IVT 12KHR-N Service Manual Download

Page: 7 / 35

12KHR-N

2 – 3

[2] MICROCOMPUTER CONTROL SYSTEM

1. Indoor unit

1.1. Electronic control circuit diagram

LED

301

R318

180

FULL

WER

OUTDOOR

TEMP

LED

304

LED

302

LED

303

R317

360

R316

100

R315

100

RED

YEL

GREEN

SG301

OPE

RATI

TIMER

GREEN

1W560

COM

R304

R305

R306

R307

R308

R309

R310

560

c2
b2

BCN301

180

560

180

R128

TERMINAL

FAN

TOR

SELECT

0.01uF

250Vx2

275V

0.1uF

C12A

C12B

275V0.1uF

CLUSTER

BCN602

0.1uF

47uF

50V

1000p

10.0KF

47K

25V

10V 100uF

25V

47K

CN90

1000p

0.1uF

0.1uF
0.1uF
0.1uF

0.1uF
0.1uF

1uF

P83
P82
P81
P80

P05
P06
P70
P71
P72
P73
P74
P75
P76
P77
P67
P66
P65
P64
P31
P63
P62
P61
P60

VDD1

P140

P141

P142

P143

P144

P145

P00

P01

P02

P03

P04

P131

P130

P20

P21

P22

P23

P24

P25

P26

P27

P150

P151

P152

P153

P154

P155

P156

P157

AVS

VSS1

P30
P87
P86
P85
P84

0.01uF

25V
25V
25V

25V
25V

0.1uF

0.01uF

0.1uF

100uF

10V

4.7K

R93

100K

C90

R90

7.5K

4.7K

4.7

10K

6.8KF

0.1u

50V

100u

35V

25V

0.1u

1/4W

3.3K

910x2

WIRELESS

47K

4.7Kx2

MODEL

BZ1

1/4W

1.8K

NF1

D1N60

11K

4.7K

56K

TEST

4.7K

CLUSTER

4.7K

6.8KF

3.3K

6.8K

56K

16V47uF

10K

6.8K

100K

R17

R19

R18

R29

R31

R32

R34

R37

R71

R77

R78

R80

R81

R86

R88

R95

R96

R100

R101

R108

R109

R110

R111

R112

R114

10KF

R105

R107

ZD1HZ24-2

C135V100uF

C235V0.047uF

C350V0.01uF

C15

C16

C17

C18

C41
C42
C43

C44
C45
C46

C58

C62

Q13

Q14

Q15

47K

JP9

JPW

R118

R119

R120

R40

DB1

1MX2

R85

R84

R41

1/2W

C12

275V0.1uF

NR1

R27

R26

0.01u

250V

Q11

25V 0.1uF

R38

100K

R39

16V

C301

C302

R83

10K

D1N60

39K

R28

1/2W

200K

1/2W

200K

R94

C61

0.1uF

1/4W

R302

R303

LED310

3.6Kx2

R121

10K

25V

4.7uF

C60

R11

R10

2.7K

KID65004AF

0.1uF

1000pF

C65
C66

50V

1000p

0.1uF

25V

47K

C402

C401

25V

16V

KID65004AF

25V

0.1uF

47uF

KID65004AF

KID65783AF

C67

R116

10K

R127

4.7K

47K

JP1

47K

R125

KID65004AF

10KF

11K

JP2

CN1

OSC1

8MHz

10K

50V

10V

P110

P111

100

P120

P47

P46

P45

P44

P43

P42

P41

P40

REST

P124

P123

FLMD

REGC

VSS

VSS0

VDD

VDD0

25V

50V

25V

106S

R92

470

5.1K

R91

HAJP

12V

KIA7815

12V

SW401

SAFET

0.01uF

50V

PC81716NIP

Vcc

GND

D1N60

10K

GND

RESET

TOOL0

FLMD0

680

PC817XP3

8.2K

680

TH1

PIPE

TEMP

TH2

R57

R70

R73

R98

R99

R102

R113

R117

IC1

R106

R104

PC5

PC6

PC7

CN3

C14

C40

C48

C49

C55

C56

IC13

IC5

10K

A224S

CN1

10D

SSR1

PR32MA11NXPF

R16

3.15A-250V

FU1

TOOL1

VDD

R74

Q10

12V

IC11

CN18

IC12

12V

R82

10K

PC817XP3

PC1

PC817XP3

SERIAL

SIGNAL

CIRCUIT

PC853HXP

PC2

R301

IC301

CN17

CN10

BCN10

CN11

BCN302

IC7

R122

R124

R123

10K

TXD0

RXD0

50V

SW1

SW2

IC401

R401

LOUVER

THERMIST

IC8

CN13

CN14

CN15

CN16

BCN401

CN15

R134

R132

R135

R133

CN17

CN608

CN609

BCN604

12V

BCN602

BCN601

CN601

CN602

CN603

CN19

IC14

CN15

CN14

HANG

PANEL

BCN603

BCN604

CN604

CN605

CN606

CN607

4.3KF

R129

10K

100K

R137

680

10KF

R51

2.7K

R52

1.5K

R89

2.2M

6.8K

R61

3.3K

R64

3.3K

R136

56K

IC3

KIA431

R54

10KF

R49

220

C30

220uF

10V

C23

10uF

16V

C29

1000uF

25V

PC8

PC817x3

R43

R42

120K

1/2W

C21

1000pF

1KV

D10

D1FL20U

R45

3.3

C19

100uF

C24

47uF

16V

D1FL20U

S3L20U

ZD3

HZ27-2

120uF

450V

R48

100K

C31

0.1uF

50V

R50

100K

R87

1.5M

PC817XP3

19V

R53

10KF

IC2

TOP258PN

C22

0.1uF

50V

12V

PC8

CONTR

TR1

R44

220

C25

0.01uF

50V

12V

275V

0.1uF

Summary of Contents for 12KHR-N

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 ...

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