Air-to-water Heat Pump Monobloc Versati

Change for life
Air-to-water Heat Pump Monobloc Versati
Test Operation & Troubleshooting & Maintenance
GREE ELECTRIC APPLIANCES, INC.OF ZHUHAI
CONTENTS
1 Trial Run�������������������������������������������������������������������������������������������������� 1
1.1 Check for Wiring��������������������������������������������������������������������������������������������������������� 1
1.2 Check for the Water System�������������������������������������������������������������������������������������� 1
1.3 Check for the Communication System����������������������������������������������������������������������� 1
1.4 Trial Run��������������������������������������������������������������������������������������������������������������������� 1
2 Error Code List���������������������������������������������������������������������������������������� 1
3 Flow Chart Of Troubleshooting������������������������������������������������������������� 3
3.1 Comp High-pressure Protection E1�������������������������������������������������������������������������� 3
3.2 Comp Low- pressure Protection E3�������������������������������������������������������������������������� 4
3.3 Comp Discharge Temp Protection E4����������������������������������������������������������������������� 4
3.4 Overload Protection of Compressor or Driver Error�������������������������������������������������� 5
3.5 DC Fan Error EF������������������������������������������������������������������������������������������������������� 5
3.6 Temperature Sensor Error����������������������������������������������������������������������������������������� 6
3.7 Communication Malfunction E6�������������������������������������������������������������������������������� 6
3.8 Capacity Switch Error (Code:"C5")���������������������������������������������������������������������������� 7
4 Diagnosis of Driving������������������������������������������������������������������������������� 7
4.1 Diagnosis Flowchart of Driving of Single-phase Unit and Three-phase Unit������������� 7
5 Daily Maintenance and Repair��������������������������������������������������������������11
5.1 Daily Maintenance���������������������������������������������������������������������������������������������������� 11
5.2 Troubleshooting�������������������������������������������������������������������������������������������������������� 12
5.3 Repair����������������������������������������������������������������������������������������������������������������������� 12
Test Operation & Troubleshooting & Maintenance
1 Trial Run
1.1 Check for Wiring
WARNING!
Do not check for the power supply unless proper checkout equipment has prepared and preventive
measures have been taken, otherwise it would lead to severe injury.
◆◆ Are sizes of connection lines and the air switch proper?
◆◆ Does wiring comply with relative standards and electric codes?
◆◆ Is there any incorrect wiring?
◆◆ Does each contact work properly?
◆◆ Is the power supply and insulation proper?
◆◆ Are initial set points of control and protective elements satisfied?
1.2 Check for the Water System
◆◆ Are water inlet and outlet directions correct?
◆◆ Is the water piping cleaned? Are there foreign matters at the pipe joints? Is the water quality satisfied?
◆◆ Is insulation of water pipes in good condition?
◆◆ Does exhaust valve of the water system work properly?
1.3 Check for the Communication System
When the unit is powered on, check for the communication system, including: communication between AP1
and AP2, between the wired controller and the main board. When there is unusual communication, this error will
be displayed at the wired controller. Then, check out the cause according to the displayed error. See the figure
below for wiring of the communication system.
Long-distance
Minitor PC(BMS)
AP1
CN5
CN6
CN7
CN8
CN5(Red)
CN4(White)
Wired controller
AP2
1.4 Trial Run
Start the unit when there is no any problem for wiring and piping. After startup, check for the electrostatic
expansion valve, water pump, fan, and compressor to see if they work normally. When there is any error, solve
it according to the troubleshooting flowchart covered in this manual. However, if the troubleshooting flowchart is
still unhelpful, please contact GREE sales agent.
2 Error Code List
No.
Full Name
Displayed Name
Error Code
1
Ambient temperature sensor error
Ambient sensor
F4
2
Defrost temperature sensor error
Defro. sensor
d6
3
Discharge temperature sensor error
Disch. sensor
F7
4
Suction temperature sensor error
Suction sensor
F5
5
Outdoor fan error
Outdoor fan
EF
6
Compressor internal overload protection
Comp. overload
H3
1
Test Operation & Troubleshooting & Maintenance
7
High pressure protection
High pressure
E1
8
Low pressure protection
Low pressure
E3
9
High discharge protection
Hi-discharge
E4
10
Refrigerant loss protection
Refri-loss
P2
11
Heat pump-water pump protection
HP-pump
E0
12
Solar kit-water pump protection
SL-pump
EL
13
Swimming pool-water pump protection
14
Incorrect capacity DIP switch setting
15
Communication error between indoor and outdoor unit
16
Drive communication error
Drive com.
17
High pressure sensor error
HI-pre. sens.
Fc
18
Enthalpy-enhancing sensor error
En. senser
F8
19
Low pressure sensor error
LOW-pre. Sens.
dL
20
Heat exchanger-leaving water temperature sensor error
Temp-HELW
F9
21
Auxiliary heater-leaving water temperature sensor error
Temp-AHLW
dH
22
Heat exchanger-entering water temperature sensor error
Temp-HEEW
23
Water tank water temperature sensor 1 error
Tank sens. 1
24
Water tank water temperature sensor 2 error
Tank sens. 2
25
Solar kit-entering water temp sensor
T-SL water out
26
Solar kit-leaving water temp sensor
T-SL water in
FH
27
Solar kit- temp sensor
T-Solar pannel
FF
28
Swimming pool-entering water temp sensor
T-Swimming in
29
Swimming pool-leaving water temp sensor
T-Swimming out
30
Swimming pool-water temp sensor
31
Remote room sensor 1
T-Remote Air1
32
Remote room sensor 2
T-Remote Air2
33
Heat pump-water flow switch
HP-Water SW
Ec
34
Solar kit-water flow switch
SL-Water SW
F2
35
Swimming pool-water flow switch
SW-Water SW
F1
36
Welding protection of the auxiliary heater 1
Auxi. heater 1
EH
37
Welding protection of the auxiliary heater 2
Auxi. heater 2
EH
38
Welding protection of the water tank heater
Auxi. -WTH
EH
39
Under-voltage DC bus or voltage drop error
DC under-vol.
PL
40
Over-voltage DC bus
DC over-vol.
PH
41
AC current protection (input side)
AC curr. pro.
PA
42
IPM defective
IPM defective
H5
43
PFC defective
FPC defective
Hc
44
Start failure
Start failure
Lc
45
Phase loss
Phase loss
LD
46
Drive module resetting
Driver reset
P6
47
Compressor over-current
Com. over-cur.
P0
48
Overspeed
Overspeed
P5
49
Sensing circuit error or current sensor error
Current sen.
LF
Swimming-pump
Capacity DIP
c5
ODU-IDU Com.
E6
FE
T-Swimming
2
F3
Test Operation & Troubleshooting & Maintenance
50
Desynchronizing
Desynchronize
Pc
51
Compressor stalling
Comp. stalling
H7
52
Communication error
drive-main com.
LE
53
Radiator or IPM or PFC module overtemperature
Overtemp.-mod.
P8
54
Radiator or IPM or PFC module temperature sensor error
T-mod. sensor
P7
55
Charging circuit error
Charge circuit
Pu
56
Incorrect AC voltage input
AC voltage
PP
57
Drive board temperature sensor error
Temp-driver
PF
58
AC contactor protection or input zero crossing error
AC contactor
P9
59
Temperature drift protection
Temp. drift
PE
60
Current sensor connection protection (current sensor not connected to
phase U/V)
Sensor con.
PD
61
Communication error to the outdoor unit
ODU Com.
E6
62
Communication error to the indoor unit
IDU Com.
E6
63
Communication error to the drive
Driver Com.
E6
64
Solar kit-superheating
Solarsuperheat
F6
3 Flow Chart Of Troubleshooting
3.1 Comp High-pressure Protection E1
Comp High-pressure protection E1
yes
Check if the High-pressure switch
is broken
Replace the High-pressure
switch
no
yes
Check if the High-pressure switch
wiring is loose.
Replace the wiring
no
no
Check if the water in
the tank is enough
Fill the tank with the water
yes
yes
Check if the installation of
tank temp sensor is correct
Install rightly the
tank temp sensor
no
yes
Check if the gas valve and
liquid valve are fully open
Fully open the valve
no
yes
Check if the electric expansion
valve can work normally
3
Replace the electronic
expansion valve
Test Operation & Troubleshooting & Maintenance
3.2 Comp Low- pressure Protection E3
Comp Low-pressure Protection E3
yes
Check if comp low-pressure switch
is broken or the wiring is loose.
Replace comp
low- pressure or rewire
no
yes
Check the fans
Check if the fans stop running or reverse
no
no
Repair the leakage of system
pipe and add refrigerant
according to the required volume
Check if the system has leaked
3.3 Comp Discharge Temp Protection E4
Comp Discharge Temp Protection E4
Measure if the exhaust
temperature of compressor
reaches120℃
no
Measure if the
resistance of temperature
sensor is correct
no
yes
yes
Replace the mainboard
of AP2
Check if the the electronic
expansion valve is blocked
Replace the electronic
expansion valve
yes
Check if the system has leaked
no
The refrigerant of the system is
not enough and add refrigerant
according to the required volume
yes
Repair the leakage of system
pipe and add refrigerant
according to the required volume
4
Replace the corresponding
exhaust temperature
sensor
Test Operation & Troubleshooting & Maintenance
3.4 Overload Protection of Compressor or Driver Error
Comp Overload Protection
yes
Check if the AC
contactor is damaged
Replace the AC contactor
no
no
Check if the compressor
wiring is correct
Adjust the
compressor wiring
yes
no
Contact the power
supply company
Check if the voltage is normal
yes
yes
Check if the refrigerant of
the system is excessive
Recharge suitable
amount of the refrigerant
3.5 DC Fan Error EF
EF is displayed on
the wired controller
Is the motor wire
phase sequence right?
no
Adjust the motor wire
yes
Is the Fan wire
terminal loose?
yes
Tighten the fan
wiring terminal
no
Replace the mainboard AP2.
Does it work normally?
yes
no
Replace the outdoor fan
Work Normally
5
Test Operation & Troubleshooting & Maintenance
3.6 Temperature Sensor Error
Temperature Sensor Error
Check if the plug
on temperature sensor is correctly
connected to the socket.
no
Check the orientation
of plug and socket
yes
no
Check if the resistance of
temperature sensor is correct.
Replace the
temperature sensor
yes
Replace the mainboard of the AP1 or AP2
3.7 Communication Malfunction E6
Communication Malfunction E6
Check if the communication
line of the unit is connected
no
Check the orientation
of plug and socket
yes
no
Measure if the Communication
line is through
Replace the communication line
yes
no
Check if the communication line
of the unit is connected correctly
Check the orientation
of plug and socket
yes
no
Check if the monobloc unit
is electrically powered
6
Please supply power
to the monobloc unit
Test Operation & Troubleshooting & Maintenance
3.8 Capacity Switch Error (Code:"C5")
Communication Malfunction E6
Check if the communication
line of the unit is connected
no
Communication
Malfunction E6
yes
Measure if the Communication
line is through
no
Communication
Malfunction E6
yes
Check if the communication line
of the unit is connected correctly
yes
Communication
Malfunction E6
no
Communication
Malfunction E6
Communication
Malfunction E6
4 Diagnosis of Driving
4.1 Diagnosis Flowchart of Driving of Single-phase Unit and Three-phase Unit
4.1.1 Drive Module Reset(Code:"P0") ; IPM or PFC Temperature Sensor Error(Code:"P7") ; AC Current
Protection (Input Side)(Code:"PA"); Current Sense Circuit Error(code:"PC"); PFC Protection(Code:"HC")
7
Test Operation & Troubleshooting & Maintenance
“Driver reset”,“T-mod. sensor”,
“AC curr. pro.”,“FPC defective”
or “Current sen.” is displayed
on the wired controller
P0, P7, PA, HC
or PC is displayed
in the mainboard
88 indicating lamp
Replace
the driver board AP4
Work Normally
4.1.2 IPM or PFC Over-temperature Protection(Code:"P8")
“Overtemp.-mod.” is
displayed on the wired
controller
P8 is displayed in the
mainboard 88
Indicating Lamp
Is the IPM or
PFC module of the driver board AP4 tightened ?
Tighten the IPM or
PFC module
Replace the driver board AP4
Work Normally
8
Test Operation & Troubleshooting & Maintenance
4.1.3 DC Busbar Over-voltage Protection(Code:"PH") ; DC Busbar Under-voltage Protection(Code:"PL")
“DC over-vol.” or “DC
under-vol.” is displayed
on the wired controller
PH or PL is displayed
in the mainboard 88
Indicating Lamp
Is input voltage ranged
from 185VAC to 264VAC?
Replace the mainboard.
Does it work normally?
Replace the mainboard
Work Normally
Please cut off
the power and notify
the power company.
Note: three-phase input voltage is in the range from 320VAC to 475VAC.
4.1.4 Drive-to-main-control Communication Error(Code:"P6")
“Drive-main com.” is
Displayed on the wired
controller
P6 is displayed in the
mainboard 88
Indicating Lamp
Is the CPU tightened?
Is the CPU tightened?
Is the CPU tightened?
Work Normally
9
Test Operation & Troubleshooting & Maintenance
4.1.5 Compressor Startup Failure(code:"LC")
"Start failure" is
displayed on the
wired controller
LC is displayed in
the mainboard 88
indicating lamp
yes
Replace the driver board AP4.
Does it work Normally?
no
Replace
the compressor
Work Normally
4.1.6 Compressor Current Protection (Code:"P5"); Compressor Motor Desynchronizing (Code:"H7");
IPM Protection (Code:"H5"); Phase Loss (Code:"LD")
"Start failure" is
displayed on the
wired controller
LC is displayed in
the mainboard 88
indicating lamp
Replace the mainboard.
Does it work Normally?
no
LC is displayed in
the mainboard 88
indicating lamp
yes
LC is displayed in
the mainboard 88
indicating lamp
yes
Replace the mainboard.
Does it work Normally?
no
Replace the mainboard.
Does it work Normally?
no
yes
LC is displayed in
the mainboard 88
indicating lamp
Replace the mainboard.
Does it work Normally?
10
Test Operation & Troubleshooting & Maintenance
4.1.7 Charging Circuit Error(Code:"PU")
“Charge circuit” is
displayed on the
wired controller
PU is displayed in
the mainboard 88
indicating lamp
Is the PFC wire
tightened or is the
sequence right?
Tighten the PFC wire
or adjust the sequence
Replace
the mainboard
Work Normally
5 Daily Maintenance and Repair
5.1 Daily Maintenance
In order to avoid damage of unit, all protecting devices in the unit had been set before outgoing, so the user
can never adjust or remove them.
For the first startup of the unit or next startup of unit after long-period stop (above 1 day)by cutting off the
power, please electrify the unit in advance to preheat the unit for more than 8hr
Never put sundries on the unit and accessories. Keep dry, clean and ventilated around the unit.
Remove the dust accumulated on the condenser fin timely to ensure performance of unit and to avoid stop
of unit for protection.
In order to avoid protection or damage of unit caused by blockage of water system, clean the filter in water
system periodically and frequently check water replenishing device.
In order to ensure anti-freezing protection, never cut off the power if ambient temp. is below zero in winter.
In order to avoid frost crack of the unit, water in the unit and pipeline system not used for a long period
should be drained. In addition, open the end cap of water tank for drainage.
Never frequently make the unit on/off and close manual valve of water system during operation of unit by
users.
Ensure frequently check the working condition of each part to see if there is oil stain at pipeline joint and
charge valve to avoid leakage of refrigerant.
If malfunction of the unit is out of control of users, please timely contact with authorized service center of
company.
Note: the water pressure gage is installed in returning water line in the indoor unit, Please adjust the hydraulics
system pressure according to next item:
①If the pressure is less than 0.5 bar, please recharge the water immediately;
②When recharging, the hydraulics system pressure should be not more than 2.5 Bar.
11
Test Operation & Troubleshooting & Maintenance
5.2 Troubleshooting
Malfunctions
Reasons
Troubleshooting
Heavy noise of
compressor
①
②
Power supply has problem.
Connection wire is loose.
Malfunction of mainboard.
Malfunction of compressor.
Fixing bolt of fan is loose.
Fan blade touches shell or grill.
Operation of fan is unreliable.
Liquid slugging happens when liquid
refrigerant enters into compressor.
Internal parts in compressor are broken.
Water pump does
not run or runs
abnormally
①
②
③
Malfunction of power supply or terminal.
Malfunction of relay.
There is air in water pipe.
Compressor starts or
stops frequently
①
②
③
Poor or excess refrigerant.
Poor circulation of water system.
Low load.
The unit does not
heat although
compressor is
running
①
②
Leakage of refrigerant.
Malfunction of compressor.
Poor efficiency of hot
water heating
①
②
③
④
Poor heat insulation of water system.
Poor heat exchange of evaporator.
Poor refrigerant of unit.
Blockage of heat exchanger at water side.
Compressor does
not start up
①
②
③
④
Heavy noise of fan
①
②
③
①
②
③
④
①
②
③
①
②
③
①
②
Phase sequence is reverse.
Check out and re-fix.
Find out the reasons and repair.
Replace compressor.
Re-fix fixing bolt of fan.
Find out the reasons and adjust.
Replace fan.
Check if expansion valve is failure and
temp. sensor is loose .If that, repair it.
Replace compressor.
Find out the reasons and repair.
Replace relay.
Evacuate.
① Discharge or add part of refrigerant.
② Water system is blocked or there is air in
it.Check water pump, valve and pipeline.
Clean water filter or evacuate.
③ Adjust the load or add accumulating
devices.
Repair by leakage detection and add
refrigerant.
② Replace compressor.
①
Enhance heat insulation efficiency of the
system.
② Check if air in or out of unit is normal and
clean evaporator of the unit.
③ Check if refrigerant of unit leaks.
④ Clean or replace heat exchanger.
①
5.3 Repair
5.3.1 Key Components
Picture
Name
Function
Compressor
It is the heart of the cooling system, mainly used to
turn the low-temperature, low-pressure refrigerant
vapor to high-temperature high-pressure vapor and
then discharge it to the evaporator. The two-stage
enthalpy-adding compressor is adopted herein, which
can improve the heating performance of the unit
largely.
Electrostatic
Expansion Valve
It is one of four main components and used to turn
the hi-pressure liquid refrigerant to low-temperature,
low-pressure vapor-liquid mixture and adjust the
refrigerant flow rate entering the evaporator.
12
Test Operation & Troubleshooting & Maintenance
Vapor Liquid
Separator
It is installed at the side of the suction line, and used
to prevent liquid refrigerant entering the compressor,
which if not avoided will lead to wet compression or
even liquid slugging.
4-way Valve
It is used the switch flow direction of refrigerant
and then realize switchover between cooling and
heating. It also can be used for defrosting through the
counterflow.
Plate Heat
Exchanger
It is the water-refrigerant plate type heat exchanger,
used to liquefy the high-temperature high-pressure
vapor refrigerant or evaporate the low-temperature
low pressure liquid refrigerant. Heat of condensation
is taken away by circulation water and heat for
evaporation is supplied also by circulation water.
Water Pump
Expansion Tank
It is the power equipment for water circulation.
It is used to keep stable pressure of the water system.
The tank is charged with a certain volume of nitrogen
which is separated from the water side with a gasbag.
When pressure of the water side exceeds the nitrogen
pressure, the gasbag will expand and water enters
into the tank so as to lower the pressure of the water
system. In contract, when pressure of the water
system goes down, nitrogen in the tank will expel
water out to the water system.
13
Test Operation & Troubleshooting & Maintenance
Flow Switch
It is used to prevent the heat exchanger from being
frozen owing to reduced water flow rate. When the
flow rate goes down to the point at which the flow
switch will act, the switch will trip off and the unit will
raise an alarm and shut down.
Three-pipe Liquid
Receiver
Three pipes are connected to two electrostatic
expansion valves and the enthalpy-adding port of the
compressor respectively. It is mainly used to further
reduce pressure of the refrigerant which has gone
through the first-stage throttling and then vaporize
some refrigerant. The vaporized refrigerant will be
sucked in the compressor again so as to enhance the
heating performance of the system.
Safety Valve
It is used to prevent the pressure of circulation water
from increasing unusually. When the pressure is larger
than the set point (0.6MPa), this valve will open to
relieve water pressure.
Exhaust Valve
It is used to expel air trapped inside the water system
to make sure normal operation of the system. It is
usually installed at the highest point of the system.
5.3.2 Charging and Discharging of Refrigerant
he unit has been charged with refrigerant before delivery. Overcharging or undercharging will cause the
compressor to run improperly or be damaged. When refrigerant is required to be charged or discharged for
installation, maintenance and other reasons, please follow steps below and nominal charged volume on the
nameplate.
(1) Discharging: remove metal sheets of the outer casing, connect a hose to the charging valve and then
discharge refrigerant.
14
Test Operation & Troubleshooting & Maintenance
Charging
valve 2
Charging
valve 1
Notes
① Discharge is allowed unless the unit has been stopped. (Cut off the power and repower it 1 minutes
later)
② Protective measures should be taken during discharging to avoid frost bites.
③ When discharging is finished, if vacuuming cannot be done immediately, remove the hose to avoid air or
foreign matters entering the unit.
(2) Vacuuming: When discharging is finished, use hoses to connect the charging valve, manometer and
vacuum pump to vacuum the unit.
Pressure Meter
Connection Pipe
Vacuum pump
Note: when vacuuming is finished, pressure inside the unit should be kept lower than 80Pa for at least 30
minutes to make sure there is no leak. Either charging valve 1 or charging valve 2 can be used for vacuuming.
(3) Charging: when vacuuming is finished and it is certain that there is no leak, charging can be done.
◆◆ Be sure to charge the specified amount of refrigerant in liquid state.
Since this refrigerant is a mixed refrigerant, adding it in gas form may cause the refrigerant composition to
change, preventing normal operation.
◆◆ Before charging, check whether the refrigerant cylinder is equipped with a siphon tube or not.
With siphon tube
No siphon tube
15
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