IVT 12KHR-N, Service Manual

Page 1: ...ND OPERATIONS 3 1 2 AIR TO AIR HEAT PUMP OPERATION IN THERMISTOR ERROR 3 3 3 THERMISTOR TEMPERATURE CHAR ACTERISTICS 3 5 4 HOW TO OPERATE THE OUTDOOR UNIT INDEPENDENTLY 3 6 5 GENERAL TROUBLESHOOTING CHART 3 6 6 MALFUNCTION PARTS CHECK METH OD 3 8 7 OUTDOOR UNIT CHECK METHOD 3 10 8 TROUBLESHOOTING GUIDE 3 14 CHAPTER 4 REFRIGERATION CYCLE 1 FLOW FOW REFRIGERANT 4 1 2 STANDARD CONDITION 4 1 3 TEMPERA...

Page 2: ...led rotary type Model DA111A1F22F Oil charge 450cc Ester oil VG74 Refrigerant system Evaporator Louver Fin and Grooved tube type Condenser Corrugate Fin and Grooved tube type Control Expansion valve Refrigerant R410A 1180g De lce system Micro computer controled reversed systems Noise level at cooling High dB A 40 47 Low dB A Soft dB A 27 Fan system Drive Direct drive Air flow quantity at cooling H...

Page 3: ...12KHR N 1 2 2 EXTERNAL DIMENSION 1 Indoor unit 2 Outdoor unit 㧔Unit㧦㨙㨙㧕 798 260 290 22 0 58 18 5 175 INVERTER AIR CONDITIONER 265 780 540 14 167 5 165 540 299 72 58 37 5 12 4 5 324 135 81 136 ...

Page 4: ... 4 100 6 10 1 4 70 6 2 0 59 6 4 㧔 㧕 75 7 0 0 0 0 6 52 1 4 70 6 7 59 0 1614 0 5 4 5 0 4 7 6 9 4 6 4 0 1 4 0 114 70 6 176 114 70 6 10641 1 4 70 6 W I R I N G D I A G R A M INVERTER AIR CONDITIONER 219 4 5722 70 6 0 554 04 178 4 8 46 6 UNIT TO UNIT CORD 4 4190 9 9 6 4 4 4 0 19 14 14 0 6 4 0 1 4 LEDINDICATIONFORSELF DIAGNOSIS BlinkingNO DPQTOCN QPVGPVU Shortcircuitoftheoutdoorthermistor Overheatofthec...

Page 5: ...ircuit Cluster generator drive circuit Indoor fan motor Fan motor pulse detect Wireless remote control operation Audible operation confirmation Room temp thermistor Heat exchanger pipe thermistor Louvre angle fan speed Wireless preheat Model select Indoor outdoor control signal I O Test run forced operation Auxiliary mode button ON OFF Self diagnostics fault diagnosis Cluster generator Unit unit w...

Page 6: ...PU reset circuit Position detection circuit AC overcurrent detection circuit Compressor thermo circuit Heat exchanger pipe thermo circuit Outdoor temp thermo circuit LED drive circuit Test mode circuit Power factor converter circuit Filter circuit Smoothing circuit Pulse amplitube modulation circuit EEPROM AC clock circuit DC overcurrent detection circuit IGBT Unit unit wiring AC power and serial ...

Page 7: ...4AF 10KF 2W 11K JP2 NC NC CN1 2 1 6 4 4 5 1 1 OSC1 8MHz 5V 10K 9 50V 50V 10V P110 P50 AVR1 AVR0 P111 P51 P52 P53 P54 P55 P56 P57 P17 P16 P15 P14 P13 P12 P11 P10 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 99 98 97 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 100 P120 P47 P46 P45 P44 P43 P42 P41 P40 REST P124 P123 FLMD X2 X1 REGC VSS VSS0 VDD VDD0 25V 25V 25V 25V 25V 50V 50V NC 2...

Page 8: ...1 R304 R305 R306 R307 R308 R309 R310 1W 620 1 2 3 4 5 6 7 8 9 10 g2 f2 e2 d2 c2 b2 a2 8 11 5 6 7 9 10 BCN301 1W 220 1W 220 1W 620 1W 220 1W 220 0 1uF 47uF 16V C301 C302 1 4W R302 R303 LED310 7 5Kx2 C402 C401 25V 16V 25V 0 1uF 47uF SW401 SAFETY SW CN18 R301 IC301 CN17 47 BCN302 PC 7 3 8 2 9 1 10 6 12 8 10 9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9 10 8 6 1 2 3 11 7 7 2 3 4 1 2 3 4 1 47 IC401 R401 BCN401 1...

Page 9: ... For 2KHN model main PWB For 2KHN model sensor PWB From cluster unit From fan motor From horizontal louver motor From pipe thermistor relay connector From sensor PWB To main PWB To vertical louver motor left To vertical louver motor right ...

Page 10: ...del display PWB To main PWB To main PWB To main PWB To main PWB From hang motor left From panel motor left From panel SW left From panel SW right From panel motor right From hang motor right From display PWB black From display PWB yellow To connection PWB ...

Page 11: ...㧼 㧝㧜㧜㧜㧼 㧯㧡㧡 㧯㧡㧟 㧯㧡㧝 㧯㧠㧥 㧜㧚㧝Ǵ 㧜㧚㧝Ǵ 㧜㧚㧝Ǵ 㧜㧚㧝Ǵ 㧝㧜㧜Ǵ 㧝㧜㨂 㧯㧠㧣 㧜㨂 㧯㧠㧢 㧝㧜㧜㧜㧼 㧡㨂 㧾㧠㧡 㧝㧜㧷 㧾㧠㧢 㧯㧠㧤 㧜㧚㧝Ǵ 㧝㧷 㧯㧠㧡 㧜㨂 㧰㧝㧝 㧟㧟㧜Ǵ 㧝㧡㨂 㧡 㧝㧛㧠㨃 㧟㧟 㧞 㧟㧟 㧞 㧝㧛㧠㨃 㧝㧠 㧝㧢 㧝㧞 㧝㧝 㧝㧜 㧝㧟 㧝㧣 㧣 㧞㧝 㧠 㧢 㧞㧞 㧟 㧤 㧞㧟 㧞 㨂㧼㧯 㧵㧼㧹 㧞㧡㨂 㧯㧟㧣 㧝㧜㧜Ǵ 㧞㧡㨂 㧞㧡㨂 㧯㧡㧠 㧝㧜㧜Ǵ 㧞㧡㨂 㧰㧥 㧰㧝㧜 㧝㧜㧜Ǵ 㧯㧡㧞 㧰㧤 㧯㧡㧜 㨂㨃㧲㧮 㨂㨁㧲㧿 㨂㨁㧲㧮 㨃㧺 㨂㧺 㨁㧺 㨃㧼 㨂㨃㧲㧿 㨂㧼㧵 㨂㧼 㨂㨂㧲㧿 㨂㨂㧲㧮 㨁㧼 㨂㧺㧯 㧲㧜 㨂㧺㧵 㧯㧠㧟 㧯㧠㧠 㨆㧰㧠 㨁 㨄 㨂 㨅 㨆 㧜㧚㧜㧝Ǵ 㨃 㧜㧚㧝Ǵ 㧯㧝㧞㧠 㧵㧯㧡 㧞 㧝 㧟 㧜㨂㧙㧼 㧾㧞㧠 㧞㧞㧷 㧾㧞㧝 㧜㨂 㧡㨂 㧵㧯㧠 㧝㨃 㧾㧞㧣 㧵㧯㧟 㧜㧚㧝...

Page 12: ...m Compressor C White From Compressor S Red To Reactor Gray From Fan Motor To Reactor Gray From 4 Way Valve From Expansion Valve From Thermistor To Terminal Board 1 Brown To Terminal Board N Blue To Control Box Green Yellow To Terminal Board 2 Red From Terminal Board ...

Page 13: ... at minimum operating fre quency the compressor stops operating and then restarts after about 180 seconds and the abovementioned control is repeated 1 6 Outdoor unit overheat prevention control During cooling operation if the temperature of the outdoor unit heat exchanger exceeds the outdoor unit heat exchanger overheat preven tion temperature about 55qC the operating frequency is decreased by abo...

Page 14: ... ing or heating mode which is determined automatically by the room temperature sensor When a circuit breaker is used to control the ON OFF operation please insert a jumper as described above 1 15 Self diagnostic malfunction code display 1 15 1 Indoor unit 1 When a malfunction is confirmed a flashing malfunction code num ber is displayed to indicate the type of malfunction When the air to air heat ...

Page 15: ...Never attempt to adjust the open panel and the lou vres manually Manual adjustment of the open panel and the louvres can cause the unit to malfunction 1 TIPS ABOUT AIR FLOW DIRECTION AUTO COOL mode The open panel will be set obliquely downward for 10 minutes and then shift to obliquely upward to deliver cool air to the ceiling HEAT mode The open panel will be set obliquely backward when outlet air...

Page 16: ...PLASMACLUSTER operation in FAN only mode press the PLASMACLUSTER button while the unit is not operating The mode symbol of the remote control will go off and the fan speed can not be set to AUTO 1 22 Hot keep If the room temperature is in the Hot keep zone during heating the compressor is turned off to prevent overheating 1 23 Winter cool Cooling operation is available during the winter season by ...

Page 17: ...uit 3 1 PAM Pulse Amplitude Modulation The PAM circuit varies the compressor drive voltage and controls the rotation speed of the compressor The IGBT shown in the block diagram charges the energy electromotive force generated by the reactor to the electrolytic capacitor for the inverter by turning ON and OFF When the IGBT is ON an electric current flows to the IGBT via the reactor L5 and diode bri...

Page 18: ...closer to that of the supply voltage 3 2 1 Detailed explanation of PAM drive circuit sequence 3 2 2 AC clock zero cross judgment The clock circuit determines the time from one rising point of the clock waveform to the next rising point The detected clock waveform is used to judge the power source frequency 50 Hz The zero cross of the AC voltage is judged as the rising of the clock waveform as show...

Page 19: ...ed PAM IGBT does not turn ON Compressor operates normally Complete shutdown does not occur 2 PAM error indication In case of error 1 An error signal is sent to the indoor unit as soon as an error is generated Malfunction No 14 0 is indicated when the error code is called out by the indoor unit s self diagnosis function The LED on the outdoor unit flashes 14 times when an error is generated The LED...

Page 20: ... board PCB 4 1 1 Brief explanation of bootstrap system single power drive system To supply power to the upper phase IC the microcomputer IC1 turns ON the lower phase IGBT LU LV LW This results in a charging current that flows to the electrolytic capacitor of each upper phase IC input and charges the bootstrap capacitor with a 15 V current The power supply for the subsequent stages is charged while...

Page 21: ...put of more then 20Ps is generated from IPM Fo pin 14 and this results in an L input to overcurrent detection input pin 34 of the microcomputer IC1 and turns OFF the PWM signal output IC1 pins 51 through 56 to the IGBT gate SET RESET About 25 A SC SC reference voltage Delay by CR time constant circuit More than 20ǴU a1 Protection circuit status Output current Ic A Sense voltage relative to shunt r...

Page 22: ...g sensor less operation at low rotation speed in the ini tial stage of operation This reduces the starting current and improves the IPM reliability 6 180q Energizing Control This is the control system to moderate the speed by the current phase difference for higher efficiency and lower noise of the compressor The current phase difference control is the control system paid attention to the interrel...

Page 23: ... overheat tem perature during heating operation Compressor stops if indoor unit heat exchanger temperature exceeds overheat temperature for 60 seconds at minimum fre quency Overheat temperature setting value indoor unit heat exchanger thermistor temperature about 45 to 54qC When in heating operation Automatic reset after safety period 180 sec None Yes Yes 5 Outdoor unit heat exchanger over heat sh...

Page 24: ...stor TH3 At compressor star tup Operation OFF or ON Yes 1 Yes Yes 17 Outdoor unit suction thermistor short cir cuit error Compressor stops if there is short circuit in outdoor unit suc tion thermistor TH4 At compressor star tup Operation OFF or ON Yes 1 Yes Yes 18 Outdoor unit 2 way valve thermistor short circuit error Compressor stops if there is short circuit in outdoor unit 2 way valve thermist...

Page 25: ...uit Room tempera ture thermistor TH1 Auto Operation mode judgment Cooling mode is activated even if room tempera ture is low Cooling mode is activated in most cases Heating mode is activated even if room tempera ture is high Heating mode is always activated Cooling Frequency control Room becomes too cold Air conditioner operates in full power even when set temperature is reached Room does not beco...

Page 26: ...it error indication Cooling Dehumidifying Operation not affected Normal operation Outdoor unit ther mistor short cir cuit error indication Normal operation Outdoor unit ther mistor open cir cuit error indication Heating Rating control Defrosting Defrosting opera tion is activated unnecessarily Outdoor unit ther mistor short cir cuit error indication Defrosting opera tion is not acti vated and fros...

Page 27: ...1 k TH1 Tester CN11 1 2 TH2 TH2 TH5 500K 400K 300K 200K 100K 0 20 0 20 60 80 100 120 Tester 1 10 Connector CN8 Resistance at 25 52 76 k 5 8K 40K 30K 20K 0 10K 20 0 20 60 40 3 06K 4 17K 1 72K 2 28K Tester In case of TH2 heat exchanger thermistor 1 10 Connector CN8 Thermistor Compressor thermistor Heat exchanger thermistor Outdoor air temperature thermistor Suction thermistor 2 way valve thermistor ...

Page 28: ...mode Check operation mode Fan speed should change except during dehumidifying operation ventilation light dehumidifying operation internally normal oper ation Explain to user Main cause Inspection method Normal value condition Remedy Batteries at end of service life Measure battery voltage 2 5 V or higher two batteries in series connection Install new batteries Batteries installed incorrectly Chec...

Page 29: ...y noise Move TV radio away from outdoor unit Other than above Check for radio wave interfer ence Main cause Inspection method Normal value condition Remedy Malfunction caused by noise Check for radio wave interfer ence Main cause Inspection method Normal value condition Remedy Erroneous inter unit connection Check wiring between indoor and outdoor units Terminal board 1 N 220 240 VAC 50 Hz Termina...

Page 30: ...d to AC outlet Normal Using remote control operate air conditioner so that compressor starts Check 220 240 VAC between 1 and N on outdoor unit PWB Is LED1 on outdoor unit flashing Compressor starts up Does LED1 indicate DC overcurrent error Does LED1 indicate rotation error Replace compressor Does LED1 remain lit Serial signal error Check inter unit wiring Check indoor and outdoor unit PWBs Replac...

Page 31: ...n polarities are reversed When measurement is taken with the polarities reversed the tester needle exceeds the scale range Therefore let the capacitor discharge before measurement Measure resistance in expansion valve coil Normal resistance between red terminal of expansion valve lead wire and each terminal about 46 at 20 Insert checker shown at left into connector CN12 on control PWB and operate ...

Page 32: ...ter startup YES YES NO NO NO YES NO Connect power cord to AC outlet Normal Using remote control operate air conditioner so that compressor starts Check 220 240 VAC between 1 and N on outdoor unit PWB Is LED1 on outdoor unit flashing Compressor starts up Does LED1 indicate DC overcurrent error Does LED1 indicate rotation error Replace compressor Does LED1 remain lit Serial signal error Check inter ...

Page 33: ...age 15 V 5 V on control PWB Each voltage should be normal All 3 lamps load should light with same intensity Replace control PWB 4 Compressor check Measure compressor coil resistance for each phase of U V and W Use multi meter or digital tester capa ble of displaying two digits right of the decimal point 0 01 Resistance value at 20qC 0 65 Correct connections at compres sor terminals Replace compres...

Page 34: ...ort circuit in PAM IGBT Q5 Defective switching power supply circuit Malfunction of 3 terminal regulator IC4 IC1 Short circuit in expansion valve coil Malfunction of transistor array IC7 Solder contact or other problems Malfunction of 3 terminal regulator IC4 IC1 Microcomputer oscillator error Malfunction of microcomputer reset IC Malfunction of microcomputer Malfunction of serial signal circuit Ch...

Page 35: ...the tester to cause damage If the sheaths of the thermistor lead wires or expansion valve lead wires inside the outdoor unit become damaged due to pinching by the front panel or other metal parts or contacting a pipe a high voltage can flow and destroy the circuits To prevent these problems carefully conduct assembly work Terminal board Ground 0 V line Point F Point E Reactor IPM Compressor motor ...