Toyotomi GAG-A128GVR-T3, GAG-A180GVR-T3 Service Manual

Service Manual

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Space to the wall

At least 15cm

At least 300cm

Space to the obstruction

Space to the wall

At least 15cm

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Space to the wall

At least 30cm

Space to the obstruction

At least 30cm

Drainage pipe

Space to the obstruction

At least 50cm

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Start installation

Preparation before installation

Read the requirements for electric connection select installation location

Prepare tools

Select indoor unit installation location

Install wall-mounting frame, drill wall holes

Connect pipes of indoor unit and drainage pipe

Connect wires of indoor unit

Bind up pipes and hang the indoor unit

Select outdoor unit installation location

Install the support of outdoor unit

(select it according to the actual situation)

Fix outdoor unit

Install drainage joint of outdoor unit

(only for cooling and heating 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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Use DC voltmeter to measure the voltage on the two ends of electrolytic capacitor

Voltage higher than 200V?

N

Measure the AC voltage between terminal L and N on wiring board

XT(power supply)

Y

Fault with the voltage testing circuit on control panel AP1

Replace the control panel AP1

Voltage within

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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

Shut down the power and repair the power supply to restore the range

210VAC~250VAC power on and restart the unit

N

Check the connection of reactor

(L in the Electrical

Wiring Diagram)

If the wiring of reactor L is normal?

Y

Replace the control panel AP1

N

Connect the reactor

Laccording to Electrical Wiring Diagram correctly

Re-energize and turn on the unit

N

If the fault is eliminated?

Y

If the fault is eliminated?

Y

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?

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.

Refer to the

Electrical Wiring

Diagram and check

if the connection between AP1 and

COMP is loose and if the connection order is correct.

Voltage between the two ends of celectrolytic capacitor is higher than

250V

N

Stop the unit and

disconnect the power

supply. Then, check

the connection of capacitor C2 according to Electrical

Wiring Diagram.

Remove the wires

on the two ends of capacitor C2. Then, use capacitance meter to measure the capacitor C2.

Verify as per the

Parameters Sheet.

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

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

N

Y

N

If capacitor

C2 is failed?

N

If there is any abnormality described above?

N

Y

Replace the capacitor

C2. Then, energize and start the unit.

Replace the control panel AP1

Y

Take corrective actions according to Technical

Service Manual, and then energize and start the unit.

Replace the control panel AP1

N

Check the supply voltage and restore it to

210VAC~250VAC unit.

N

If the unit can work normally?

Reconnect the capacitor C2 according to Electrical Wiring

Diagram. Then,

Restart the

If the unit can work normallv?

If the unit can work normally?

If the unit can work normally?

N

Y

Y

Y

Y

If the connection between AP1 and

COMP is unsecure or the connection order is wrong?

Y

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?

Y

Use ohmmeter to measure the resistance between the three terminals on compressor

COMP, and compare the measurements with the compressor resistance on

Service Manual.

Use ohmmeter to measure the resistance between the two terminals of compressor

COMP and copper tube.

If the resistance is normal?

N

Resistance higher than 500MΩ?

Y

Replace the control panel

AP1

Replace the compressor

COMP

N

END

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Overheat and high temperature protection

Is outdoor ambient temperature higher than 53?

N

20 minutes after the complete unit is powered off.

Y

Normal protection, please operate it after the outdoor ambient temperature is normalized.

Is heat dissipation of the indoor unit and outdoor unit abnormal?

N

Y

Improve the heat dissipation environment of the unit

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 control panel AP1

Replace the fan capacitor C1

Replace the outdoor fan

End

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Power on the unit

N

Is stop time of the compressor longer than 3 minutes?

Y

Does startup fail?

Y

Are the wires for the compressor connected correctly? Is connection sequence right?

N

Restart it up after

3 minutes

N

Connect the wires as per the connection diagram

Y

Replace the control panel AP1

If the fault is eliminated?

N

Replace the compressor

Y

End

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Out of step occurs once the unit is powered on.

Is stop time of the compressor longer than

3 minutes?

Are the wires for the compressor connected correctly? Is connection sequence right?

Is the connection made in clockwise direction?

Connect the wires correctly

Replace the control panel AP1

If the fault is eliminated?

Replace the compressor

End

Out of step occurs in operation

Is the outdoor fan working normally?

Check if the fan terminal

OFAN is connected correctly

Replace the fan capacitor C1

Replace the outdoor fan

Remove foreign objects

Is the outdoor unit blocked by foreign objects?

Replace the control panel AP1

If the fault is eliminated?

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

End

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Start

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

N

Remove the PFC capacitor and measure resistance between the two terminals.

Is the resistance around zero?

N

Disconnect the terminals for the reactor and measure the resistance between the two terminals of the reactor by an ohm gauge

Y

The capacitor is short circuited and the capacitor should be replaced

N

Restart the unit

N

Whether there is any damage or short-circuit?

Y Replace the reactor

N

Restart the unit

Replace the control panel AP1

N

If the fault is eliminated?

If the fault is eliminated?

If the fault is eliminated?

Y

Y

Y

End

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Start

Y

Check wiring inside of the indoor and outdoor units

The AP1 voltage detection circuit is at fault

Y

If the fault is eliminated?

N

Are wires broken?

N

Check the communication circuit of the outdoor unit

Did the equipment operate normally before the failure occurs?

Y

N

N

Check the wiring of the indoor and outdoor units with reference to the wiring diagram

Is the connection right?

N

Correctly connect the corresponding wires for the indoor and outdoor units with reference to the wiring diagram

If the fault is eliminated?

Y

The communication circuit is abnormal

Y

Replace the main board

AP1 of the outdoor unit

N

Replace the main board of the indoor unit

N

If the fault is eliminated?

Y

End

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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?

N

Measure the AC voltage between terminal L and N on wiring board

XT(power supply)

Y

Fault with the voltage testing circuit on control panel AP1

Voltage within

210VAC~250VAC?

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

Shut down the power and repair the power supply to restore the range

210VAC~250VAC

Replace the control panel AP1 power on and restart the unit

N

Check the connection of reactor

(L in the Electrical

Wiring Diagram)

If the fault is eliminated?

If the wiring of reactor L is normal?

Y

Replace the control panel AP1

N

Connect the reactor

Laccording to

Electrical Wiring

Diagram correctly

Re-energize and turn on the unit

N

If the fault is eliminated?

Y

Y

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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)

Refer to the Electrical Wiring

Diagram and check if the connection between AP1 and

COMP is loose and if the connection order is correct.

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.

Voltage between the two ends of celectrolytic capacitor (test3) is higher than

250V

N

Stop the unit and disconnect the power supply. Then, check the connection of capacitor

C2 according to Electrical

Wiring Diagram.

Remove the wires on the two ends of capacitor C2. Then, use capacitance meter to measure the capacitor C2.

Verify as per the

Parameters Sheet.

If capacitor

C2 is failed?

N

Y

If there is any abnormality described above?

Y

If the voltage between terminal L and N on wiring board XT is within

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 (test3)

The connection of capacitor C2 is loose.

Replace the the unit.

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

Replace the capacitor

C2. Then, energize and start the unit.

control panel AP1

Take corrective actions according to Technical

Service Manual, and then energize and start

N

Y

N

N

N

Check the supply voltage and restore it to

210VAC~250VAC

If the unit can work normally?

Reconnect the capacitor C2 according to Electrical

Wiring Diagram. Then,

Restart the unit.

If the unit can work normallv?

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If the unit can work normally?

Y

Y

Y

Y

Replace the control panel AP1

N

If the connection between AP1 and COMP is unsecure or the connectionorder is wrong?

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?

Y

Use ohmmeter to measure the resistance between the three terminals on compressor COMP, and compare the measurements with the compressor resistance on

Service Manual.

If the resistance is normal?

N

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?

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

N

Normal protection, please use it after improving ambient temperature of indoor and outdoor unit

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?

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)

N

1. Check if fan terminal

OFAN is connected well

2. Test if the motors of indoor and outdoor unit are broken

Replace fan capacitor C1

Y

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)

Is the tube temp sensor normal?

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?

Y

If the compressor wire COMP(UVW) is well connected and connection sequence is correct

Y

If the refrigerant charging is too much?

Y

Charge the refrigerant according to service manual

N

N

Improve the connection situation of control board AP1 and compressor COMP, connect it with wiring diagram

N

If the stop time is not enough and the high and low pressure of system is not balance , please start it after 3min

Does the unit start up normally?

Does the unit start up normally?

N

Replace control board AP1

If malfunction is removed?

N

Replace the compressor

End

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N

Synchronism after energize the unit and start it

N

If the stop time of compressor is more than

3min

Y

If the compressor wire COMP(UVW) is well connected, the connection sequence forwards to clockwise direction?

Connect wire well

Y

Y

Replace control board

AP1

Remove malfunction?

N

Replace compressor

End

Synchronism occurred during operation

If the outdoor fan works normally?

Y

N

Check if the fan terminal OFAN is connected well

If the radiating of unit is well?

N

Y

Improve the radiating of unit (clean heat exchanger and increase ventilation)

N

Start to run until the power resume normal voltage

If the input voltage of unit is normal?

Y

If the refrigerant is too much?

N

Replace control board

AP1

Y

Charge the refrigerant with service manual

Remove malfunction?

N

Replace compressor

Y

End

Replace fan capacitor C1

Replace outdoor fan

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After the u nit de-energized for 20min

N

If the overload protector SAT is well connected?

Y

Under ambient temperature, test the resistance of overload protector with ohmic meter, the resistance value<10000Ω

Y

If the wiring terminal FA of electron expansion is well connected?

Y

Check if the coil of electron expansion is installed on the valve normally

N

N

Connect the wire well according to wiring disgram

Replace overload protector SAT

Check if the expansion valve is blocked

Remove malfunction?

N

Check refrigerant, if there is leakage, please refer to specification

Y

Remove malfunction?

N check if the discharge temp sensor is normal according to the resistance sheet

Y

Replace control board

End

Y

N

Replace discharge temp sensor

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If the unit is operating normally before malfunction

Y

Check if the controller connection wire inside indoor and outdoor electric box is loose

N

Connectwire of indoor and outdoor unit according to circuit diagram

If the connection wire is normal?

Y

Check communication circuit of outdoor unit

N

If the malfunction is removed ?

Problem of communication circuit

N

Replace indoor mainboard

Y

Y

Replace outdoor mainboard (AP1)

If the malfunction is removed?

Y

End

Y

N

N

Check connection wire of indoor and outdoor unit with circuit diagram

Connection correct?

N

Connect wire of indoor and outdoor unit according to circuit diagram

If the malfunction is removed?

Y

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Test voltage valueof Test10 position in diagram with voltage meter

Number jumping

Y

Test voltage value of Test 13 position in diagram with voltage meter

Y

Number jumping

Y

Test voltage value of Test

10 position in diagram with voltage meter

Number jumping

Y

Test voltage value of Test 12 position in diagram with volltage meter

N

N

N

Outdoor unit malfunction

End

N

Number jumping

Y

Communication circuit of outdoor unit is normal

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