Toyótomi GAN-A128GVR T3, GAG-A128GVR T3, GAN-A135GVR T3, GAG-A135GVR T3 split-system air conditioner Service Manual

Service Manual
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Space to the wall
Space to the wall
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Start installation
Preparation before installation
Read the requirements
for electric connection
select installation
location
Select indoor unit
installation location
Prepare tools
Select outdoor unit
installation location
Install the support of outdoor unit
(select it according to the actual situation)
Install wall-mounting
frame, drill wall holes
Connect pipes of indoor
unit and drainage pipe
Fix outdoor unit
Connect wires of indoor unit
Install drainage joint of outdoor unit
(only for cooling and heating unit)
Bind up pipes and
hang the indoor unit
Make the bound pipes pass
through the wall hole and then
connect outdoor unit
Connect pipes of outdoor unit
Connect wires of outdoor unit
Neaten the pipes
Vacuum pumping and leakage detection
Check after installation and test operation
Finish installation
Note: this flow is only for reference; please find the more detailed installation steps in this section.
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Turn on the unit
and wait 1 minute
Use DC voltmeter
to measure the
voltage on the two
ends of electrolytic
capacitor
Voltage higher than 200V?
Y
Fault with the voltage
testing circuit on
control panel AP1
Replace the control
panel AP1
N
Measure the AC voltage between
terminalL and N on wiring board
XT(power supply)
Voltage within
210VAC~250VAC?
N
Shut down the power
and repair the power
supply to restore the
range
210VAC~250VAC
power on and
restart the unit
If the fault is
eliminated?
Y
Y
Shut down the power and wait 20 minutes;
or use DC voltmeter to measure the voltage
on the two ends of capacitor , until the
voltage is lower than 20V
N
Check the
connection of reactor
(L in the Electrical
Wiring Diagram)
If the wiring of
reactor Lis normal?
N
Connect the reactor
Laccording to Electrical Wiring Diagram correctly
Re-energize and
turn on the unit
If the fault is
eliminated?
Y
Y
Replace the control
panel AP1
N
End
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Energize and
switch on
IPM protection
occurs after the
machine has run for
a period of time?
Y
Use AC voltmeter
to measure the
voltage between
terminal L and N
on the wiring
board XT)
If the voltage
between terminal L
and N on wiring
board XT is within
210VAC~250VAC?
N
Check the supply
voltage and
restore it to
210VAC~250VAC
Y
Restart the unit. Before
protection occurs,
use DC voltmeter to
measure the voltage
between the two
ends of electrolytic
capacitor on control
panel AP1
Voltage between
the two ends of celectrolytic
capacitor is
higher than
250V
Y
Please confirm:
1. If the indoor and
outdoor heat
exchangers are
dirty? If they are
obstructed by other
objects which affect
the heat exchange
of indoor and
outdoor unit.
2. If the indoor and
outdoor fans are
working normally?
3. If the environment
temperature is too
high, resulting in
that the system
pressure is too high
and exceeds the
permissible range?
4. If the charge
volume of
refrigerant is too
much, resulting in
that the system
pressure is too
high?
5. Other conditions
resulting in that the
system pressure
becomes too high.
The connection
of capacitor C2
is loose.
N
Remove the wires
on the two ends of
capacitor C2. Then,
use capacitance
meter to measure
the capacitor C2.
Verify as per the
Parameters Sheet.
If capacitor
C2 is failed?
Replace the capacitor
C2. Then, energize
and start the unit.
Y
Replace the
control panel AP1
N
If there is any
abnormality
described above?
Y
Reconnect the
capacitor C2 according
to Electrical Wiring
Diagram. Then,
Restart the
unit.
Y
Stop the unit and
disconnect the power
supply. Wait 20 minutes,
or use DC voltmeter to
measure the voltage
between the two ends of
capacitor C2, until the
voltage is lower than 20V
Y
Take corrective actions
according to Technical
Service Manual, and
then energize and start
the unit.
Connect the control panel
AP1 and compressor
COMP correctly according
to the Electrical Wiring
Diagram. Then, energize
and start the unit.
If the
resistance is
normal?
N
N
If the unit can
work normallv?
If the unit can
work normally?
Y
Y
N
Replace the
control panel AP1
N
Use ohmmeter to
measure the resistance
between the three
terminals on compressor
COMP, and compare the
measurements with the
compressor resistance on
Service Manual.
Y
N
Stop the unit and
disconnect the power
supply. Then, check
the connection of
capacitor C2
according to Electrical
Wiring Diagram.
Refer to the
Electrical Wiring
Diagram and check
if the connection
between AP1 and
COMP is loose and if
the connection order
is correct.
If the connection
between AP1 and
COMP is unsecure
or the connection
order is wrong?
If the unit can
work
normally?
N
If the unit can
work
normally?
If the unit can
work normally?
Y
N
Y
Replace the
compressor
COMP
N
Use ohmmeter to
measure the resistance
between the two
terminals of compressor
COMP and copper tube.
Resistance higher
than 500MΩ?
Y
Replace the
control panel
AP1
END
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Overheat and high
temperature protection
Is outdoor ambient temperature higher than 53?
Y
Normal protection, please operate
it after the outdoor ambient temperature is normalized.
N
20 minutes after the complete
unit is powered off.
Is heat dissipation of the indoor unit
and outdoor unit abnormal?
Y
Improve the heat
dissipation environment of the unit
N
Does the outdoor fan work normally?
N
1. Check if the fan terminal OFAN
is connected correctly
2. Resistance between any two
terminals is measure by an ohm
gauge and should be less than 1K
Ohm.
Y
Replace the fan
capacitor C1
Replace the
control panel AP1
Replace the
outdoor fan
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Power on the unit
Is stop time of the compressor
longer than 3 minutes?
Restart it up after
3 minutes
N
Y
Does startup fail?
Y
Are the wires for the compressor connected
correctly? Is connection sequence right?
N
Connect the wires as
per the connection
diagram
Y
Replace the control panel AP1
N
If the fault is eliminated?
N
Replace the
compressor
Y
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Out of step occurs once the
unit is powered on.
Out of step occurs in
operation
Is stop time of the
compressor longer than
3 minutes?
Is the outdoor fan working
normally?
Is the outdoor unit blocked
by foreign objects?
Check if the fan terminal
OFAN is connected correctly
Replace the fan
capacitor C1
Replace the
outdoor fan
Remove foreign objects
Are the wires for the compressor connected
correctly? Is connection sequence right?
Is the connection made in clockwise
direction?
Replace the
control panel AP1
Connect the
wires correctly
Replace the control
panel AP1
If the fault is eliminated?
If the fault is eliminated?
Replace the
compressor
Replace the
compressor
End
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20 minutes after the
complete unit is
powered off
Is the terminal FA for the
electronic expansion valve
connected correctly?
Connect the
wires correctly
Resistances between the first four pins
close to the terminal hole and the fifth
pin are almost the same, less than 100
ohm.
Replace the electronic
expansion valve
If the fault is eliminated?
Replace the
control panel
AP1
If the fault is eliminated?
Coolant leakage, refilling
the coolant
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Check wiring of the
reactor (L) of the
outdoor unit and the
PFC capacitor
Whether there is any
damage or
short-circuit?
Y
Replace it as per the
wiring diagram and
reconnect the wires
If the fault is eliminated?
N
Remove the PFC capacitor
and measure resistance
between the two terminals.
Is the resistance around zero?
N
Y
The capacitor is
short circuited and
the capacitor
should be replaced
Restart the unit
If the fault is eliminated?
Y
N
Disconnect the terminals for the
reactor and measure the resistance
between the two terminals of the
reactor by an ohm gauge
Whether there is any damage
or short-circuit?
N
Y
Replace the reactor
Restart the unit
If the fault is eliminated?
Y
N
Replace the control
panel AP1
N
Y
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Start
Y
Did the equipment operate
normally before the failure
occurs?
N
Check the wiring of the indoor and
outdoor units with reference to the
wiring diagram
Check wiring inside of
the indoor and outdoor
units
Y
Is the connection right?
N
N
The AP1 voltage
detection circuit
is at fault
Y
Correctly connect the
corresponding wires for
the indoor and outdoor
units with reference to
the wiring diagram
Are wires broken?
N
If the fault is eliminated?
N
Check the communication
circuit of the outdoor unit
If the fault is eliminated?
The communication
circuit is abnormal
Y
N
Replace the main board
AP1 of the outdoor unit
If the fault is eliminated?
N
Replace the main board
of the indoor unit
Y
Y
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Turn on the unit
and wait 1 minute
Use DC voltmeter
to measure the
voltage on the two
ends of electrolytic
capacitor
Voltage higher than 200V?
Y
Fault with the voltage
testing circuit on
control panel AP1
Replace the control
panel AP1
N
Measure the AC voltage between
terminal L and N on wiring board
XT(power supply)
Voltage within
210VAC~250VAC?
N
Shut down the power
and repair the power
supply to restore the
range
210VAC~250VAC
power on and
restart the unit
If the fault is
eliminated?
Y
Y
Shut down the power and wait 20n muties; or
use DC voltmeter to measure the voltage
on the two ends of capacitor (test3), until
the voltage is lower than 20V
N
Check the
connection of reactor
(L in the Electrical
Wiring Diagram)
If the wiring of
reactor L is normal?
N
Connect the reactor
Laccording to
Electrical Wiring
Diagram correctly
Re-energize and
turn on the unit
If the fault is
eliminated?
Y
Y
Replace the control
panel AP1
N
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Energize and
switch on
IPM protection
occurs after the machine has run for
a period of time?
Use AC voltmeter
to measure the
voltage between
terminal L and N
on the wiring
board XT)
Y
If the voltage
between terminal L and N on wiring
board XT is within
210VAC~250VAC?
Check the supply
voltage and
restore it to
210VAC~250VAC
N
Y
Restart the unit. Before
protection occurs,use DC
voltmeter to measure the
voltage between the two
ends of electrolytic
capacitor on control
panel AP1 (test3)
Voltage between
the two ends of celectrolytic
capacitor (test3) is higher than
250V
Y
If the unit can
work normally?
N
Y
N
Please confirm:
1. If the indoor and
outdoor heat exchangers
are dirty? If they are
obstructed by other
objects which affect the
heat exchange of indoor
and outdoor unit.
2. If the indoor and
outdoor fans are
working normally?
3. If the environment
temperature is too
high, resulting in
that the system
pressure is too high
and exceeds the
permissible range?
4. If the charge
volume of refrigerant is
too much, resulting in
that the system
pressure is too high?
5. Other conditions
resulting in that the
system pressure
becomes too high.
Stop the unit and disconnect
the power supply. Then, check
the connection of capacitor
C2 according to Electrical
Wiring Diagram.
The connection
of capacitor C2 is loose.
N
Stop the unit and disconnect the
power supply. Wait 20 minutes,
or use DC voltmeter to measure
the voltage between the two
ends of capacitor C2, until the
voltage is lower than 20V
Remove the wires on the two
ends of capacitor C2. Then,
use capacitance meter to
measure the capacitor C2.
Verify as per the
Parameters Sheet.
If capacitor
C2 is failed?
Replace the
control panel AP1
If there is any
abnormality
described above?
Use ohmmeter to measure the
resistance between the two
terminals of compressor
COMP and copper tube.
Y
Y
N
Replace the
control panel AP1
If the unit can
work normally?
Y
N
Connect the control panel AP1 and
compressor COMP correctly according
to the Electrical Wiring Diagram.
Then, energize and start the unit.
If the unit can
work normally?
Use ohmmeter to measure the
resistance between the three
terminals on compressor COMP,
and compare the measurements
with the compressor resistance on
Service Manual.
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Take corrective actions
according to Technical
Service Manual, and
then energize and start
the unit.
Y
N
Y
If the unit can
work normallv?
N
Replace the capacitor
C2. Then, energize
and start the unit.
Y
N
Refer to the Electrical Wiring
Diagram and check if the
connection between AP1 and
COMP is loose and if the
connection order is correct.
If the connection
between AP1 and COMP is unsecure
or the connectionorder is wrong?
Reconnect the capacitor C2
according to Electrical
Wiring Diagram. Then,
Restart the unit.
Y
If the
resistance is
normal?
N
Y
Replace the
compressor COMP
N
Resistance higher
than 500MΩ?
N
Replace the
control panel AP1
END
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High temperature,
overload protection
If the outdoor
ambient temperature is higher than 53 ºC in
cooling mode?/if the ambient temperature of indoor
and outdoor unit is too high?
Y
Normal protection, please use it
after improving ambient temperature
of indoor and outdoor unit
N
If the radiating of outdoor
and indoor unit is well?
Y
Improve the radiating
environment of the unit
N
If the indoor and outdoor
fan work well?
N
1. Check if fan terminal
OFAN is connected well
2. Test if the motors of
indoor and outdoor unit are
broken
Y
check if the tube temp sensor is normal
according to the resistance sheet(check
outdoor tube temp in cooling mode, check
indoor tube temp sensor in heating mode)
Y
Replace fan
capacitor C1
Is the tube temp sensor normal?
De-energize the unit
and wait for 20min
Replace the control board(replace the outdoor
control board in cooling mode, replace the
indoor control board in heating mode)
Replace
outdoor fan
N
Replace the tube
temperature
sensor
End
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Energize the unit
and start it
If the stop time of compressor
is more than 3min?
If the stop time is not enough and the
high and low pressure of system is not
balance , please start it after 3min
N
Y
If the compressor wire COMP(UVW) is
well connected and connection sequence
is correct
Improve the connection situation
of control board AP1 and
compressor COMP, connect it
with wiring diagram
N
Y
Does the unit start
up normally?
If the refrigerant charging is
too much?
N
Y
Charge the
refrigerant according
to service manual
Does the unit start
up normally?
Y
N
Replace control board AP1
If malfunction is
removed?
N
Replace the
compressor
End
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Synchronism after
energize the unit
and start it
Synchronism
occurred during
operation
N
If the stop time of
compressor is more than
3min
Check if the fan
terminal OFAN is
connected well
Replace fan
capacitor C1
Y
Improve the radiating
of unit (clean heat
exchanger and
increase ventilation)
Replace
outdoor fan
N
Start to run until the
power resume normal
voltage
If the outdoor fan works
normally?
N
Y
Y
If the compressor
wire COMP(UVW) is well connected, the
connection sequence forwards to
clockwise direction?
N
Connect
wire well
Y
Replace
control board
AP1
Y
Remove
malfunction?
N
Replace
compressor
If the radiating of unit is
well?
N
If the input voltage of unit
is normal?
Y
If the refrigerant is too
much?
Charge the
refrigerant with
service manual
Y
N
Replace
control board
AP1
Remove
malfunction?
End
N
Y
Replace
compressor
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After the u nit
de-energized
for 20min
If the overload protector SAT
is well connected?
N
Y
Under ambient temperature, test the
resistance of overload protector with ohmic
meter, the resistance value<10000Ω
Y
N
If the wiring terminal FA of electron
expansion is well connected?
N
Connect the wire
well according to
wiring disgram
Y
Check if the coil of electron
expansion is installed on the
valve normally
Replace overload
protector SAT
Check if the expansion valve
is blocked
Remove
malfunction?
Y
N
Check refrigerant, if there is leakage,
please refer to specification
Remove
malfunction?
Y
N
check if the discharge temp
sensor is normal according to the
resistance sheet
N
Replace discharge
temp sensor
Y
Replace control
board
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Start
If the unit is operating
normally before malfunction
N
Y
Check connection wire
of indoor and outdoor
unit with circuit diagram
Check if the controller connection
wire inside indoor and outdoor
electric box is loose
Connection
correct?
Y
N
N
N
Connectwire of indoor
and outdoor unit
according to
circuit diagram
Connect wire of indoor
and outdoor unit
according to
circuit diagram
If the connection wire
is normal?
Y
Check communication
circuit of outdoor unit
If the malfunction
is removed?
N
Y
If the malfunction
is removed ?
Replace outdoor
mainboard (AP1)
Problem of
communication
circuit
N
If the
malfunction is
removed?
Replace indoor
mainboard
Y
Y
End
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Start
Test voltage
valueof Test10
position in
diagram with
voltage meter
Number jumping
N
Y
Test voltage value
of Test 13 position
in diagram with
voltage meter
Y
Number jumping
N
Y
Outdoor unit
malfunction
Test voltage
value of Test
10 position in
diagram with
voltage meter
Number jumping
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N
Y
Test voltage value
of Test 12 position
in diagram
with volltage
meter
N
Number jumping
Y
Communication
circuit of
outdoor
unit is normal
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