Service Manual 9. Maintenance · Fuse of controller burnt out The air condi-tioner does not react...
Transcript of Service Manual 9. Maintenance · Fuse of controller burnt out The air condi-tioner does not react...
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Service Manual
Installation and Maintenance
9. Maintenance9.1 Troubleshooting for Normal Malfunction
The remotecontroller doesnot receivesignals (after itis powered, thebuzzer willsound, unless ithasmalfunction)
Trip of breaker orblow of fuse
Air
cond
ition
er c
an n
otst
art u
p
Measure insulation resistanceto ground to see if there is anyleakage.
The circuit or the part of the airconditioner has malfunction.They heat and break the insula-tion and lead to short circuit orcreepage. Measure the insula-tion resistance or eliminate themalfunction one by one. If thebreaker itself has malfunction,then replace the breaker.
The transformer connection isloose or has bad contact or thetransformer has malfunction.
Fasten the wiring; measure theoutput voltage of the trans-former , if it is incorrect, changethe transformer.
No power Check power supply circuit.
Power plug is not well plugged inand poor connection.
Check if the plug is properlyplugged in and make the loosecontact firm.
Fuse of controller burnt out
The air condi-tioner does notreact after it ispowered ( afterthe plug isinserted, thebuzzer does notsound and theremote startuphas noresponse)
Remote controller malfunction
Receiver loose or poor connection
Receiver is broken
Change controller fuse
Controller is broken Check remote controller
Remote controller is short of power Change batteries
First, press the manual switchbutton AUTO,i f there is noresponse,check based on theabove methods. If it runs nor-mally after pressing the button,check again whether the instal-lation position and the connec-tion wire of the reception headis correct. If it is correct,then re-place the receiver or the remotecontroller.
Power voltage is too lowCheck the voltage. If it is lower than 10% ofthe rated voltage, check the cause, improvethe power supply condition and add the sta-bilized voltage power supply.
The breaker trips at once when itis set to “ON”.
The breaker trips in few minuteswhen it is set to “ON”.
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Improper set of temperature Adjust set temperature
If cooling (heating) load isproper
Check the forecasted load of cooling (heating)
The refrigerant has leakage or isinsufficient
Check and f i l l the leakage, thenvacuumize it and supplement the re-frigerant as required
Leakage between the high pres-sure and the low pressure in-side the compressor
Replace the compressor
Malfunction of four-way valve Replace the four-way valve
Local block of capillary Replace the capillary
Blockage of cooling system
Judge whether the system is blocked byobserving the condensation of evapora-tor and the pressure value of the highpressure manometer and take measuresto deal with the system.
Malfunction ofr e f r i g e r a n tflow
Heat insulation for the connectionpipes of the indoor unit and the out-door unit is bad.
Make sure that heat insulation for the thick and thin pipesis good. Heat insulation must also be provided for thejoint andthe exposed part of the copper pipe .
Block of outdoor heat ex-changer
Clean the dust accumulated on the surface of the heat exchanger.
Air filter were blocked Clean the filter
Fan speed was set too slowTo set the fan speed to high ormiddle speedAir circulation
is insufficient
Fan rotation speed becomeslow
Capacitordamage
Motor damage
Replace the capacitor
Replace the motor
The installation position of theoutdoor unit is not appropriate.
Good ventilation must be provided for theinstallation position of the outdoor unit.
The outdoor temperature is too high. Properly install the rainproof plate or the sunproof plate. If themaximum cool air still can not meet the requirement, it is sug-gested to replace the air conditioner.
Keep certain air tightness indoors, try not to useelectricalappliance with large quantity of heat
The air tightness is not enough. Peoplecome in and out too frequently. Thereare heating devices indoors.
Poo
r CO
OL(
HE
AT) o
pera
tion
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The indoor fan motor is burned orbreaks or has the heat protectormalfunction.
Replace the fan motor or the defective part.
Wrong connectionMake the correction connection based onthe circuit drawing.
The fan capacitor has open circuit oris damaged.
The fan does notrun when it is setto supply air.
Replace the fan capacitor of the same typeand same specification.
The outdoor fan motor is damaged. Replace the fan motor
Wrong connection Make the correct connection based on thecircuit drawing
The outdoor fan capacitor is damaged. Replace the fan capacitor
Malfunction of compressor Replace the compressor
Breakage of running capacitor ofcompressor Replace the capacitor
The voltage is too low or toohigh.
Manostat is recommended.
Wrong wire connection Connect the circuit diagram correctly
The built-in heat protector of themotor breaks frequently because themotor is abnormal.
Replace the fan motor
Adjust the volume of the refrigerantThe refrigerant is not enough or is toomuch.
Replace the capillaryThe capillary is blocked and the tem-perature rises.
The compressor does not runsmoothly or is stuck. The air dischargevalve is damaged
Replace the compressor
The protector itself has malfunction. Replace the protector
The compres-sor is too hotand leads to theaction of theprotector.
The protector itself has malfunction.Use the multimeter to check whether thecontact of the compressor is on when it isnot overheated. If it is not on, then replacethe protector
In the cooling andheating mode,the compressorruns, but the out-door fan does notrun.
In the coolingand heatingmode, theoutdoor fanruns, but thecompressordoes not run.
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Adjust fan locationFan of indoor unit contacts other parts
Foreign object in indoor unit Take out the foreign object
Adjust support washer of compressor, andtighten loosen screws
Touch of pipeline of outdoor unit Separate the touching pipeline.Abnormal soundand shake
Touch of inner plates1. Tighten connect screw.2. Stick absorbing clay between plates.
Louver of outdoor unit touched outercase. Adjust location of louver.
Abnormal sound inside compressor Change compressor
Drainage pipe blocked or broken Change drainage pipe
Re-wrap and make it tight.Wrap of refrigerant pipe joint is notclose enough.
Water leakage
Change controller
Wire loose or wrong connection
In cool, heatmode, theoutdoor unitand compres-sor will not run.
Correctly wire according to the drawing
Improper setting of temperature Adjust setting temp.
Contro l ler mal funct ion ( IC2003broken, creepage of parallel capaci-tor of relay loop, relay is broken etc.)
First, check whether the connection iswrong. If no, replace the partsThe swing fan
does not run.
The torque of the swing motor is notenough
Wrong connection
The controller is damaged(IC2003 isdamaged, the swing relay can notclose, etc)
Compressor shakes too much
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9.2 Error Code List
No. 8 Code Display
Yellow Indicator
RedIndicator
GreenIndicator
1 protection of system
E1operation, except indoor fan operates, all loads stop operation.
2 Antifreezingprotection E2
3 times
operation, compressor and
operates.
3Refrigerant
protection 9 times stops.
4 protection of compressor
E47 times
operation, compressor and
operates.
stop.
5 protection E55 times
operation, compressor and
operates.
stop.
6 E6 AlwaysON indoor fan motor operates.
7 resistantprotection
E86 times
operation:compressor will stop
8 EEPROM EE11 times
operation, compressor will
AP1
9
Limit/decrease
EUcompressor is decreased
control panel AP1.
10 protection of C5
mainboard.
mainboard.
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No. 8 Code Display
Yellow Indicator
RedIndicator
GreenIndicator
11 refrigerant 17 timesrefrigerant
Nominal cooling mode
12
Indoor ambient
sensor is open/
1. Loosening or bad contact ofindoor ambient temp. sensor and mainboard terminal.2. Components in mainboard fell
3. Indoor ambient temp. sensor
4. Mainboard damaged.
13 sensor is open/Cooling,drying:internal fan motor
Heating: AC stop operation
1. Loosening or bad contact of
and mainboard terminal.
4. Mainboard damaged.
14 sensor is open/ 6 times
15condenser
sensor is open/ 5 times
16sensor is open/ 7 times
operation, compressor will
17Limit/decrease
3 times compressor is decreased
18Decrease
once compressor is decreased
19Decrease
twice compressor is decreased
20Limit/decrease
antifreezing 4 times compressor is decreased fan speed is too low
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No. 8 Code Display
Yellow Indicator
RedIndicator
GreenIndicator
21Voltage for DC
PH13 times
operation, compressor will stop normal range.
electrolytic capacitor C on control
22 Voltage of DC PL12 times
operation, compressor will stop normal range.
electrolytic capacitor C on control
23Compressor Min
stateP0
24Compressor rated
stateP1
25
Compressor
state
P2
26
Compressorintermediate
state
P3
27 protection of
compressor
P5operation, compressor will stop analysis (IPM protection, loss
28capacitor
PUoperation, compressor will stop
29 P7operation, compressor will stop
AP1
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No. 8 Code Display
Yellow Indicator
RedIndicator
GreenIndicator
30protection
P8operation,compressor will stop
control panel AP1.
31 protection for compressor
H38 times
operation, compressor will stop
32 IPM protection H54 times
operation, compressor will stop
33 H510 times
1. Wiring terminal OVC-COMP
34Internal motor(fan motor) do not operate
H6
Internal fan motor, external fan motor, compressor and electric
stops at present location.
35 of compressor H7operation, compressor will stop analysis (IPM protection,loss
36 HC14 times
operation, compressor will stop
37 L314 times lead to compressor stop operation
1. Bad contact of DC motor
2. Bad contact of DC motor controlend.
38 power protection L99 times
compressor stop operation and
and compressor will restart
analysis (IPM protection,loss
39 LP16 times
40 LCoperation, compressor will stop
loosed
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No. 8 Code Display
Yellow Indicator
RedIndicator
GreenIndicator
41
for compressor
U1operation,compressor will stop
power
42 U3operation, compressor will stop
43 U5
44 U7 AP1
45 limiting(power) 13 times
46 Compressor
once
478 times
2.Wiring terminal 4V is loosened
3.4V is damaged, please replace 4V.
4811 times AP1
49 Normal
once
50Defrosting(Heating indicator mode.Compressor will operate
operation.
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9.3 Troubleshooting for Main Malfunction
1. Malfunction of Temperature Sensor F1, F2
Troubleshooting for F1,F2 malfunction
Isthe wiring terminal between the
temperature sensor and the controllerloosened or poorly contacted?
Insert the temperature sensor tightly
yes
Is malfunction eliminated
Is there short circuit due to trip-over ofthe parts?
Make the parts upright
yes
Is malfunctioneliminated
Replace the mainboard with the same model.
End
no
no
Is the temperature sensor normal according
to the Resistance Table?
no
Replace it with atemperature sensorwith the same model
no
yes
yesIs malfunction removed
no
yes
yes
no
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2. Malfunction of Blocked Protection of IDU Fan Motor H6
End
No
YesNo
Yes
No
Yes
Yes
Yes
No
No
No
Yes
YesNo
Turn the fan blades
by hand under
power-off condition
Whether the fan blades can run smoothly?
Adjust the motor and blade assembly so that rotor can run smoothly.
Under power-off condition, check whether the wiring terminal
between indoor fan and main board is loose.
Turn unit on to check whether the
malfunction is eliminated.
Turn unit on to check whether the
malfunction is eliminated.
Reinsert the wiring terminal of indoor fan.
It's the malfunction of main board.Replace a new main board that is of the same model.
It's the malfunction of main board.Replace a new main board that is of the same model.
Replace a new main board that is of the same model.
It's the malfunction of main board.
Then check whether the voltage
between terminal 2 and terminal 3
of the motor interface is 15VDC.
Connect power and restart the unit.
Test whether the voltage between terminal 1 and terminal 2 of motor interface is within 280~310VDC.
Then check whether there is voltage
between terminal 2 and terminal 4
of the motor interface.
It's the malfunction of motor. Replace a new motor that is of the same model.
Start
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3. Malfunction of Protection of Jumper Cap C5
Appearance ofthe jumper cap
Troubleshooting for C5malfunction
Is there jumper cap on the mainboard?
Isthe jumper cap inserted
correctly and tightly?
Replace the jumper cap with the same model
End
yes
yes
Assemble the jumpercap with the samemodel
no
Is malfunctioneliminatedno
yes
Insert the jumper cap
tightly
Is malfunction eliminated
no
no yes
Is malfunction eliminated
no
yes
Replace the mainboard with the same model.
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4. Communication malfunction E6
Start
Cut off power, check if the wire between indoor unit and outdoorunit, and the wire inside electric box are connected correctly
Connected correctly? No
No
No
No
NoNo
No
End
Yes
Yes
Yes
Yes
Yes
Yes
Malfunction is eliminated
Malfunction is eliminated
Malfunction is eliminated
Malfunction is eliminated
Replace outdoormainboard
Replace indoormainboard
Communication wire connection is broken?
Replace the wire
Is there incorrectmatch between the mainboardand the display panel or between
the indoor and outdoor mainboards?
Match them according tothe requirement
Reconnect the wire according towiring diagram
Yes
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(1) Capacitor charge fault (Fault with outdoor unit) (AP1 below refers to the outdoor control panel)
N
Y
N
Y
N
Y
N
Y
N
Y
Turn on the unitand wait 1 minute
Use DC voltmeter to measure the
voltage on the two ends of electrolytic
capacitor
Voltage higher than 200V?Fault with the voltage
testing circuit on control panel AP1
Replace the control panel AP1
Measure the AC voltage between terminalL andN on wiring boardXT(power supply)
Voltage within 210VAC~250VAC?
Shut down the powerand repair the powersupply to restore therange210VAC~250VAC
power on andrestart the unit
If the fault iseliminated?
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
Check the connection of reactor (L in the Electrical Wiring Diagram)
If the wiring ofreactor L is normal?
Connect the reactor Laccording to Elec-trical Wiring Diagr-am correctly
Re-energize andturn on the unit
If the fault iseliminated?
End
Replace the controlpanel AP1
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(2) IPM Protection, Out-of-step Fault, Compressor Phase Overcurrent (AP1 below refers to the outdoor control panel)
Energize and switch on
IPM protection occurs after the
machine has run for a period of time?
Use AC voltmeterto measure the voltage betweenterminal L and N on the wiring board XT)
If the voltage between terminal L and N on wiringboard XT is within 210VAC~250VAC?
Check the supply voltage and restore it to
210VAC~250VAC
Voltage between the two ends of celectrolytic
capacitor is
Restart theunit. Beforeprotection occurs,use DC voltmeter tomeasure the voltage
between the two ends of electrolyticcapacitor on control
panel AP1
If the unit can work
normally?
Please confirm: 1. If the indoor and outdoor heatexchangers are dirty? If they are obstructed by other
objects which affectthe heat exchange of indoor andoutdoor unit. 2. If the indoor and outdoor fans are working normally?
3. If the environment temperature is too high, resulting inthat the system
pressure is too high and exceeds the
permissible range? 4. If the chargevolume ofrefrigerant is too much, resulting in that the systempressure is too high?
5. Other conditionsresulting in that the system pressurebecomes too high.
The connection of capacitor C2
is loose.
Reconnect the capacitor C2 according to Electrical WiringDiagram. Then,Restart theunit.
Stop the unit and disconnect the power supply. Wait 20 minutes, or use DC voltmeter tomeasure the voltage
between the two ends ofcapacitor C2, until the
voltage is lower than 20V
Replace the capacitor C2. Then, energize and start the unit.
Replace the control panel AP1
Take corrective actions according to TechnicalService Manual, and
then energize and start the unit.
If there is any abnormality
described above?
Replace the control panel AP1
If the connection between AP1 and COMP is unsecure or the connection order is wrong?
Connect the control panelAP1 and compressorCOMP correctly according to the Electrical WiringDiagram. Then, energizeand start the unit.
Use ohmmeter tomeasure the resistancebetween the three terminals on compressorCOMP, and compare the measurements with the
compressor resistance on Service Manual.
If the resistance is
normal?
Use ohmmeter tomeasure the resistancebetween the two
terminals of compressorCOMP and copper tube.
Replace the compressor
COMP
Resistance higherthan 500MΩ?
Replace the control panel
AP1
END
Y N
YN
Y
N
Y
If the unit can work normallv? Y
If the unit can work normally? Y
N
N
Y
N
If the unit can worknormally? YY
N N
If the unit can work
normally?Y
Y
N
Y
N
N
Y
higher than 250V
Remove the wires on the two ends ofcapacitor C2. Then,use capacitancemeter to measurethe capacitor C2.Verify as per theParameters Sheet.
Stop the unit and disconnect the power supply. Then, check the connection ofcapacitor C2according to ElectricalWiring Diagram.
If capacitorC2 is failed?
Refer to the Electrical Wiring Diagram and check if the connectionbetween AP1 andCOMP is loose and ifthe connection orderis correct.
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(3) High temperature and overload protection diagnosis (AP1 hereinafter refers to the control board of the outdoor unit)Mainly detect:
End
Y
N
Y
N
Y
N
Overheat and high temperature protection
Is outdoor ambient temperature higher than 53?
20 minutes after the complete unit is powered off.
Is heat dissipation of the indoor unit and outdoor unit abnormal?
Normal protection, please operate it after the outdoor ambient temp-erature is normalized.
Improve the heatdissipation environ-ment of the unit
Does the outdoor fan work normally?
1. Check if the fan terminal OFANis connected correctly2. Resistance between any two terminals is measure by an ohm gauge and should be less than 1KOhm.
Replace the control panel AP1
Replace the fan capacitor C1
Replace the outdoor fan
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(4) Start-up failure (following AP1 for outdoor unit control board)Mainly detect:
Y
N
Y
N
N
Y
Y
N
Power on the unit
Is stop time of the compressor longer than 3 minutes?
Restart it up after 3 minutes
Does startup fail?
Are the wires for the compressor connected correctly? Is connection sequence right?
Connect the wires as per the connectiondiagram
Replace the control panel AP1
If the fault is eliminated?
Replace the compressor
End
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(5) Out of step diagnosis for the compressor (AP1 hereinafter refers to the control board of the outdoor unit)Mainly detect:
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?
Is the outdoor unit blocked by foreign objects?
Replace the control panel AP1
If the fault is eliminated?
Replace the compressor
End
Check if the fan terminal OFAN is connected correctly
Remove foreign objects
Replace the fan capacitor C1
Replace the outdoor fan
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(6) Overload and air exhaust malfunction diagnosis (following AP1 for outdoor unit control board)Mainly detect:
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 pinsclose to the terminal hole and the fifthpin are almost the same, less than 100ohm.
Replace the electronic expansion valve
If the fault is eliminated?
If the fault is eliminated?
Replace the control panel
AP1
Coolant leakage, refilling the coolant
End
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(7) Power factor correct or (PFC) fault (a fault of outdoor unit) (AP1 hereinafter refers to the control board of the outdoor unit)Mainly detect:
Y
Y
N
N
N
N
N
N
Y
Y
Y
Start
Check wiring of the reactor (L) of theoutdoor unit and thePFC capacitor
Whether there is anydamage or
short-circuit?
Replace it as per the wiring diagram and
reconnect the wiresIf the fault is eliminated?
Remove the PFC capacitorand measure resistance
between the two terminals.
Is the resistance around zero?
The capacitor isshort circuited and
the capacitorshould be repla-ced
Restart the unit If the fault is eliminated?
Disconnect the terminals for the reactor and measure the resistancebetween the two terminals of the reactor by an ohm gauge
Whether there is any damageor short-circuit?
Replace the reactor Restart the unit If the fault is eliminated?
Replace the control panel AP1
End
Y
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(8) Communication malfunction: (following AP1 for outdoor unit control board)Mainly detect:
Y
N
Y
N
N
Y
N
N
Y
N
Y
N
Y
Y
Start
Did the equipment operate normally before the failure
occurs?
The AP1 voltagedetection circuitis at fault
Check wiring inside ofthe indoor and outdoor
units
Are wires broken?
Check the communication circuit of the outdoor unitIf the fault is eliminated?
The communication circuit is abnormal
Replace the main boardof the indoor unit
End
If the fault is eliminated?
Replace the main board AP1 of the outdoor unit
If the fault is eliminated?
Is the connection right?
Check the wiring of the indoor and outdoor units with reference to the
wiring diagram
Correctly connect the corresponding wires for the indoor and outdoorunits with reference to
the wiring diagram
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10. Exploded View and Parts List10.1 Indoor Unit
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No. Description Part CodeQtyGWH09TA-K3DNA1B/I(dred) GWH12TB-K3DNA1B/I(dred)
CB148N02801 CB148N029011 20012854T01 20012850K 12 Display Board 30565140 30565140 13 11122117 1112211602 24 20022003 20012889 15 10512712 10512147 16 10512176 10512127 17 10542036 10542036 28 10512234 10512232 19 2611226001 2611224401 110 10512037 10512037 111 SteppingMotor 15212123 15212123 112 1054202101 1054202101 113 76512210 76512210 114 / / 015 24212114 24212114 116 Cold Plasma Generator / / 017 0100230101 01002641 118 10352038 10352033 119 Drainage Hose 0523001408 05230014 120 15012510 15012510 121 01252484 01252484 122 Motor Press Plate 26112209 26112209 123 76712012 76712012 124 Connecting pipe clamp 2611216402 2611216402 125 Rear Case assy 2220217101 2220216104 126 10582070 10582070 127 SteppingMotor 15212125 15212125 128 SteppingMotor 15212126 15212126 129 2012240901 2012240901 130 01592084 01592084 131 Terminal Board 42011233 42011233 132 4202300101 4202300103 133 Main Board 30138000313 30138000313 134 Electric Box Assy 10000200782 10000200783 135 20122075 20122075 136 24252016 24252016 337 Power Cord / / 038 Connecting Cable 4002052330 4002052330 039 390000598 390000598 140 390000451 390000451 141 Remote Controller 30510137 30510137 1
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10.2 Outdoor UnitGWH09TA-K3DNA1B/O(dred)
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No. Description Part CodeQtyGWH09TA-K3DNA1B/O(dred)
CB148W028011 Electric Box Assy 10000100124 12 10000500046 13 Main Board 30138000320 14 Reactor 43130184 15 Terminal Board 42010313 16 Wire Clamp 71010003 27 22413008 18 01533034P 19 10333004 1
10 02803151P 111 1501308506 112 Small Handle 26233100 113 0125307002 114 0170310401 115 Condenser Assy 01163760 116 Sensor Insert 42020063 117 Rear Grill 01473009 118 03163170 119 05212423 120 07133082 121 Big Handle 26233433 122 071302391 123 0171314201P 124 0130317801 125 03073043 126 0123338502 127 Magnetic Ring 49018000015 128 0010322402_G 129 Drainage Connecter 06123401 1
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GWH12TB-K3DNA1B/O(dred)
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No. Description Part CodeQtyGWH12TB-K3DNA1B/O(dred)
CB148W029011 Left Side Plate 01303200P 12 1501308506 13 01703136 14 Condenser Assy 01100200122 15 01253081 16 Rear Grill 01475014 17 01233180 18 00103892 19 76713027 3
10 03015200083 111 Big Handle 26233431 112 03005700067 113 0713380601 114 0171314201P 115 22413014 116 Cabinet 01433033P 117 10333011 118 01700000033P 119 Electric Box Assy 10000100125 120 Electric Box 20113032 121 30110103 122 Main Board 30138000436 123 Reactor 43130184 124 Wire Clamp 71010003 225 Terminal Board 42010313 1