/OFF button is pressed.
- If you want to stop operation, re-press the button.
Only for training and service purposes
- 20 -
Setting speed of
indoor fan
High speed
Part 2 Functions & Controls
5.6 Sleep Timer Operation
• When the sleep time is reached after <1,2,3,4,5,6,7,0(cancel) hr> is input by the remote control while in appliance
operation, the operation of the appliance stops.
• While the appliance is on pause, the sleep timer mode cannot be input.
• While in cooling mode operation, 30 min later since the start of the sleep timer, the setting temperature increases by
1.8℉. After another 30 min elapse, it increases by 1.8℉ again.
• When the sleep timer mode is input while in cooling cycle mode, the airflow speed of the indoor fan is set to the low.
• When the sleep timer mode is input while in heating cycle mode, the airflow speed of the indoor fan is set to the medium.
5.7 Timer(On/Off)
5.7.1 On-Timer Operation
• When the set time is reached after the time is input by the remote control, the appliance starts to operate.
• The timer LED is on when the on-timer is input. It is off when the time set by the timer is reached.
• If the appliance is operating at the time set by the timer, the operation continues.
While in Fuzzy operation, the airflow speed of the indoor fan is automatically selected according to the temperature.
5.7.2 Off-Timer Operation
• When the set time is reached after the time is input by the remote control, the appliance stops operating.
• The timer LED is on when the off-timer is input. It is off when the time set by the timer is reached.
• If the appliance is on pause at the time set by the timer, the pause continues.
5.8 Defrost Control (Heating)
• Defrost operation is controlled by timer and sensing temperature of outdoor pipe.
• The first defrost starts only when the outdoor pipe temperature falls below 42.8℉ after starting of heating operation
and more than 4 minutes operation of compressor.
• Defrost ends after 12 minutes passed from starting of defrost operation when the outdoor rises over 59℉ even before
12 minutes.
• The second defrost starts only when the outdoor pipe temperature falls below 42.8℉ after from ending of the first
defrost and more than 4 minutes operation of compressor.
Only for training and service purposes
- 21 -
3. Control logic
1. Compressor ......................................................................................................................23
2. Step(frequency) control ...................................................................................................24
3. Reversing valve operaton................................................................................................25
4. Discharge pipe control.....................................................................................................26
5. Input Current Control .......................................................................................................27
6. Outdoor Fan Control ........................................................................................................28
7. Defrost Control .................................................................................................................29
8. EEV Control.......................................................................................................................30
9. Oil restoration operation..................................................................................................32
10. Compressor warm-up control logic..............................................................................32
11. Heat sink control.............................................................................................................33
Only for training and service purposes
- 22 -
Part 3 Control logic
1. Compressor
Basic principle is to control the rpm of the motor by changing the working frequency of the compressor.
Three phase voltage is supplied to the motor and the time for which the voltage will supplied is controlled by IPM
(intelligent power module).
Switching speed of IPM defines the variable frequency input to the motor.
RPM → Revolutions/Minute
F
→ Frequency
P
→ Number of poles
RPM = 120 f
P
BLDC Motor
IPM (Inverter)
EMF
UVWXYZ
MCU
(16Bits)
Only for training and service purposes
U
V
W
Position
Detect
Circuit
- 23 -
Part 3 Control logic
2. Step(frequency) control
2.1 Frequency control
Frequency that corresponds to each rooms capacity will be determined according to the difference in the temperature of
each room and the temperature set by the remote controller.
There are various factors determining the frequency.
1. Indoor unit capacity value.
2. Temperature compensation factor
3. Initial frequency setting
To & fro
feedback
Indoor temperature
Indoor capacity
Indoor On/OFF
Selected fan speed
System
ON/Setting
Indoor
data
Outdoor
Temperature
Outdoor
data
Basic formula of
calculation
Compressor setting
Calculation of
set frequency
Start
system
Continues
check
Stop
system
System
error
2.2 Primary step setting
: Capacity steps of compressor are decided by ∑Qj (Summation of capacity code), TA0(Outdoor temp.), TAI(Indoor
temp.), DTAI (Step Compensation of temperature difference Indoor Temp. and Setting Temp.
Comp Step = (Step base+Long piping compensation) x ΔStep TAO x ΔStep TAI x ΔStep DTAI
Step base
Standard frequency step by ∑Qj (Summation of capacity code)
Long piping
Comp. Step compensation by setting long piping
ΔStep TAO
step compensation by TAO (Outdoor temp.)
ΔStep TAI
step compensation by TAI (Indoor temp.)
ΔStep DTAI
Step Compensation of temperature difference Indoor Temp. and Setting Temp.
] Target frequency step (Step base) exceeds maximum step, the Step base value follows the maximum step value.
] The compressor get the minimum step in case Step base value is lower than the minimum step of operating
capacity.
Only for training and service purposes
- 24 -
Part 3 Control logic
3. Reversing valve operation
1. At the starting (outdoor is powered on,indoor is not) reversing valve continues OFF(cooling).
2. For the cooling and defrosting operation :valve OFF, for the heating operation :valve ON
3. Method of changing mode from heating to defrosting : As defrosting starts Inverter compressor Hz is lowered to 30Hz
for 5 sec and the valve is OFF for the defrost mode. (refer “working process of each component in defrosting and
returning to heating mode ”)
4 . Method of changing mode from defrosting to heating : As the defrosting is finished inverter compressor frequency is
lowered to 30Hz for 10 sec. And the valve is ON for the heating mode.
5. If the operating mode is changed to heating from cooling, “3 min. restarting rule” is applied, and reversing valve
position is changed within 30 sec. after compressor turns OFF.
6. If the compressor is stopped during heating mode by remote controller operation or error mode, reversing valve
position is changed to OFF in 30 sec. after compressor turns OFF.
7. If the compressor is stopped during heating mode by Thermistor signal, reversing valve will remain in heating
position.
Only for training and service purposes
- 25 -
Part 3 Control logic
4. Discharge pipe control
1) There can be two situations
a) Sensor is failed (error code for sensor failure will be generated)
b) Abnormal high temperature discharge temperature (error code for high discharge will be generated)
Both cases unit will stop.
Compressor working
1. If discharge pipe temperature < T1 No limitation on compressor frequency
2. T2 ≤ discharge pipe temperature < Toff (Hysteresis control) Compressor frequency down by 5 pulse & Expansion
valve up by 10 pulse in every 1 min. If EEV is in the starting control it will follow starting control first.
3. discharge pipe temperature ≥ Toff then compressor will be OFF System will stop if this situation occurs 5 times in 1
hour and error code will be generated also self diagnosis will start.
Discharge pipe temp.
COMP Hz
Set
Expansion valve
Set
Only for training and service purposes
5Hz(Option)
Down
10 pulse
(Option) up
Set
Set
- 26 -
5Hz
(Option)
Down
10 pulse
(Option) up
OFF
Set
Stop control
Set
Part 3 Control logic
5. Input Current Control
5.1 Function
Controlling total current to protect power semiconductor devices from burn-out by the low current (including connecting
mistake) and over current.
Operating process
1. Detection : check the output DC voltage of Current Transformer(CT).
5.2 Operating process
CT 1 detection :
1) If total current exceeds CT1+1 value, reduce inverter operation by 1 step.
- Step down 5Hz(Option) from current step.
- If new Hz is below minimum Hz of operation (cooling & heating), then turn off the compressor.
2) After step down, still if the total current exceed CT1 for more than 5 sec.
then step down inverter operation by 1 more step.
3) If the current continue below CT1 for more than 1 min., return the to setting step Hz.
CT 2 detection :
1) If total current exceeds CT2 turn off compressor.
And after 3 min turn on the compressor and check the current again.
2) If CT2 occurs 5 times in 1 hour,stop the operation and shows Self-Diagnosis Error Mode 22
Current(CT)
CT2
(Option)
CT1+1
(Option)
CT1
(Option)
Frequency
[Hz]
Setting Frequency
frequency
fixed
Only for training and service purposes
5 Hz
(Option)
Down
Frequency
fixed
- 27 -
Setting
frequency
Frequency
fixed
5 Hz
(Option)
Down
OFF
Part 3 Control logic
6. Outdoor Fan Control
6.1 Function
Working of outdoor fan are different in different models.
Some models are single fan some are two fan type.
6.2 Operating process
Control logic of outdoor fan depends on outdoor temperature
1. AC motor fan control
COOLING
HEATING
FAN1
OUTDOOR
TEMP.
Step_Fan + 1
105.8 ℉
FAN2
FAN1
OUTDOOR
TEMP.
Step_Fan - 1
68 ℉
FAN2
Step_Fan + 2
100.4 ℉
Step_Fan + 1
Step_Fan
Step_Fan - 2
Step_Fan - 1
57.2 ℉
Step_Fan
Step_Fan
82.4 ℉
Step_Fan
39.2 ℉
Step_Fan + 1
Step_Fan - 1
71.6 ℉
Step_Fan - 1
Step_Fan + 1
36.6 ℉
Step_Fan + 2
Step_Fan - 2
50 ℉
Step_Fan - 3
2. DC motor fan control
COOLING
OUTDOOR
TEMP.
FAN
HEATING
OUTDOOR
TEMP.
-6
3
113 ℉
78.8 ℉
-4
2
105.8 ℉
71.6 ℉
-3
1
100.4 ℉
64.4 ℉
-2
0
82.4 ℉
57.2 ℉
-1
-2
75.2 ℉
50 ℉
-4
0
64.4 ℉
39.2 ℉
-6
1
57.2 ℉
32 ℉
-7
2
48.2 ℉
24.8 ℉
-8
3
35.6 ℉
17.6 ℉
-9
4
26.6 ℉
-11
Only for training and service purposes
FAN
- 28 -
Part 3 Control logic
7. Defrost Control
7.1 Function
:These are about the control of compressor, fan of outdoor unit, reversing valve, EEV.
7.2 Starting to the defrosting operation
A) Defrost operation will be start when all the conditions below are matched simultaneously
Accumulation time of operation and the period after completion of defrost = 35min (Outdoor air temperature 26.6℉)
B) Outdoor piping temperature is below than 21.2℉ for starting defrosting operation.
7.3 Completion of defrost operation
Send signal of defrost completion in case of meeting one of the condition as below.
1. Defrosting time 7 minutes
2. Piping temperature maintain 10 seconds (Option ) in condition of more than 59℉.
7.4 Defrosting Control Algorithm
Satisfy
Defrost
Start
Condition
1
2
Satisfy
Defrost
End
Condition
Defrost
Start
3
4
5
6
Heating
Start
(Defrost flag clear)
7
8
9
10
Baseline
80 Hz (Option)
Control
Inverter Comp.
350 Pulse (Option)
Control
Outdoor EEV
ON
Defrost signal of
indoor unit on/
Starting maximum defrosting
time count
Reversing Valve
Indoor defrost signal OFF
ON
OFF
Indoor Fan
OFF
ON
Outdoor Fan
Only for training and service purposes
OFF
- 29 -
Hot
start
ON/OFF
Part 3 Control logic
8. EEV Control
8.1 Control of EEV opening
1. EEV openings have a controllable ranges 70 (option) to 460 (option) pulse in both condition of cooling and heating.
2. Products do not be operated before initializing of EEV when starting.
3. Time constant control period of EEV is every 2 minutes except below conditions.
- Control EEV every 1 minutes for 10 minutes after starting.
- When indoor capacity changed, Control EEV every 1 minutes for 10 minutes after starting
- Control EEV every 1 minutes for 10 minutes after starting in case of the special situation such as defrost completion,
oil recovery, oil equalizing control, oil supplying, current transformer limitation, limitation of discharge temperature, low
ambient operation control.
EEV
opening
(Pulse)
Power input
(Reset)
Comp
On
Comp
Off
Comp
On
460
Open
Close
0
-200
time
Initializin
Starting
control
Time constant
control
Starting
control
Off
Heating and cooling
Heating
Cooling
Only for training and service purposes
- 30 -
Part 3 Control logic
8.2 Starting control
1) Only 1 EEV will be operate as below and others are closed fully.
2) Starting control does not use the time when the system operate with partial load after (example) after finishing starting
control for 1 indoor unit, another indoor unit is ON additionally is operated with target opening of EEV.
3) The indoor units which are in the middle of starting control are continuing starting control with the opening of its
opening.
4) Urgent control by indoor piping temperature
1. EEV open 4 pulse with every 10 sec when the indoor piping temperature is below 35.6˚F
2. When the temperature reaches 39.2˚F, system return to the starting control pulse value.
Pull open
Starting EEV
opening
Target Pulse
Target step
Time (Option)
Comp starting
Time(sec)
Only for training and service purposes
- 31 -
Part 3 Control logic
9. Oil restoration operation
1) When the accumulated compressor running time is over 3 hr.(option), oil restoring operation is made for 3 minutes.
If it’s on the way of compressor starting,it’s made after the starting.
2) Accumulated running time is cleared after the defrosting and oil restoring operation.
Operating process :
1) Fully open all the indoor’s EEV.
2) After the EEV opening,change the compressor step to 70 Hz(option)
3) Reversing valve will be same as in defrosting process.
4) Outdoor fan operates in low speed.
5) During this operation, if operating frequency should be changed by safety control. then follow safety control first. If
compressor should be OFF by that,stop operation.
6) The EEV openings after this operation is 120% of the opening at the point of starting.
10. Compressor warm-up control logic (at low temperatures)
A function protecting inverter compressor from damages, by increasing oil viscosity in low outdoor temperature.
For the control,compressor operates in low frequencies.
Operating condition :in case of the following 3 conditions are fulfilled at the same time
- Outdoor temperature ,D-pipe temperature, Heat sink temperature: below 32℉
23℉≤ OD temp.<32℉
starting
starting
Comp. 15Hz
starting
15Hz
starting
EEV
OD temp < 14℉
14℉≤ OD temp.<23℉
Opening target : 0.7
0 sec. 90 sec.
Time (option)
Only for training and service purposes
15Hz
starting
Opening target : 0.7
0 sec.
180 sec.
Time (option)
starting
Opening target : 0.7
0 sec.
300 sec.
Time (option)
- 32 -
Part 3 Control logic
11. Heat sink control
11.1 Function
: Power module failure protection by checking the temperature of heat sink.
There is a temperature sensor for checking the heat sink temperature.
11.2 Heat sink sensor failure error
Short Check : if temperature ≥ 266℉
Open Check : if temperature < -22℉
System will go in self diagnosis (error 65) is displayed and product stops.
11.3 Heat sink temperature control
a) Heat sink temperature < T2 : No limitation on compressor frequency
b) T2 ≤ heat sink temperature < Toff : Compressor frequency down by 5 Hz
c) Heat sink temperature ≥ Toff : Compressor will be off.
System will stop if this situation occurs 5 times in 1 hour and error code will be generated also self diagnosis will start.
If high temperature situation occurs 5 times in 1 hr system counts 1 error and after that 4 times if this situation occurs
system stops and give error code.
If the temperature reached Toff condition system will count 5 times after that and system will stop with error code.
Heat Sink temp
Toff=185℉
T2=167℉
T1=158℉
COMP Hz
Set
frequency
Only for training and service purposes
5 Hz
5 Hz
Set
(Option) frequency (Option)
Down
Down
- 33 -
OFF
Set
frequency
4. Test Run
1. Check before Test Run.....................................................................................................35
2. Test Run Flow chart .........................................................................................................36
3. Test Running .....................................................................................................................37
Only for training and service purposes
- 34 -
4. Test Run
1. Check before Test Run
1
Check to see whether there is any refrigerant leakage, and check whether the power or transmission
cable is connected properly.
Check liquid pipe and gas pipe valves are fully opened.
2
NOTE: Be sure to tighten caps.
Confirm that 500 V megger shows 2.0 MΩ or more between power supply terminal block and
ground. Do not operate in the case of 2.0 MΩ or less.
3
NOTE: Never carry out mega ohm check over terminal control board.
Otherwise the control board may break.
Immediately after mounting the unit or after leaving it turned off for an extended length of
time, the resistance of the insulation between the power supply terminal board and the
ground maydecrease to approx. 2.0 MΩ as a result of refrigerant accumulation in the internal
compressor.
If the insulation resistance is less than 2.0 MΩ, turn on the main power supply.
Only for training and service purposes
- 35 -
4. Test Run
2. Test Run Flow chart
START
Test operation for indoor unit
Operate the unit in cooling mode.
Does Test operation start?
No
Refer to part4, 6 Electric part
Yes
Is cold air discharged for
more than 3 minutes ?
No
Yes
Is there any temperature
difference between intake and
discharged air?
Refer to part4, 5 Cycle part
No
Yes
Is the operating current
normal ?
No
Yes
Operation mode change
to Heating mode
Is hot air discharged ?
After Hot Start
* Check the load (In/Out Temp.)
* Check pipe length and amount of
refrigerant
* Check for abnormal sound in
outdoor unit (comp.,Fan, others )
No
Yes
Normal
• Each indoor unit should be tested.
• If the unit has accessory, it should be tested.
Only for training and service purposes
- 36 -
Refer to Troubleshooting
Guide
4. Test Run
3. Test Runing
3.1 PRECAUTIONS IN TEST RUN
• The initial power supply must provide at least 90% of the rated voltage.
Otherwise, the air conditioner should not be operated.
CAUTION:
① For test run, carry out the cooling operation first even during winter season. If heating operation is carried out
first, it leads to the trouble of compressor.
② Carry out the test run more than 5 minutes without stopping.
(Test run will be cancelled 18 minutes later automatically)
• The test run is started by pressing the room temperature checking button and down timer button for 3 seconds
at the same time.
• To cancel the test run, press any button.
3.2 CHECK THE FOLLOWING ITEMS WHEN INSTALLATION IS COMPLETE
• After completing work, be sure to measure and record trial run properties, and store measured data, etc.
• Measuring data are room temperature, outside temperature, suction temperature, blow out temperature,
air velocity, air volume, voltage, current, presence of abnormal vibration and noise, operating pressure, piping
temperature.
• As to the structure and appearance, check following items.
o Is the circulation of air adequate?
o Is the drainage OK?
o Is the heat insulation complete
(refrigerant and drain piping)?
o Is there any leakage of refrigerant?
Only for training and service purposes
o Does the romote controller works properly?
o Is there any error on wiring?
o Aren't terminal screws loosened?
- 37 -
5. Trouble Shooting
1. Self-diagnosis Function.................................................................................................39
2. Pump Down.....................................................................................................................41
3. Evacuation ......................................................................................................................42
4. Gas Charging ..................................................................................................................43
5. Cycle Part ........................................................................................................................44
6. Electronic Parts ..............................................................................................................45
Only for training and service purposes
- 38 -
5. Trouble Shooting
1. Self-diagnosis Function
1.1 Error Indicator (Indoor)
Ceiling Cassette Type Display
10 degrees 1 degrees
The number of times to blink = Error code
Wall Mounted Type Display
1 degrees
10 degrees
The number of times to blink = Error code
Error Indicator
• The function is to self-diagnoisis airconditioner and express the troubles identifically if there is any trouble.
• Error mark is ON/OFF for the operation LED of evaporator body in the same manner as the following table.
• If more than two troubles occur simultaneously, primarily the highest trouble fo error code is expressed.
• After error occurrence, if error is released, error LED is also released simultaneously.
• To operate again on the occurrence of error code, be sure to turn off the power and then turn on.
• Having or not of error code is different from Model.
Indoor Error
Error code
Indoor Status
Description
00
No Error
ON
01
Indoor Room themistor error
OFF
02
Indoor in-piping sensor error
OFF
03
Remote controller error
OFF
04
Drain Pump error
OFF
05
Communcation error between in and out
OFF
06
Indoor Out-Piping sensor error
OFF
07
Differnt mode operation
OFF
09
EEPROM Check Sum Error
OFF
10
Indoor BLDC Fan Lock
OFF
Only for training and service purposes
- 39 -
5. Trouble Shooting
1.3 Error Indicator (Outdoor)
Outdoor Error
Ex) Error 21 (DC Peack)
2 Times
2 Times
2 Times
LED01G
(RED)
1 Sec.
1 Sec.
1 Time
1 Sec.
1 Time
1 Time
LED02G
(GREEN)
2 Sec.
Error
Code
21
22
2 Sec.
Contents
25
26
27
29
32
35
DC Link Peak (IPM Fault)
CT 2 (Max CT)
DC Link Low Volt.
DC Link High Volt.
Low Voltage/Over Voltage
DC Compressor Position Error
PSC/PFC Fault Error
COMP Over Current
D-Pipe High
Low Pressure Error
39
Communication Error
40
41
44
45
46
48
51
53
60
61
62
65
67
73
CT Sensor (Open/Short)
INV. D-Pipe Th Error
Outdoor Air Th Error
Cond. Mid-Pipe Th Error
Suction Pipe Th Error
Cond. Out-Pipe Th Error
Capacity Over
Signal Error (Indoor <-> Outdoor)
EEPROM Check Sum Error
Cond. Pipe Th High
Heaksink Th High
Heaksink Th Error
Outdoor BLDC Fan Lock
PFC Fault Error(S/W)
23
LED01G/M LED02G/M
Outdoor
case of Error
(Red)
(Green)
Status
2times Ⱥ 1times Ⱥ Over Rated Current
Off
2times Ⱥ 2times Ⱥ Input Over Current
Off
DC Link Volt is below 140Vdc
2times Ⱥ 3times Ⱥ
Off
DC Link Volt is above 420Vdc
2times Ⱥ 5times Ⱥ Abnormal AC Volt Input
Off
2times Ⱥ 6times Ⱥ Compressor Starting Fall Error
Off
2times Ⱥ 7times Ⱥ Over Inverter PCB input current
Off
2times Ⱥ 9times Ⱥ Over Inverter Compressor Current
Off
3times Ⱥ 2times Ⱥ D-Pipe Temp. High
Off
3times Ⱥ 5times Ⱥ Excessive decrease of Low Pressure
Off
3times Ⱥ 9times Ⱥ Communication Error Between PFC
Micom and INV Micom
4times Ⱥ
○
CT Circuit Malfunction
4times Ⱥ 1times Ⱥ Open/Short
4times Ⱥ 4times Ⱥ Open/Short
4times Ⱥ 5times Ⱥ Open/Short
4times Ⱥ 6times Ⱥ Open/Short
4times Ⱥ 8times Ⱥ Open/Short
5times Ⱥ 1times Ⱥ Over combination
5times Ⱥ 3times Ⱥ Communication Poorly
6times Ⱥ
○
Check Sum Mismatching
6times Ⱥ 1times Ⱥ Cond. Temp. High
6times Ⱥ 2times Ⱥ Heatsink Temp. High
6times Ⱥ 5times Ⱥ Open/Short
6times Ⱥ 7times Ⱥ Outdoor Fan is not operation
7times Ⱥ 3times Ⱥ Over Current of Outdoor Unit PFC
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Ⱥ: A light on the display panel is blink.
Only for training and service purposes
- 40 -
5. Trouble Shooting
2. Pumping Down
Liquid side
Indoor unit
Open
2-Way�
valve
Outdoor unit
Gas side
Closed
3-Way�
valve
Lo
CLOSE
CLOSE
Purge the air
• Procedure
(1) Confirm that both the 2-way and 3-way valves
are set to the open position.
– Remove the valve stem caps and confirm that
the valve stems are in the raised position.
– Be sure to use a hexagonal wrench to operate
the valve stems.
(6) Operate the air conditioner at the cooling
cycle and stop it when the gauge indicates
14.19 lb/in3.
(7) Immediately set the 3-way valve to the closed
position.
– Do this quickly so that the gauge ends up indicating 42.58 lb/in3 to 70.97 lb/in3.
(2) Operate the unit for 10 to 15 minutes.
(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.
(8) Disconnect the charge set, and mount the 2way and 3-way valve’s stem nuts and the service port nut.
– Use torque wrench to tighten the service port
nut to a torque of 0.405 lbf.
– Be sure to check for gas leakage.
(4) Air purging of the charge hose.
– Open the low-pressure valve on the charge set
slightly to air purge from the charge hose.
(5) Set the 2-way valve to the closed position.
Only for training and service purposes
- 41 -
5. Trouble Shooting
3. Evacuation (All amount of refrigerant leaked)
Liquid side
Indoor unit
Outdoor unit
3-Way�
valve
Open
Gas side
3-Way�
valve
Open
Vacuum pump
Vacuum�
Gage
Lo
OPEN
OPEN
• Procedure
(1) Connect the vacuum pump to the center hose
of charge set center hose
(2) Evacuation for approximately one hour.
– Confirm that the gauge needle has moved
toward 0.8Torr.
(3) Close the valve (Lo side) on the charge set,
turn off the vacuum pump, and confirm that
the gauge needle does not move (approximately 5 minutes after turning off the vacuum
pump).
(4) Disconnect the charge hose from the vacuum
pump.
– Vacuum pump oil.
If the vacuum pump oil becomes dirty or
depleted, replenish as needed.
Only for training and service purposes
- 42 -
5. Trouble Shooting
4. Gas Charging (After Evacuation)
Liquid side
Indoor unit
Open
3-Way�
valve
Outdoor unit
Gas side
Open
3-Way�
valve
Check valve
Charging�
cylinder
Lo
(1)
OPEN
Vacuum�
Gage
• Procedure
(1) Connect the charge hose to the charging
cylinder.
– Connect the charge hose which you dis-connected from the vacuum pump to the valve at
the bottom of the cylinder.
– If you are using a gas cylinder, also use a
scale and reverse the cylinder so that the system can be charged with liquid.
(2) Purge the air from the charge hose.
– Open the valve at the bottom of the cylinder
and press the check valve on the charge set to
purge the air. (Be careful of the liquid refrigerant). The procedure is the same if using a gas
cylinder.
(3) Open the valve (Lo side on the charge set and
charge the system with liquid refrigerant.
– If the system can not be charged with the specified amount of refrigerant, it can be charged
with a little at a time (approximately 0.035 oz
each time) while operating the air conditioner in
the cooling cycle; however, one time is not sufficient, wait approximately 1 minute and then
repeat the procedure (pumping down-pin).
Only for training and service purposes
This is different from previous procedures.
Because you are charging with liquid refrigerant
from the gas side, absolutely do not attempt to
charge with larger amounts of liquid refrigerant
while operating the air conditioner.
(4) Immediately disconnect the charge hose from
the 3-way valve’s service port.
– Stopping partway will allow the gas to be discharged.
– If the system has been charged with liquid
refrigerant while operating the air conditioner
turn off the air conditioner before disconnecting
the hose.
(5) Mount the valve stem nuts and the service
port nut.
– Use torque wrench to tighten the service port
nut to a torque of 0.405 lbf.
– Be sure to check for gas leakage.
- 43 -
5. Trouble Shooting
5. Cycle Part
Trouble analysis
1. Check temperature difference between intake and discharge air, and check for the operating current too.
Case
Symptom
Supposed Caused
Case 1
Temp. difference : approx. 32℉
Current : less than 80% of rated current
All amount of refrigerant leaked out.
Check refrigeration cycle.
Case 2
Temp. difference : approx. 46.4℉
Current : less than 80% of rated current
Refrigerant leakage Clog of refrigeration cycle
Defective Compressor.
Case 3
Temp. difference : less than 46.4℉
Current : over the rated current
Excessive amount of refrigerant
Case 4
Temp. difference : over 46.4℉
Normal
NOTICE
Temperature difference between intake and discharge air depends on room air humidity. When the room air humidity is
relativery higher, temperature difference is smaller. When the room air humidity is relatively lower temperature difference
is larger.
2. Check temperature and pressure of refrigeration cycle in cooling mode.
Suction pressure
(Compared with
the normal value)
Temperature of
Discharge Air (Compared
with the normal valve)
Cause of Trouble
High
Defective compressor
Defective 4-way reverse valve
Current is low.
Excessive amount of
refrigerant
High pressure does not quickly
rise at the beginning of
operation.
Insufficient amount of
refrigerant (Leakage)
Clogging
Current is low.
Higher
Normal
Lower
Higher
Description
NOTICE
1. The suction pressure is usually 120.9 – 135.12 PSI(Cooling) at normal condition.(R410A)
2. The temperature can be measured by attaching the thermometer to the low pressure tubing and wrap it with putty.
Only for training and service purposes
- 44 -
5. Trouble Shooting
6. Electronic Parts
6.1 The Product doesn’t operate at all
Turn off the main power and
wait for 10 seconds.
Turn on the main power again.
A "Beeping" sound is made
from the indoor unit
Yes
Primarily, the operating condition of
Micom is O.K.
* Check, Remote controller & Receiver.
* Check CN-DISP1, CN-DISP2 of
indoor PCB
No
Check the voltage of power supply (AC230V, 50Hz) and check
for the following :
* The voltage of main power supply.
* The voltage applied to the unit.
* The connecting method of Indoor/Outdoor connecting cable (each color)
* The P.C.B. Assembly (Fuse, Noise Filter, Power Module, Bridge Diode, etc.)
The operation check of the Indoor P.C.B. Ass'y
Procedure
Specification
Remedy
1) The input voltage of power module.
1) AC230V ± 30V
: Check the rated voltage
1) Check the power outlet.
2) The output voltage of power module.
2) 12V ± 3V
2) Replace
P.C.B Ass'y
4) IC04D(7805)
4) DC5V
4) Replace P.C.B Ass'y
5) IC01A(KIA7036)
5) The voltage of micom pin 19
: DC4.5V↑
5) Replace P.C.B Ass'y
Only for training and service purposes
- 45 -
5. Trouble Shooting
6.2 The Product doesn't operate with the remote controller
Turn on the main power
A "Beeping" sound is made
from the indoor unit
No
* Refer to 10.1
Yes
Is it possible to turn on the unit
by ON/OFF button on display?
No
* Check the voltage of power
(AC230V, 50Hz).
Yes
Is the remote controller
working properly?
No
* When the mark ( ) is displayed
in LCD screen, replace battery.
Yes
* Check the contact point of CN-DISP 1, 2 connector & Re connector.
* Check display P.C.B Assembly
- Voltage between CN-DISP1 3 - 6 should be DC +5V,
- If problem still persists, Replace display PCB
Only for training and service purposes
- 46 -
5. Trouble Shooting
6.3 The Compressor/Outdoor Fan are don't operate
Turn on the main power.
Operate Cooling Mode by setting the disired temperature of the remote controller is less
than one of the Indoor temperature by 1°F at least.
When in air circulation mode, compressor/outdoor fan is stopped.
Check the sensor for Indoor temperature is attatched as close as to be effected by the
themperature of Heat Exchange (EVA.)
When the sensor circuit for Indoor temperature and connector are in bad connection or are
not engaged, Compressor/Outdoor fan is stopped.
• Check the related circuit of R02H(12.1K), R01H(1K), R04H(6.2K), R03H(1K), C01H(102),
C02H(102), Micom(pin No. ⑪, ⑫).
• Check the Indoor temperature sensor is disconnected or not (about 10K at 77°F).
Check the Relay(RY-PWR, RY-START) for driving Compressor.
• Check the voltage between brown and blue cable of terminal to connect the Outdoor
(About AC220V / 240V).
• Check the related circuit of relay in Outdoor PCB Ass'y.
Check Point
Comp. ON
Comp. OFF
Between Micom(No. 19) and
GND
DC 5V
DC 0V
Between IC01M(No. 10) and
GND
DC 1V↓
DC 12V
Turn off main power.
Check the electrical wiring diagram of Outdoor side.
Check the open or short of connecting wires between Indoor and Outdoor.
Only for training and service purposes
- 47 -
5. Trouble Shooting
6.4 When indoor Fan does not operate.
Turn off main power.
Check the connection of CN-FAN.
Check the Fan Motor.
Check the Fuse(AC250V, T2A).
Check the related circuit of indoor Fan Motor.
• The pin No. 38 of micom and the part for driving SSR.(Q01M)
• Check the related pattern.
• Check the SSR.
- SSR Open: Indoor Fan Motor never operate.
- SSR short: Indoor Fan Motor always operates in case of ON or OFF.
Turn on the main power
Check the SSR high speed operation by remote control.
(the Indoor Fan Motor is connected)
The voltage of Pin No 1(orange) and 3(black) of CN-FAN.
About AC 160V over
About AC 50V over
SSR is not damaged
Check SSR
Only for training and service purposes
- 48 -
5. Trouble Shooting
6.5 When the louver does not operate.
• Confirm that the vertical louver is normally geared with the shaft of Stepping Motor.
• If the regular torque is detected when rotating the vertical louver with hands ⇒ Normal
• Check the connecting condition of CN-U/D or CN0L/R Connector
• Check the soldering condition(on PCB) of CN-U/D or CN0L/R Connector
Check the operating circuit of the vertical louver
• Confirm that there is DC +12V between pin ¿ of CN-U/D, CN0L/R and GND.
• Confirm that there is a soldering short at following terminals.
- Between 1 , 2 , 3 and 4 of MICOM
- Between 17 , 18 , 19 and 20 of MICOM
- Between 4 , 5 , 6 and 7 of IC01M
- Between 5 , 6 , 7 and 8 of IC01M
If there are no problems after above checks.
• Confirm the assembly condition that are catching and interfering parts in the link of the
vertical louver
Only for training and service purposes
- 49 -
5. Trouble Shooting
6.6 Troubleshooting Indoor Error
Display
code
Title
01
Indoor air sensor
• Open / Short
• Soldered poorly
• Internal circuit error
Normal resistor : 10KΩ/ at 77℉ (Unplugged)
Normal voltage : 2.5Vdc / at 277℉ (plugged)
02
Indoor inlet pipe sensor
• Open / Short
• Soldered poorly
• Internal circuit error
Normal resistor : 5KΩ/ at 77℉ (Unplugged)
Normal voltage : 2.5Vdc / at 77℉ (plugged)
06
Indoor outlet pipe sensor
• Open / Short
• Soldered poorly
• Internal circuit error
Normal resistor : 5KΩ/ at 77℉ (Unplugged)
Normal voltage : 2.5Vdc / at 77℉ (plugged)
Cause of error
Check point & Normal condition
10k�
2.5Vdc
Ω�
V
Check the resistance
Check the voltage�
�
Check Point
1. Unplug the sensor on Indoor unit PCB.
2. Estimate the resistance of each sensor.
3. If the resistance of the sensor is 10KΩ/ 5KΩ at 77°F, then sensor is normal.
4. If the resistance of the sensor is 0 KΩ or ∞, then sensor is abnormal. ’ Change the sensor.
5. Plug the sensor on Indoor unit PCB and Power ON.
6. Estimate the voltage of each sensor.
7. If the voltage of the sensor is 2.5Vdc at 77°F, then sensor is normal.
8. If the resistance of the sensor is 0 or 5Vdc, then sensor is abnormal. ’ Repair or Change the PCB.
Only for training and service purposes
- 50 -
5. Trouble Shooting
Display
code
Title
03
Communication
Wired R/C
Cause of error
Wired R/C
12V
S
• Open / Short
• Wrong connection
Indoor Unit
GND
12V
S
• Connection of wire
• Main PCB Volt. DC12V
• Noise interference
CN-REMO
GND
12Vdc
12Vdc
V
V
Check the Volt.
Check point & Normal condition
Check the Volt.
Check Point
1. Check the wire connection. (Open / Short) ’ Repair the connection
2. Check the soldering state of connector. (Soldered poorly) ’ Repair or Change the PCB.
3. Check the volt. Of main PCB power source. (DC 12V, DC 5V) ’ Repair or Change the main PCB.
4. Check the installation of wired remote controller. (Noise interference) ’ Adjust the state of installation
Only for training and service purposes
- 51 -
5. Trouble Shooting
Display
code
Title
04
Drain pump
/ Float switch
Cause of error
• Float switch Open.
(Normal : short)
Check point & Normal condition
• The connection of wire(Drain pump/ Float switch)
• Drain pump power input. (220V)
• Drain tube installation.
• Indoor unit installation. (Inclination)
CN Float
CN-D/PUMP
CN-Float
0Ω�
Ω�
Check the resistance
Check Point
1. Check the wire connection. (Open, Soldered poorly) ’ Repair the connection or change the PCB.
2. Check the resistance of float switch (Abnormal : Open, Normal : short) ’ Check the float switch.
3. Check the level of water
4. Check the volt. Of Drain pump power supply. (AC 230V) ’ Repair or Change the main PCB.
Only for training and service purposes
- 52 -
5. Trouble Shooting
Display
code
Title
07
Different Operation Mode
Cause of error
Check point & Normal condition
• One of Indoor Unit operate cooling Another Unit • At the same time, this model cannot use cool and
heating mode
operate heating
Check Point
1. Check another indoor model operation mode
2. Operating the same mode with the first operated indoor unit
3. Clearing the "CH07"
Press the on/off button or mode change button and matching the indoor unit mode same as the first operated
indoor unit
Only for training and service purposes
- 53 -
5. Trouble Shooting
Display
code
Title
09
Indoor EEPROM Check
Sum Error
Cause of error
• Check sum error
Check point & Normal condition
1. Check the poor soldering
2. Check the insertion condition of the EEPROM
3. Check the PCB Connection
<EEPROM Direction Check Point>
Check Point
1. Check the EEPROM Direction
2. If the EEPROM value & the Program value are not matched, the Code is Displayed
3. After Checking the connection and Insertion, replace the PCB or Option PCB
Only for training and service purposes
- 54 -
5. Trouble Shooting
Display
code
Title
Cause of error
10
Indoor BLDC Fan Motor
Lock
The Fan is not operated
properly
Yellow
Check point & Normal condition
Check the Indoor fan locking
White
Blue
Black Red
Fan motor
connector
Tester
Check Point
Check the PCB during the Power on
1. Check the Voltage Red line to Black line
’ The Voltage is about [input voltage x 1.414]
’ if the Voltage does not come with the above Voltage,
’ Check the power input
’ Replace the PCB & Motor
2. Check the Voltage Black line to White
’ the Voltage is DC 15V
’ Check the Power input
’ Replace the motor
Check the Motor
1. Check the shaft
’ if the shaft is not turn smoothly, the Motor Power IC is defected
’ replace the motor
2. Check the motor resistance(if the shaft is turn smoothly, check the resistance)
’ Check Red line to Black line, Blue line to Black line
’ The resistance should infinite
’ replace the motor
Only for training and service purposes
- 55 -
5. Trouble Shooting
6.7 Troubleshooting Outdoor Error
Display
code
05
/
53
Title
Title
Communication
(Indoor ’ Outdoor)
Cause of error
• Communication poorly
Check point & Normal condition
• Power input AC 230V. (Outdoor, Indoor)
• The connector for transmission is disconnected.
• The connecting wires are misconnected.
• The communication line is shorted at GND.
• Transmission circuit of outdoor PCB is abnormal.
• Transmission circuit of indoor PCB is abnormal.
Check Point
1. Check the input power AC230V. (Outdoor, Indoor unit)
2. Check the communication wires are correctly connected.
Adjust the connection of wire Confirm the wire of "Live",
"Neutral"
3. Check the resistance between communication line and
GND. (Normal : Over 2MΩ)
4. Check the connector for communication is correctly connected.
5. If one indoor unit is operated normally, outdoor PCB is no
problem.
Check the another indoor unit.
* CH05 is displayed at indoor unit, CH53 is displayed at
outdoor unit.
6. If all indoor unit is displayed CH05 but outdoor PCB not
display
CH53 : Check the CN_COM and CN_POWER is correctly
connected.
L
< TERMINAL BLOCK >
• 24k/36k
1. In Case of CH53, Check the Connection ’ L , N at the terminal block
Only for training and service purposes
N
- 56 -
5. Trouble Shooting
Display
code
Title
Cause of error
• Instant over current
• Over Rated current
• Poor insulation of IPM
DC PEAK
(IPM Fault)
21
Check point & Normal condition
• An instant over current in the U,V,W phase
- Comp lock
- The abnormal connection of U,V,W
• Over load condition
- Overcharging of refrigerant
Pipe length.
Outdoor Fan is stop
• Poor insulation of compressor
n Error Diagnosis and Countermeasure Flow Chart
1. Check Pipe clogging/distortion
2. Check Covering (Indoor/Outdoor Unit)
3. Check EEV connector assemble condition/normal
operation
4. Check refrigerant pressure
Reassemble or manage if abnormality found
No
Is installation
condition normal?
Yes
Are the resistance
Between each phase and
insulation resistance of Inverter
compressor normal?
1. Check resistance between each terminal of compressor
(0.34~0.35
7%)
2. Check insulation resistance between compressor
terminal and pipe (over 50M )
Replace compressor if abnormality found
No
Yes
Is compressor
Wire connection
condition normal?
No
1. Check inverter PCB assembly U,V,W connector
connection condition
2. Check wire disconnection and wiring
3. Check compressor terminal connection condition
(bad contact)
Reassemble if abnormality found
No
Check inverter PCB assembly IPM normality
Replace inverter PCB assembly
Yes
Is inverter PCB assembly normal?
Yes
Recheck power and installation condition
n Comp checking method
Comp
U
Resistance(Ω) at 68˚F
Terminal
V
U-V
V-W
W-U
W
Comp
Copper
pipe
Inverter Constant
comp.
comp.
0.64
0.64
0.64
0.8
0.8
0.8
Resistance(Ω) at 68˚F
Terminal
U-GND
V-GND
W-GND
Only for training and service purposes
Inverter Constant
comp.
comp.
2M
2M
2M
2M
2M
2M
- 57 -
5. Trouble Shooting
LED01M
LED02M
U,V,W CONNECTOR
U
V
W
1. Wait until inverter PCB DC voltage is discharged after main power off.
2. Pull out V, V, W COMP connector.
3. Set multi tester to resistance mode.
4. If the value between P and N terminal of IPM is short(0Ω) or open(hundreds MΩ), PCB needs to be replaced.(IPM damaged)
5. Set the multi tester to diode mode.
6. In case measured value is different from the table, PCB needs to be replaced.(PCB damaged).
P
U
V
W
Nu Nv Nw
P
U
V
W
Nu Nv Nw
27
26
25
24
23 22 21
27
26
25
24
23 22 21
0.4 ~ 0.6 V
0.4 ~ 0.6 V
PFC_IPM check
U, V, W ➔ R S T
CAUTION
In case that the control box is opend and before checking electrical parts, it should be checked that the
LED 01M, 02M turned off(wait 7 minutes after main power OFF), otherwise it may cause electrical shock.
Only for training and service purposes
- 58 -
5. Trouble Shooting
Display
code
22
Title
Cause of error
Max. C/T
Input Over Current(18k13A↑, 24k/36k-20A↑)
Check point & Normal condition
1. Malfunction of Compressor
2. Blocking of Pipe
3. Low Voltage Input
4. Refrigerant, Pipe length, Blocked...
n Error Diagnosis and Countermeasure Flow Chart
Is installation
condition normal?
No
1. Check Pipe clogging/distortion
2. Check Covering (Indoor/Outdoor Unit)
3. Check EEV connector assemble condition/normal
operation
4. Check refrigerant pressure
→ Reassemble or manage if abnormality found
Yes
Are the resistance
Between each phase and
insulation resistance of Inverter
compressor normal?
No
1. Check resistance between each terminal of compressor
(0.188 ±7%)
2. Check insulation resistance between compressor
terminal and pipe (over 50MΩ )
→ Replace compressor if abnormality found
Yes
Is compressor
Wire connection
condition normal?
No
1. Check inverter PCB assembly U,V,W connector
connection condition
2. Check wire disconnection and wiring
3. Check compressor terminal connection condition
(bad contact)
→ Reassemble if abnormality found
Yes
Is inverter PCB assembly
power connection normal?
No
Check connection between inverter PCB assembly and
bridge diode(misconnection, disconnection)
→ wiring again if abnormality found
No
Check
L~N phase is 220V ±15%
→ Check connection condition and wiring if power is
abnormal
No
Check inverter PCB assembly IPM normality
→ Replace inverter PCB assembly
Yes
Is input voltage normal?
Yes
Is inverter PCB assembly
normal?
Yes
Recheck power and installation condition
Only for training and service purposes
- 59 -
5. Trouble Shooting
Check Point
1. Check the power source.(220V ±15%)
2. Check the fan operation is right.
3. Check the current.
4. Check the install condition.
5. Check the CT Sensor Output signal
- Check output the CT Sensor : DC 2.5±0.2V
Vdc
< Input Power Source Check Point >
< Main PCB>
<CT Sensing Check Point>
Only for training and service purposes
- 60 -
5. Trouble Shooting
Display
code
23
Title
DC Link Low voltage
Cause of error
• DC Link volt is below
140Vdc
Check point & Normal condition
• Check point & Normal condition
• Check theCN_(L),CN_(N) Connection.
• At not operating : DC Link voltage(280V↑)
• At Comp operating : DC Link voltage(340V↑)
n Error Diagnosis and Countermeasure Flow Chart
No
Check L~N Voltage is 220V±15%
Is input voltage normal ?
Yes
No
Is Inverter PCB assembly
Power connection normal?
Check connection from terminal block to
Inverter PCB assembly CN(L), CN(N)
Yes
No
Is Inverter PCB Normal?
Replace inverter PCB assembly
Yes
Recheck power and installation
condition
Only for training and service purposes
- 61 -
5. Trouble Shooting
Check Point
1. Check the WCN_P(L),P(N) Connection condition at the Main PCB.(Refer to outdoor wiring diagram)
2. Check the DC Link voltage at not operating(280V↑)
3. Check the DC Link voltage at Comp operating(340V↑)
4. Check DC Link Sensing Signal :2.4~2.8V (Refer the Picture)
< Input Power Source Check Point >
Vdc
< Main PCB>
Vdc
<DC_LINK Sensing Check Point>
<DC Link Voltage Check Point>
Only for training and service purposes
- 62 -
5. Trouble Shooting
Check Point
1. Check the connection of H/press switch
2. Check short or not at the connector of high pressure switch (Normal open)
< Main PCB : Connection Check Point >
Only for training and service purposes
< Checking the Press switch >
- 63 -
5. Trouble Shooting
Display
code
Title
Cause of error
25
Input voltage
• Abnormal Input voltage
(140Vac , 300Vac)
Check point & Normal condition
• Check the power source.
• Check the components.
n Error Diagnosis and Countermeasure Flow Chart
Is input voltage normal ?
No
Check L~N Voltage is 220V±15%
Yes
Is Inverter PCB Normal?
No
Replace inverter PCB assembly
Yes
Recheck power and
installation condition
Check Point
1. Check the Input Voltage (L–N ‘ 220V±10%)
2. Check Input Voltage Sensor output voltage (2.5Vdc±10%)
< Input Power Source Check Point >
Only for training and service purposes
- 64 -
5. Trouble Shooting
Vdc
< Inverter PCB>
< Input Voltage Sensing Check Point >
INPUT(V)
GND
Only for training and service purposes
- 65 -
5. Trouble Shooting
Display
code
27
Title
Cause of error
Check point & Normal condition
1. Overload operation (Pipe clogging/Covering/EEV
defect/Ref. overcharge)
2. Compressor damage (Insulation damage/Motor
Inverter PCB input
damage)
current is over100A(peak)
3. Input voltage abnormal (L,N)
for 2us
4. Power line assemble condition abnormal
5. Inverter PCB assembly Damage (input current
sensing part)
AC Input Instant over
Current Error
n Error Diagnosis and Countermeasure Flow Chart
Is installation
condition normal?
No
Yes
1.Check Pipe clogging/distortion
2.Check Covering (Indoor/Outdoor Unit)
3.Check EEV connector assemble condition/normal operation
4.Check refrigerant pressure
→ Reassemble or manage if abnormality found
No
Check
L~N phase voltage is 220V ±15%
→ Check connection condition and wiring if power is abnormal
No
1.Check L,N connection condition
2.Check wire disconnection and wiring
→ Reassemble if abnormality found
No
1.Check inverter PCB assembly U,V,W connector connection condition
2.Check wire disconnection and wiring
3.Check compressor terminal connection condition(bad contact)
→ Reassemble if abnormality found
Is input voltage normal?
Yes
Is AC input Wire connection
condition normal?
Yes
Is compressor
Wire connection
condition normal?
Yes
Is inverter PCB assembly
normal?
No
Check inverter PCB assembly PFCM normality
→ Replace inverter PCB assembly
Yes
Recheck power and
installation condition
※ PFCM Moudle checking method
① Set the multi tester to diode mode.
② Check short between input signal pin which are
placed below PFC Module
③ Replace PCB assembly if it is short between pins
except No.4,5 pins.
Signal pin
CAUTION
PFCM module No.4,5 pins are internal short state.
Only for training and service purposes
8
- 66 -
1
5. Trouble Shooting
Display
code
Title
Cause of error
28
Inverter DC link high
voltage error
Inv PCB DC link voltage
supplied over 420V
Check point & Normal condition
1. Input voltage abnormal (L~N)
2. ODU inverter PCB damage(DC Link voltage
sensing part)
n Error Diagnosis and Countermeasure Flow Chart
No
Is input voltage normal ?
Check L~N Voltage is 220V±15%
Yes
Is Inverter PCB assembly
Power connection normal?
No
Check connection from terminal block to
Inverter PCB assembly CN(L), CN(N)
Yes
No
Is Inverter PCB Normal?
Replace inverter PCB assembly
Recheck power and installation
condition
Only for training and service purposes
- 67 -
5. Trouble Shooting
Check Point
1. Check the CN_(L),CN_(N) Connection condition at the Inverter PCB.(Refer to outdoor wiring diagram)
2. Check the DC Link voltage at not operating(280V↑)
3. Check the DC Link voltage at Comp operating(340V↑)
4. Check DC Link Sensing Signal : 2.4~2.8V (Refer the Picture)
< Input Power Source Check Point >
Vdc
< Main PCB>
Vdc
<DC_LINK Sensing Check Point>
<DC Link Voltage Check Point>
Only for training and service purposes
- 68 -
5. Trouble Shooting
Display
code
29
Title
Inverter compressor over
current
Cause of error
Check point & Normal condition
1. Overload operation
(Pipe clogging/Covering/EEV defect/Ref. overcharge)
Inverter compressor input
2. Compressor damage(Insulation damage/Motor
current is over 30A
damage)
3. Input voltage low
4. ODU inverter PCB assembly damage
n Error Diagnosis and Countermeasure Flow Chart
Is installation
condition normal?
No
Yes
Are the resistance
Between each phase and
insulation resistance of Inverter
compressor normal?
No
1. Check Pipe clogging/distortion
2. Check Covering (Indoor/Outdoor Unit)
3. Check EEV connector assemble condition/normal
operation
4. Check refrigerant pressure
→ Reassemble or manage if abnormality found
1. Check resistance between each terminal of compressor
(0.188 ±7%)
2. Check insulation resistance between compressor
terminal and pipe (over 50MΩ )
→ Replace compressor if abnormality found
Yes
Is compressor
Wire connection
condition normal?
No
1. Check inverter PCB assembly U,V,W connector
connection condition
2. Check wire disconnection and wiring
3. Check compressor terminal connection condition
(bad contact)
→ Reassemble if abnormality found
Yes
Is input voltage normal?
No
Check
L~N phase is 220V ±15%
→ Check connection condition and wiring if power is
abnormal
No
Check inverter PCB assembly IPM normality
→ Replace inverter PCB assembly
Yes
Is inverter PCB assembly
normal?
Yes
Recheck power and installation condition
Only for training and service purposes
- 69 -
5. Trouble Shooting
Display
code
Title
32
D-pipe (Inverter)
temp. high
(221℉↑)
Cause of error
Check point & Normal condition
• Discharge sensor
(Inverter) temp. high
• Check the discharge pipe sensor for INV.
• Check the install condition for over load.
• Check the leakage of refrigerant.
• Check the SVC V/V open.
D-Pipe temp.
Toff 221℉
T2 203℉
T1 194℉
COMP Frequency
Normal
(Hz)
EEV Openness
(Pulse)
Normal
Normal
OFF
Normal
OFF Control
Check Point
1. Check the install condition for over load.
2. Check the SVC V/V open.
3. Check the leakage of refrigerant.
Only for training and service purposes
- 70 -
5. Trouble Shooting
Display
code
35
Title
Cause of error
Excessive decrease of low
pressure
Low Presser Error
Check point & Normal condition
• Defective low pressure sensor
• Defective outdoor/indoor unit fan
• Refrigerant shortage/leakage
• Deformation because of damage of refrigerant pipe
• Defective indoor / outdoor unit EEV
• Covering / clogging (outdoor unit covering during
the cooling mode / indoor unit filter clogging during heating mode)
• SVC valve clogging
• Defective outdoor unit PCB
• Defective indoor unit pipe sensor
n Error diagnosis and countermeasure flow chart
Is service valve
opened?
Open service valve
Yes
Are communication cable/
piping normal?
No
check communication/
piping correction.
Yes
Is amount of refrigerant
normal?
[refer refrigerant part]
No
Yes
Is there pipe crack or trace
of refrigerant leakage?
No
Adjust the amount of
refrigerant (Additive charge)
Yes
Weld / reconnect the cracked
portion and recharge refrigerant
Is fan normal?
(in heating outdoor fan,
in cooling indoor fan)
No
Check and replace related parts
(error 105~108 reference)
Yes
Is strainer Ok?*
No
Replace the strainer
Yes
Are the values of manifold
No
and low pressure sensor same?
( Is the low pressure value
actually low?)
Replace the pressure sensor
Yes
Check indoor / outdoor unit EEV
Check Indoor unit PCB
Check indoor / outdoor unit
installation conditions
Only for training and service purposes
* If the temperature difference between inlet and outlet of strainer
is so large that frost or ice formation can be seen or confirmed
then clogging of strainer should be checked
(Notice: it is not full ice forming of strainer, in case that there is
not at inlet portion but at outlet portion)
- 71 -
5. Trouble Shooting
Display
code
Title
C/T
Sensor Error
40
Cause of error
Check point & Normal condition
• Initial current error
• Malfunction of current detection circuit.
(Open / Short)
• Check CT Sensor output voltage :
2.5Vdc ±5%
n Error Diagnosis and Countermeasure Flow Chart
Is input voltage normal ?
No
Check L~N Voltage is 220V±15%
Yes
Is Inverter PCB Normal?
No
Replace inverter PCB assembly
Yes
Recheck power and
installation condition
Check Point
1. Check the Input Voltage (L–N ‘ 220V±10%)
2. Check Input Voltage Sensor output voltage (2.5Vdc±10%)
< Input Power Source Check Point >
Only for training and service purposes
- 72 -
5. Trouble Shooting
Vdc
1
2
3
< CT Sensing Check Point >
< Inverter PCB>
Display
code
Title
52
Transmission error
between (Inverter PCB ‘
Main PCB)
Cause of error
Check point & Normal condition
Main controller of Master 1. Power cable or transmission cable is not
connected
unit of Master unit can’t
2. Defect of outdoor Main fuse/Noise Filter
receive signal from
3. Defect of outdoor Main / inverter PCB
inverter controller
INPUT(CT)
n Error diagnosis and countermeasure flow chart
Is transmission
LED (Yellow) of inverter
compressor
PCB on?
No
Yes
Is noise filter or fuse
normal?
GND
No
Yes
Replace inverter compressor PCB
Is transmission cable
connected correctly?
No
Re-connect transmission cable
Yes
No
Is MAIN PCB normal?
Replace MAIN PCB
Yes
Replace inverter compressor PCB
Only for training and service purposes
- 73 -
Replace noise filter or fuse
5. Trouble Shooting
Display
code
Title
41
D-pipe sensor (Inverter)
• Open / Short
• Soldered poorly
• Internal circuit error
• Normal resistor : 200KΩ / at 77°F (Unplugged)
• Normal voltage : 4.5Vdc / at 77°F (plugged)
44
Air sensor
• Open / Short
• Soldered poorly
• Internal circuit error
• Normal resistor : 10KΩ / at 77°F (Unplugged)
• Normal voltage : 2.5Vdc / at 77°F (plugged)
45
Condenser Pipe sensor
• Open / Short
• Soldered poorly
• Internal circuit error
• Normal resistor : 5KΩ / at 77°F (Unplugged)
• Normal voltage : 2.5Vdc / at 77°F (plugged)
Suction Pipe sensor
• Open / Short
• Soldered poorly
• Internal circuit error
• Normal resistor : 5KΩ / at 77°F (Unplugged)
• Normal voltage : 2.5Vdc / at 77°F (plugged)
Heat sink sensor
• Open / Short
• Soldered poorly
• Internal circuit error
• Normal resistor : 10KΩ / at 77°F (Unplugged)
• Normal voltage : 2.5Vdc / at 77°F (plugged)
46
65
Cause of error
Check point & Normal condition
Check Point
1. Estimate the resistance of each sensor.(Unplugged)
2. Estimate the voltage of each sensor.(Plugged)
3. If the resistance of the sensor is 0 kΩ or ∞, then sensor is abnormal.
Ω�
Only for training and service purposes
If the voltage of the sensor is 0 V or 5Vdc, then sensor is abnormal.
- 74 -
5. Trouble Shooting
Display
code
Title
51
Over capacity
Cause of error
• Over capacity
Combination
Check Point
1. Check the indoor unit capacity.
Only for training and service purposes
- 75 -
Check point & Normal condition
• Check the indoor unit capacity.
• Check the combination table.
5. Trouble Shooting
Display
code
60
Title
Cause of error
Check point & Normal condition
1. EEPROM contact defect/wrong insertion
2. Different EEPROM Version
3. ODU Inverter & Main PCB assembly damage
Inverter PCB & Main
EEPROM Access error
EEPROM check sum error and Check SUM error
n Error Diagnosis and Countermeasure Flow Chart
Is EEPROM insertion normal?
No
1.Check EEPROM insert direction/connection condition
2.Check EEPROM Check SUM
→ Replace if abnormality found
Yes
Is inverter PCB assembly normal?
No
Replace inverter PCB assembly
Yes
MAIN PCB assembly normal?
No
Replace MAIN PCB assembly
Yes
Recheck power and installation condition
Check Point
- Check the EEPROM Check sum & Direction
<EEPROM Direction Check Point>
<MAIN PCB>
Only for training and service purposes
- 76 -
5. Trouble Shooting
Display
code
Title
Cause of error
61
Condenser
pipe sensor
temp. high
• Condenser pipe sensor
detected high temp.
Check Point
- Check the install condition for over load.
(Refrigerant, Pipe length, Blocked, …)
Only for training and service purposes
- 77 -
Check point & Normal condition
• Check the load condition.
• Check the sensor of Condenser pipe sensor.
5. Trouble Shooting
Display
code
62
Title
Heatsink High error
Cause of error
Inverter PCB heatsink
temperature is over
185°F
Check point & Normal condition
2. ODU fan locking
3. Heatsink assembly of INV PCB assemble condition abnormal
4. Defect of temperature sensing circuit part defect
of INV PCB
n Error Diagnosis and Countermeasure Flow Chart
Is installation
condition normal ?
No
1. Check fan locking
2. Check covering of heat exchanger
3. Check distance between ODU and obstacles
4. Check pipe distortion and abnormality
5. Check service valve is opened
➝ Eliminate causes for abnormal condition
Yes
Is assemble condition
of INV PCB heatsink normal ?
No
Check assemble condition between INV PCB heatsink and
PFC & IPM module ➝ Reassemble if abnormality found
Yes
Is PCB temperature
sensing part normal ?
No
Check resistance between NO.19 pin and NO.20 pin
of PFC module
Check resistance between NO.24 pin and NO.25 pin
of PFC module
➝ 7K 10%(at 77˚F)
➝ Replace PCB if abnormality found
Check Point
1. Check resistance between No.19 pin and NO.20 pin of PCB PFC module
2. Check resistance between No.24 pin and NO.25 pin of PCB PFC module - only 48/56k
3. Resistance value should be in 7kΩ ±10%.(at 77°F).
PFCM :
Measuring resistance
between No.19,20 pin
Only for training and service purposes
- 78 -
5. Trouble Shooting
Display
code
65
Title
Heatsink High error
Cause of error
Inverter PCB heatsink
sensor is open or short
Check point & Normal condition
1. ODU fan locking
2. Heatsink assembly of INV PCB assemble
condition abnormal
3. Defect of temperature sensing circuit part defect
of INV PCB
n Error Diagnosis and Countermeasure Flow Chart
Is installation
condition normal ?
No
1. Check fan locking
2. Check covering of heat exchanger
3. Check distance between ODU and obstacles
4. Check pipe distortion and abnormality
5. Check service valve is opened
➝ Eliminate causes for abnormal condition
Yes
Is assemble condition
of INV PCB heatsink normal ?
No
Check assemble condition between INV PCB heatsink and
PFC & IPM module
➝ Reassemble if abnormality found
Yes
Is PCB temperature
sensing part normal ?
No
Check resistance between NO.19 pin and NO.20 pin
of PFC module
Check resistance between NO.24 pin and NO.25 pin
of PFC module
➝ 7K 10%(at 77˚F)
➝ Replace PCB if abnormality found
Check Point
1. Check resistance between No.19 pin and NO.20 pin of PCB PFC module
2. Check resistance between No.24 pin and NO.25 pin of PCB PFC module - only 48/56k
3. Resistance value should be in 7kΩ ±10%.(at 77°F).
4. Check the PFC Module No.19, 20 and IPM Module No.24, 25 pin soldering condition.
PFCM :
Measuring resistance
between No.19,20 pin
Only for training and service purposes
- 79 -
5. Trouble Shooting
Display
code
67
Title
Fan Lock Error
Cause of error
Check point & Normal condition
1. ODU fan locking
Fan RPM is 10RPM or
2. Heatsink assembly of INV PCB assemble condiless for 5 sec. when ODU
tion abnormal
fan starts or 40 RPM or
3. Defect of temperature sensing circuit part defect
less after fan starting.
of INV PCB
n Error Diagnosis and Countermeasure Flow Chart
Is ODU Fan Motor Assemble
condition normal?
No
Check ODU Fan Motor assemble condition and fan locking
→ Reassemble or replace if abnormality found
No
1. Set the multi tester to diode mode.
2. Check voltage between 1pin and 4pin of Fan Motor
(1±0.2V)
3. Replace Inverter PCB if abnormality found.
Yes
Is ODU Fan Motor normal?
Yes
Is wire connection of
ODU Fan Motor wire normal?
No
Check wiring between OUD fan motor and Inverter PCB
( Check if Hall Senor and Motor output terminal color is
matched)
→ Reassemble if abnormality found
Yes
Is Inverter PCB assembly normal?
No
Replace Inverter PCB assembly
Yes
Recheck power and installation condition
Check Point
1. Check voltage between 1pin and 4pin of Fan Mortor connector (Tester diode mode)
2. Voltage vaule should be in 1V ±0.2V.
Check voltage betwen
1pin and 4pin of fan motor
Fan motor
connector
Tester
<Main PCB>
Only for training and service purposes
- 80 -
5. Trouble Shooting
Display
code
73
Title
AC input instant over current error
(Matter of software)
Cause of error
Check point & Normal condition
Inverter PCB input power
current is over 48A(peak)
for 2ms
1. Overload operation (Pipe clogging/Covering/EEV
defect/Ref.overcharge)
2. Compressor damage
(Insulation damage/Motor damage)
3. Input voltage abnormal (L, N)
4. Power line assemble condition abnormal
5. Inverter PCB assembly damage
(input current sensing part)
n Error Diagnosis and Countermeasure Flow Chart
Is installation
condition normal?
No
Yes
1.Check Pipe clogging/distortion
2.Check Covering (Indoor/Outdoor Unit)
3.Check EEV connector assemble condition/normal operation
4.Check refrigerant pressure
→ Reassemble or manage if abnormality found
No
Check
L~N phase voltage is 220V ± 10%
→ Check connection condition and wiring if power is abnormal
No
1.Check L,N connection condition
2.Check wire disconnection and wiring
→ Reassemble if abnormality found
No
1.Check inverter PCB assembly U,V,W connector connection condition
2.Check wire disconnection and wiring
3.Check compressor terminal connection condition(bad contact)
→ Reassemble if abnormality found
Is input voltage normal?
Yes
Is AC input Wire connection
condition normal?
Yes
Is compressor
Wire connection
condition normal?
Yes
Is inverter PCB assembly
normal?
No
Check inverter PCB assembly IPM normality
→ Replace inverter PCB assembly
Yes
Recheck power and
installation condition
Only for training and service purposes
- 81 -
5. Trouble Shooting
N
L
< Main PCB wiring Check Point >
< Input Power Source Check Point >
Only for training and service purposes
- 82 -
P/No : MFL68280203
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