Service Manual 9. Maintenance · Fuse of controller burnt out The air condi-tioner does not react...

37

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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Service Manual


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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Service Manual


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


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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Service Manual


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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Service Manual


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


operates.

stop.

5 protection E55 times


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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Service Manual


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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Service Manual


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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Service Manual


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


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


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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Service Manual


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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Service Manual


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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Service Manual


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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Service Manual


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


no

no yes


no

yes

Replace the mainboard with the same model.

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Service Manual


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




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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Service Manual


(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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Service Manual


(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.


Take corrective actions according to TechnicalService Manual, and

then energize and start the unit.

If there is any abnormality

described above?


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.


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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Service Manual


(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 fan capacitor C1

Replace the outdoor fan

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Service Manual


(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


If the fault is eliminated?


End

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Service Manual


(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




End

Out of step occurs in operation

Is the outdoor fan working normally?

Is the outdoor unit blocked by foreign objects?




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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Service Manual


(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



Replace the control panel

AP1

Coolant leakage, refilling the coolant

End

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Service Manual


(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?


End

Y

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Service Manual


(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


Replace the main board AP1 of the outdoor unit


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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Service Manual


10. Exploded View and Parts List10.1 Indoor Unit

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Service Manual


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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Service Manual


10.2 Outdoor UnitGWH09TA-K3DNA1B/O(dred)

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Service Manual


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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Service Manual


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

Service Manual 9. Maintenance · Fuse of controller burnt out The air condi-tioner does not react...

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Transcript of Service Manual 9. Maintenance · Fuse of controller burnt out The air condi-tioner does not react...