KSIV SERIES SERVICE MANUAL
Table of Contents §. Safety Precautions 1. Precautions 2. Information servicing(For flammable materials) §. Specifications 1. Model Reference 2. Pipe length and the Drop Height 3. Electrical Wiring Diagrams §. Product Features 1. Display Function 2. Safety Features 3. Basic Features 4. Optional Features §. Maintenance 1. First Time Installation Check 2. Refrigerant Recharge 3. Re-Installation §. Indoor Unit Disassembly 1. Dimension 2. Indoor Unit Disassembly §.
Table of Contents §. Troubleshooting 1. Safety Caution 2. General Troubleshooting 3. Complain Record Form 4. Information Inquiry 5. Error Diagnosis and Troubleshooting Without Error Code 6. Quick Maintenance by Error Code 7. Troubleshooting by Error Code 8.
Safety Precautions Contents 1. Precautions..............................................................................................................2 2. Information servicing(For flammable materials)..................................................
1. Precautions CAUTION To prevent personal injury, or property or unit damage, adhere to all precautionary measures and instructions outlined in this manual. Before servicing a unit, refer to this service manual and its relevant sections. Failure to adhere to all precautionary measures listed in this section may result in personal injury, damage to the unit or to property, or in extreme cases, death.
2. Information servicing(For flammable materials) 2.1 • NO SMOKING signs shall be displayed. Checks to the area • Prior to beginning work on systems containing flammable refrigerants, safety checks are necessary to ensure that the risk of ignition is minimized. • For repair to the refrigerating system, the following precautions shall be complied with prior to conducting work on the system. 2.
• that capacitors are discharged: this shall be done in a safe manner to avoid possibility of sparking; • that there no live electrical components and wiring are exposed while charging, recovering or purging the system; • that there is continuity of earth bonding. 2.10 Repairs to sealed components • During repairs to sealed components, all electrical supplies shall be disconnected from the equipment being worked upon prior to any removal of sealed covers, etc.
• The refrigerant charge shall be recovered into the correct recovery cylinders. The system shall be flushed with OFN to render the unit safe. This process may need to be repeated several times. Compressed air or oxygen shall not be used for this task. Flushing shall be achieved by breaking the vacuum in the system with OFN and continuing to fill until the working pressure is achieved, then venting to atmosphere, and finally pulling down to a vacuum.
• Empty recovery cylinders are evacuated and, if possible, cooled before recovery occurs. • The recovery equipment shall be in good working order with a set of instructions concerning the equipment that is at hand and shall be suitable for the recovery of flammable refrigerants. In addition, a set of calibrated weighing scales shall be available and in good working order. • Hoses shall be complete with leak-free disconnect couplings and in good condition.
Specifications Contents 1. Model Reference ....................................................................................................2 2. Pipe Length and Drop Height ...............................................................................3 3. Electrical Wiring Diagrams ....................................................................................
1. Model Reference Refer to the following table to determine the specific indoor and outdoor unit model.
2. Pipe Length and Drop Height The length and elevation of connection pipe are shown in the table below. if the pipe length exceeds max pipe length, additional refrigerant should be charged to ensure nominal cooling/heating capacity. Capacity(Btu) Standard Length Max Pipe Length Max Elevation 82ft 32.8ft Additional Refrigerant 9k 12K 0.32oz/ft 24.6ft 18K 98.4ft 65.6ft 24K 164ft 82ft 0.
3.
Indoor unit abbreviations Abbreviation Paraphrase Y/G Yellow-Green Conductor ION Positive and Negative Ion Generator CAP Capacitor PLASMA Electronic Dust Collector L LIVE N NEUTRAL Heater The Electric Heating Belt of Indoor Unit T1 Indoor Room Temperature T2 Coil Temperature of Indoor Heat Exchanger Abbreviation Paraphrase 4-WAY Gas Valve Assembly/4-WAY VALVE AC-FAN Alternating Current FAN DC-FAN Direct Current FAN CT1 AC Current Detector COMP Compressor T3 Coil Temperature
Y/G Y/G BROWN BLUE Outdoor unit wiring diagram: KSIV009-H119-O 1 2 3 L N Y/G Y/G TO I NDOOR UNI T 4-WAY BLUE RED CRANKCASE HEATER BLACK V W CN 25 Y/G CN 7 Y/G OPTIONAL: DC-FAN AC-FAN U PAN HEATER Y/G
Outdoor unit wiring diagram: KSIV009-H219-O / KSIV012-H219-O Y/G Y/G BLUE OR BLACK BROWN 2 1 3 Y/G I NDOOR UNI T 4-WAY CRANKCASE HEATER PAN HEATER CAPACITOR RED AC-FAN BLUE BLACK CN 7 U V W AMBIENT TEMP. SENSOR CONDENSER TEMP.
Indoor KSIV009-H119-IW, KSIV009-H219-IW, KSIV012-H219-IW, KSIV012-H119-IW KSIV018-H219-IW, KSIV024-H219-IW 16022000019694 M OPTI ONAL Y/ G I ON M M 5 CN12_1 CN12_2 HEATER CN6_1 CN6_2 1 2 2 OPTIONAL 3 INDOOR WIRING DIAGRAM OPTIONAL
Outdoor unit printed circuit board diagram: KSIV009-H119-O
No. 1 Name Power Supply CN# Meaning CN3 Earth: connect to Ground CN1 N_in: connect to N-line (100-130V AC input) CN2 L_in: connect to L-line (100-130V AC input) 2 S CN16 S: connect to indoor unit communication 3 HEAT1 CN17 connect to compressor heater, 100-130V AC when is ON 4 4-WAY CN60 connect to 4 way valve, 100-130V AC when is ON. 5 AC-FAN CN25 connect to AC fan 6 TP T4 T3 CN21 connect to pipe temp. sensor T3, ambient temp. sensor T4, exhaust temp.
Outdoor unit printed circuit board diagram: KSIV009-H219-O
No. 1 Name Power Supply CN# Meaning CN3 Earth: connect to Ground CN1 N_in: connect to N-line (208-230V AC input) CN2 L_in: connect to L-line (208-230V AC input) 2 S CN16 S: connect to indoor unit communication 3 HEAT1 CN17 connect to compressor heater, 208-230V AC when is ON 4 4-WAY CN60 connect to 4 way valve, 208-230V AC when is ON. 5 HEAT2 CN15 connect to chassis heater, 208-230V AC when is ON 6 AC-FAN CN25 connect to AC fan 7 TP T4 T3 CN22 connect to pipe temp.
Product Features Contents 1. Display Function.....................................................................................................2 2 Safety Features.......................................................................................................3 3. Basic Functions........................................................................................................4 3.1 Table......................................................................................................
1. Display Function Unit display functions (A) (B) (D) (C) Function Display Activation of Timer ON, Fresh, Swing, Turbo, or Silent (3s) Cancellation of Timer OFF, Fresh, Swing, Turbo, or Silent (3s) Defrost Warming in heating mode Self-clean (available on select units only) Heating in room tempurature under 47°F ECO function (available on select units only) Lights up in different colour according to the operation mode(some units)： Under COOL and DRY mode, it displays as cool colour.
2. Safety Features Compressor three-minute delay at restart Compressor functions are delayed for up to one minute upon the first startup of the unit, and are delayed for up to three minutes upon subsequent unit restarts. Zero crossing detection error protection(Except for DC fan units) If AC can not detect zero crossing signal for 4 minutes or the zero crossing signal time interval is not correct, the unit will stop and the LED will display the failure.
3. Basic Functions 3.1 Table Cooling Mode&Heating mode Heating Mode Outdoor Fan Control Defrosting Mode Functions Cases Auto Mode Case 1: Compressor Frequency and T4 Case 2:T4 Case 1:T3 and T4,15 min Case 2: T3,10 min A=2°C(3.6°F), B=-2°C(-3.6°F) KSIV009-H119-IW KSIV009-H219-IW Models KSIV012-H219-IW KSIV012-H119-IW KSIV018-H219-O KSIV024-H219-O Note: The detailed description of case 1 or case 2 is shown in the following function sections(from 3.4 to 3.6).
3.2 Abbreviation auto. • If the compressor ceases operation when the configured temperature is reached, the indoor fan motor operates at the minimum or configured speed. Unit element abbreviations Abbreviation Element T1 Indoor room temperature T2 Coil temperature of evaporator T3 Coil temperature of condenser T4 Outdoor ambient temperature Set temperature Td Control target temperature T1-Td ℃(°F) setting parameter of EEPROM.
parameter of EEPROM. It’s value ranges from 21°F to 43°F. • When T1-Ts>-∆T3, the compressor ceases operation. T1-Td • When T1-Ts<-∆T3 2.7°F, the compressor continues operation. • When the AC is operating in mute mode, the compressor operates at a low frequency. • When the current exceeds the preset value, the current protection function activates and the compressor ceases operation. 3.5.2 Indoor Fan Control: • When the compressor is on, the indoor fan speed can be set to high, medium, low, or auto.
• If any one of the following conditions is satisfied, defrosting ends and the machine switches to normal heating mode: • T3 rises above TCDE1. • T3 maintained above TCDE2 for 80 seconds. • Forced auto mode: Forced auto mode operates the same as normal auto mode with a preset temperature of 76°F. • The unit exits forced operation when it receives the following signals: • Unit runs for 10 minutes consecutively in defrosting mode. 3.5.
failure, will restore those setting automatically within 3 minutes after power returns. • If the unit was in forced cooling mode, it will run in this mode for 30 minutes and turn to auto mode with temperature set to 76°F. • If there is a power failure while the unit is running, the compressor starts 3 minutes after the unit restarts. If the unit was already off before the power failure, the compressor starts 1 minute after the unit restarts. 3.
4. Optional Functions 4.1 4.3 47°F Heating In heating mode, the temperature can be set to as low as 47°F, preventing the indoor area from freezing if unoccupied during severe cold weather. 4.2 Self clean • If you press “Self Clean” when the unit is in cooling or drying mode: • For cooling models, the indoor unit will run in low fan mode for a certain time, then ceases operation. • For heat pump models, the indoor unit will run in fan-only mode, then low heat, and finally in fanonly mode.
Maintenance Contents 1. First Time Installation Check..................................................................................2 2 Refrigerant Recharge.............................................................................................4 3 Re-Installation ........................................................................................................5 3.1 Indoor Unit.....................................................................................................5 3.
1. First Time Installation Check Air and moisture trapped in the refrigerant system affects the performance of the air conditioner by: • Increasing pressure in the system. • Increasing the operating current. To prevent air and moisture from affecting the air conditioner’s performance, the indoor unit, as well as the pipes between the indoor and outdoor unit, must be be leak tested and evacuated. Leak test (soap water method) • Decreasing the cooling or heating efficiency.
Procedure: 1. Tighten the flare nuts of the indoor and outdoor units, and confirm that both the 2- and 3-way valves are closed. 2. Connect the charge hose with the push pin of Handle Lo to the gas service port of the 3-way valve. 3. Connect another charge hose to the vacuum pump. 4. Fully open the Handle Lo manifold valve. 5. Using the vacuum pump, evacuate the system for 30 minutes. • If the pressure successfully reaches -0.1 MPa (14.
2. Refrigerant Recharge 2OW[OJ YOJK /TJUUX [TOZ 5[ZJUUX [TOZ :]U ]G_ \GR\K 5VKT -GY YOJK :NXKK ]G_ \GR\K )NKIQ \GR\K 5VKT )NGXMOTM I_ROTJKX 2U .O 56+4 )259+ mV V A V mA OFF A A mA A COM V :KSVKXGZ[XK 9KTYUX +RKIZXUTOI YIGRK Procedure: 1. Close both 2- and 3-way valves. 2. Slightly connect the Handle Lo charge hose to the 3-way service port. 8. Operate the air conditioner in cooling mode to charge the system with liquid refrigerant. 3.
3. Re-Installation 3.1 Indoor Unit Collecting the refrigerant into the outdoor unit 5[ZJUUX [TOZ 2OW[OJ YOJK /TJUUX [TOZ :]U ]G_ \GR\K )RUYK -GY YOJK :NXKK ]G_ \GR\K 5VKT )RUYK 2U .O )RUYK Procedure: 1. Confirm that the 2- and 3-way valves are opened. 6. 2. Connect the charge hose with the push pin of Handle Lo to the 3-way valve’s gas service port. Close the 3-way valve so that the gauge rests between 0.3 MPa (43.5 Psi) and 0.5 MPa (72.5 Psi). 7.
Air purging with vacuum pump 2OW[OJ YOJK /TJUUX [TOZ 5[ZJUUX [TOZ :]U ]G_ \GR\K )RUYK -GY YOJK 3GTOLURJ \GR\K )USVU[TJ SKZKX 6XKYY[XK MG[MK :NXKK ]G_ \GR\K )RUYK 36G 2U .GTJRK 2U )NGXMK NUYK .O .GTJRK .O )NGXMK NUYK
3.2 Outdoor Unit Evacuation for the whole system 2OW[OJ YOJK /TJUUX [TOZ 5[ZJUUX [TOZ :]U ]G_ \GR\K 5VKT -GY YOJK :NXKK ]G_ \GR\K 5VKT 56+4 2U .O
Refrigerant charging 2OW[OJ YOJK /TJUUX [TOZ 5[ZJUUX [TOZ :]U ]G_ \GR\K 5VKT -GY YOJK :NXKK ]G_ \GR\K )NKIQ \GR\K 5VKT )NGXMOTM I_ROTJKX 2U 56+4 .O )259+ mV V A V mA OFF A A mA A COM V :KSVKXGZ[XK 9KTYUX +RKIZXUTOI YIGRK Procedure: 1. Close both 2- and 3-way valves. 7. 2. Slightly connect the Handle Lo charge hose to the 3-way service port. Fully open the Handle Lo manifold valve, 2- and 3-way valves. 8.
Indoor Unit Disassembly Contents 1. Dimension ..............................................................................................................2 2. Indoor Unit Disassembly .......................................................................................3 2.1 Front Panel ....................................................................................................3 2.2 Electrical parts ............................................................................................
1. Dimension Model W (in) D (in) H (in) 9K 28.4 7.4 11.4 12K 31.6 7.4 11.7 18K 38.0 8.5 12.6 24K 42.5 8.9 13.
2. Indoor Unit Disassembly 2.1 Front Panel Procedure Illustration 1) Hold the front panel by the tabs on the both sides and lift it (see Fig. 1). Front Panel Tab Fig. 1 2) Push up the bottom of an air fi lter (step 1), and then pull it out downwards (step 2) (see Fig. 2). Fig. 2 Note: This section is for reference only. Actual unit appearance may vary.
3) Open the horizontal louver and push the hook towards left to open it (see Fig. 3). Horizontal Louver Hook Fig. 3 4) Bend the horizontal louver lightly by both hands to loosen the hooks, then remove the horizontal louver (see Fig. 4). Hook Fig. 4 Note: This section is for reference only. Actual unit appearance may vary.
Procedure Illustration 5) Pry the electrical cover by a screw driver, and rotate it towars left, then remove it. (see Fig. 5). Fig. 5 6) Disconnect the connector for display board. (see Fig. 6) . Fig. 6 Note: This section is for reference only. Actual unit appearance may vary.
Procedure Illustration 7) Slid the front panel side to side to release each axis (see Fig. 7) Fig. 7 8) Open the screw cap and then remove the 3 screws (see Fig. 8). Fig. 8 Note: This section is for reference only. Actual unit appearance may vary.
Procedure Illustration 9) Release the hooks with hands. (see Fig. 9) Fig. 9 10)Release the 5 hooks in the back (see Fig. 10). Fig. 10 11)Pull out the panel frame while pushing the hook through a clearance between the panel frame and the heat exchanger. (see Fig. 11) Fig. 11 Note: This section is for reference only. Actual unit appearance may vary.
Procedure Illustration 12)Release the 5 hooks of the vertical blades, then pull the vertical blades rightward and remove it (see Fig. 12). Fig. 12 13)Remove 1 screw of the display board.(see Fig. 13). 14)Rotate the display board in the direction shown in the right picture. (see Fig. 13). Fig. 13 Note: This section is for reference only. Actual unit appearance may vary.
2.2 Electrical parts (Antistatic gloves must be worn.) Note: Remove the front panel (refer to 1. Front panel) before disassembling electrical parts. Procedure Illustration Ground Screws 1) Cut the ribbon by a shear, then pull out the coil temperature sensor (T2) (see Fig. 14). 2) Remove one fixingscrewofthe electronic control box and two screws used for the ground connection (see Fig. 14). T2 Sensor Ribbon Fig.
Procedure Illustration 4) Remove the fixed devices of the connectors (see Fig. 16). Fig. 16 5) Disconnect the connectors of fan motor, the step motor and the T2 sensor (see Fig. 17). Fig. 17 6) Open the left side plate of electronic control box (see Fig. 18). Fig. 18 Note: This section is for reference only. Actual unit appearance may vary.
Procedure Illustration 7) Open the two clips on the front of the electric box. (see Fig. 19) Fig. 19 8) Open the upper cover plate of electronic control box (see Fig. 20). Fig. 20 Note: This section is for reference only. Actual unit appearance may vary.
Procedure Illustration 9) Remove 1 screw and open the 2 clips along the direction indicated in right image (see Fig. 21). Fig. 21 Display board 10)Pull out the electrical main board along the direction indicated in right image to remove it (see Fig. 22). Terminal (1L) Terminal (W) Terminal (S) Pipe Temperature Sensor Room Temperature Sensor Fig. 22 Note: This section is for reference only. Actual unit appearance may vary.
2.3 Evaporator Note: Remove the front panel and electrical parts (refer to 1. Front panel and 2. Electrical parts) before disassembling evaporator. Procedure Illustration 1) Disassemble the pipe holder located at the rear of the unit (see Fig. 23). Fig. 23 2) Remove the 1 screws on the evaporator located at the fixedplate (see Fig. 24). Fig. 24 Note: This section is for reference only. Actual unit appearance may vary.
Procedure Illustration 3) Release the hook on the evaporator (see Fig. 25). Fig. 25 Remote the one screw on the evaporator located at the fixedplate(see Fig. 26). Fig. 26 4) Pull out the evaporator (see Fig. 27) Fig. 27 Note: This section is for reference only. Actual unit appearance may vary.
2.4 Fan motor and fan Note: Remove the front panel, electrical parts and evaporator (refer to 1. Front panel, 2. Electrical parts, and 3. Evaporator). before disassembling fan motor and fan. Procedure Illustration 1) Remove the two screws and remove the fixingboardofthefanmotor(see Fig. 28). Screws Fig. 28 2)�Remove the bearing sleeve (see Fig. 29) Fig. 29 Note: This section is for reference only. Actual unit appearance may vary.
Procedure 3) Remove the fixingscrew(see Illustration Fig. 30). 4) Pull out the fan motor and fan assembly� from the side. Fig. 30 Note: This section is for reference only. Actual unit appearance may vary.
2.5Step motor Note: Remove the front panel and electrical parts (refer to 1. Front panel, 2. Electrical parts) before disassembling step motor. Procedure Illustration 1) Remove the two screws, then remove the stepping motor (see Fig. 31). Stepping Motor Fig. 31 Note: This section is for reference only. Actual unit appearance may vary.
2.6 Drain Hose Procedure Illustration 1) Rotate the fixed wire clockwise indicated in right image (see Fig. 32). Fig. 32 2) Pull up the drain hose to remove it (see Fig. 33). Fig. 33 Note: This section is for reference only. Actual unit appearance may vary.
Outdoor Unit Disassembly Contents 1. Outdoor Unit Table ................................................................................................2 2. Dimension ..............................................................................................................3 3. Outdoor Unit Disassembly ....................................................................................9 3.1 Panel Plate.................................................................................................
1. Outdoor Unit Disassembly 1.
2. Dimension 1. Panel Plate AA30 27.3 " 17.1" 18.1" 26.8 0.16" 11.2" 2.8" 0.59 11.5" 3.5" 12.6" 10.4" 1.85" 2.4" 3.3" R0.24" 0.
2. Panel Plate AB30 28.1" 21.6" 10.8" 0.47" 17.7" 27.6" 2.9" 11.3" 9.9" 2.4" 3.5" Outdoor Unit Disassembly 4 10.
3. Panel Plate BA30 30.7" 21.9" 0.47" 19.2" 11.8" 30.3" 2.76" 1" 11.7" 3.5" 12.7" 11.3" 2.42" 2.36" 3.7" R0.24" 0.
For US models: 30.7" 21.9" 0.47" 19.2" 11.8" 30.3" 2.75" 1" 3.54" 12.7" 11.7" 11.3" 2.36" 2.42" 3.7" R0.24" 0.
4. Panel Plate B30 32.1" 21.8" 0.47" 20.2" 13.1" 2.75" 31.5" 2.44" 13.4" 4.17" 14.4" 12.2" 2.4" R0.79" 0.79" 3.37" R0.24" 2.
For US models: 32.1" 21.8" 0.47" 20.2" 13.1" 2.75" 31.5" 2.44" 13.4" 4.17" 14.4" 12.2" R0.79" 0.79" R0.24" 2.
5. Panel Plate CA30 33.7" 27.6" 0.51" 14.3" 21.25" 33.3" 36" 13.8" 14.8" 13.2" 2.61 2.4" 3.6" 0.
For US models: 33.7" 27.6" 14.3" 21.25" 0.51" 33.27" 36" 15" 13.8" 14" 2.6" 1.
6. Panel Plate D30 40.55" 37.2" 31.9" 26.5" 16.1" 17.9" Outdoor Unit Disassembly 11 15.
For US models: 7.4" 8.35" 31.9" 26.5" 17.9 18.1" 37.3" 3.4" 3.6" 15.2" 16.3" Outdoor Unit Disassembly 12 15.
3. Outdoor Unit Disassembly 3.1 Panel Plate 1. AA30 / AB30 Procedure Illustration 1) Turn off the air conditioner and the power breaker. 2) Remove the screws of the big handle and then remove the big handle (1 screws) (see Fig. 1). Big Handle Top Cover Fig. 1 3) Remove the screws of the top cover and then remove the top cover (3 screws). One of the screws is located underneath the big handle (see Fig. 2). Fig. 2 Note: This section is for reference only. Actual unit appearance may vary.
Procedure Illustration 4) Remove the screws of the front panel and then remove the front panel (6 screws) (see Fig. 3). Front Panel Fig. 3 5) Remove the screws of water collecting cover (1 screw) (see Fig. 4). Water Collecting Cover Fig. 4 Note: This section is for reference only. Actual unit appearance may vary.
Procedure Illustration 6) Remove the screws of the rear net and then remove the rear net (2 screws)(see Fig. 5. (for some models) Fig. 5 7) Remove the screws of the right panel and then remove the right panel (6 screws) (see Fig. 6). Right Panel Fig. 6 Note: This section is for reference only. Actual unit appearance may vary.
2. BA30 Procedure Illustration 1) Turn off the air conditioner and the power breaker. Big Handle 2) Remove the screws of the big handle and then remove the big handle (1 screws) (see Fig. 1). Fig. 1 Top Cover 3) Remove the screws of the top cover and then remove the top cover (3 screws). One of the screws is located underneath the big handle (see Fig. 2). Fig. 2 Note: This section is for reference only. Actual unit appearance may vary.
Procedure Illustration 4) Remove the screws of the front panel and then remove the front panel (7 screws) (see Fig. 3). Front Panel Fig. 3 5) Remove the screws of water collecting cover (1 screw) (see Fig. 4). Water Collecting Cover Fig. 4 Note: This section is for reference only. Actual unit appearance may vary.
Procedure Illustration 6) Remove the screws of the rear net and then remove the rear net (2 screws) (see Fig. 5). (for some models) Fig. 5 7) Remove the screws of the right panel and then remove the right panel (6 screws) (see Fig. 6). Right Panel Fig. 6 Note: This section is for reference only. Actual unit appearance may vary.
3. B30 Procedure Illustration 1) Turn off the air conditioner and the power breaker. Big Handle 2) Remove the screws of the big handle and then remove the big handle (1 screws) (see Fig. 1). Fig. 1 3) Remove the screws of the top cover and then remove the top cover (3 screws). One of the screws is located underneath the big handle (see Fig. 2). Top Cover Fig. 2 Note: This section is for reference only. Actual unit appearance may vary.
Procedure Illustration 4) Remove the screws of the front panel and then remove the front panel (8 screws) (see Fig. 3). Fig. 3 5) Remove the screws of water collecting cover and then remove the water collecting cover (1 screw) (see Fig. 4). Water Collecting Cover Fig. 4 Note: This section is for reference only. Actual unit appearance may vary.
Procedure Illustration 6) Remove the screws of the rear net and then remove the rear net (2 screws) (see Fig. 5). (for some models) Fig. 5 7) Remove the screws of the right panel and then remove the right panel (5 screws) (see Fig. 6). Fig. 6 Note: This section is for reference only. Actual unit appearance may vary.
4. CA30 Procedure Illustration 1) Turn off the air conditioner and the power breaker. 2) Remove the screws of the big handle and then remove the big handle (1 screws) (see Fig. 1). Big Handle Fig. 1 3) Remove the screws of the top cover and then remove the top cover (3 screws). One of the screws is located underneath the big handle (see Fig. 2). Top Cover Fig. 2 Note: This section is for reference only. Actual unit appearance may vary.
Procedure Illustration 4) Remove the screws of the front panel and then remove the front panel (7 screws) (see Fig. 3). Front Panel Fig. 3 5) Remove the screws of water collecting cover and then remove the water collecting cover (1 screw) (see Fig. 4). Water Collecting Cover Fig. 4 Note: This section is for reference only. Actual unit appearance may vary.
Procedure Illustration 6) Remove the screws of the rear net and then remove the rear net (2 screws)(see Fig. 5). (for some models) Fig. 5 7) Remove the screws of the right panel and then remove the right panel (7 screws) (see Fig. 6). Right Panel Fig. 6 Note: This section is for reference only. Actual unit appearance may vary.
5. D30 Procedure Illustration 1) Turn off the air conditioner and the power breaker. Big Handle 2) Remove the screws of the big handle and then remove the big handle (2 screws) (see Fig. 1). Fig. 1 3) Remove the screws of the top cover and then remove the top cover (4 screws). Two of the screws is located underneath the big handle (see Fig. 2). Top Cover Fig. 2 Note: This section is for reference only. Actual unit appearance may vary.
Procedure Illustration 4) Remove the screws of the front right panel and then remove the front right panel (2 screws) (see Fig. 3). Front Right Panel Fig. 3 5) Remove the screws of the front panel and then remove the front panel (9 screws) (see Fig. 4). Front Panel Fig. 4 Note: This section is for reference only. Actual unit appearance may vary.
Procedure Illustration 6) Remove the screws of water collecting cover and then remove the water collecting cover (2 screw) (see Fig. 5). Water Collecting Cover Fig. 5 7) Remove the screws of the rear net and then remove the rear net (2 screws) (see Fig. 6). (for some models) Fig. 6 Note: This section is for reference only. Actual unit appearance may vary.
Procedure Illustration 8) Remove the screws of the right panel and then remove the right panel (8 screws) (see Fig. 7). Right Panel Fig. 7 Note: This section is for reference only. Actual unit appearance may vary.
3.2 Electrical parts WARNING: Antistatic gloves must be worn when you disassemble the electronic box. Note: Remove the air outlet grille(refer to 3.1 Panel Plate) before disassembling electrical parts.
ii) PCB for Inverter Models 3. PCB board 4 Procedure Illustration 1) Remove the screws of the top cover. (2 screws) (see Fig. 3.1). Fig. 3.1 2) Unfix the hooks and then open the electronic control box cover (4 hooks)(see Fig. 3.2). 3) Disconnect the connector for fan motor from the electronic control board (see Fig. 3.3). Fig. 3.2 4) Remove the connector for the compressor (see Fig. 3.3). 4-Way Valve 5) Pull out the two blue wires connected with the four way valve (Fig. 3.3).
4. PCB board 5 Procedure Illustration 1) Unfix the hooks and then open the electronic control box cover (4 hooks)(see Fig. 4.1). 4-Way Valve 2) Disconnect the connector for fan motor from the electronic control board (see Fig. 4.2). Fig. 4.1 3) Remove the connector for the compressor (see Fig. 4.2). Reactor DR 4) Pull out the two blue wires connected with the four way valve (see Fig. 4.2). 5) Pull out connectors of the condenser coil temp. sensor(T3),outdoor ambient temp.
5. PCB board 6 Procedure Illustration 1) Remove the screws and unfix the hooks, then open the electronic control box cover (5 screws and 2 hooks )(see Fig. 5.1). Fig. 5.1 2) Disconnect the connector for fan motor from the electronic control board (see Fig. 5.2). 3) Remove the connector for the compressor (see Fig. 5.2). 4) Pull out the two blue wires connected with the four way valve (see Fig. 5.2). 5) Pull out connectors of the condenser coil temp. sensor(T3),outdoor ambient temp.
6. PCB board 7 Procedure Illustration 1) Remove the screws of the top cover. (1 screws) (see Fig. 6.1). Fig. 6.1 2) Unfix the hooks and then open the electronic control box cover (5 hooks)(see Fig. 6.2). Fig. 6.2 3) Disconnect the connector for fan motor from the IPM board (see Fig. 6.3). Compressor 4) Remove the connector for the compressor (see Fig. 6.3). Fig. 6.3 Note: This section is for reference only. Actual unit appearance may vary.
Procedure Illustration 5) Pull out the wire connected with the terminal. (see Fig. 6.4). 6) Pull out connectors of the condenser coil temp. sensor(T3),outdoor ambient temp. sensor(T4) and discharge temp. sensor(TP) (see Fig. 6.4). 7) Disconnect the electronic expansion valve wire (see Fig Fig. 6.4). T3/T4 TP 8) Remove the connector for 4-way valve. (see Fig. 6.4). 4-Way Valve 9) Remove the connector for the reactor (see Fig. 6.4). 10) Then remove the electronic control box (see Fig. 6.4).
7. PCB board 8 Procedure Illustration 1) Unfix the hooks and then open the electronic control box cover (4 hooks)(see Fig. 7.1). 2) Disconnect the connector for outdoor DC fan from the electronic control board (see Fig. 7.2). 3) Remove the connector for the compressor (see Fig. 7.2). 4) Pull out the two blue wires connected with the four way valve (see Fig. 7.2). Fig. 7.1 5) Pull out connectors of the condenser coil temp. sensor(T3),outdoor ambient temp. sensor(T4) and discharge temp.
3.3 Fan Assembly Note: Remove the panel plate (refer to 3.1 Panel Plate) before disassembling fan. Procedure Illustration 1) Remove the nut securing the fan with a spanner (see Fig. 8). 2) Remove the fan. D-cut Fig. 8 Note: This section is for reference only. Actual unit appearance may vary.
3.4 Fan Motor Note: Remove the panel plate and the connection of fan motor on PCB (refer to 3.1 Panel Plate and 3.2 Electrical parts) before disassembling fan motor. Procedure Illustration 3) Remove the fixing screws of the fan motor (4 screws) (see Fig. 9). 4) Remove the fan motor. Fig. 9 Note: This section is for reference only. Actual unit appearance may vary.
3.5 Sound blanket Note: Remove the panel plate (refer to 3.1 Panel plate) before disassembling sound blanket. Procedure Illustration 1) Remove the sound blanket (side and top) (see Fig. 10). Sound Blanket(top) Sound Blanket(side) Fig. 10 Note: This section is for reference only. Actual unit appearance may vary.
3.6 Four-way valve (for heat pump models) WARNING: Evacuate the system and confirm that there is no refrigerant left in the system before removing the four-way valve and the compressor. (For R32 & R290, you should evacuate the system with the vacuum pump; flush the system with nitrogen; then repeat the two steps before heating up the brazed parts. The operations above should be implemented by professionals.) Note: Remove the panel plate, connection of four-way valve on PCB (refer to 3.1 Panel plate and 3.
3.7 Compressor WARNING: Evacuate the system and confirm that there is no refrigerant left in the system before removing the four-way valve and the compressor. (For R32 & R290, you should evacuate the system with the vacuum pump; flush the system with nitrogen; then repeat the two steps before heating up the brazed parts. The operations above should be implemented by professionals.) Note: Remove the panel plate, connection of compressor on PCB (refer to 3.1 Panel plate and 3.
Procedure Illustration 3) Remove the hex nuts and washers securing the compressor, located on the bottom plate (see Fig. 14). Fig. 14 Suction Pipe 4) Heat up the brazed parts and then remove the the discharge pipe and the suction pipe (see Fig. 15). 5) Lift the compressor from the base pan assembly with pliers. Discharge Pipe Fig. 15 Note: This section is for reference only. Actual unit appearance may vary.
Troubleshooting Contents 1. Safety Caution........................................................................................................3 2. General Troubleshooting.......................................................................................4 3. Complain Record Form...........................................................................................6 4. Information Inquiry................................................................................................8 5.
Troubleshooting Contents 7.8 F0 (Overload current protection diagnosis and solution)................................28 7.9 P0 (IPM malfunction or IGBT over-strong current protection diagnosis and solution).......................................................................................................29 7.10 P1 (Over voltage or too low voltage protection diagnosis and solution).........30 7.11 P2 (High temperature protection of IPM module diagnosis and solution).......31 7.
1. Safety Caution WARNING Be sure to turn off all power supplies or disconnect all wires to avoid electric shock. While checking indoor/outdoor PCB, please equip oneself with antistatic gloves or wrist strap to avoid damage to the board. WARNING Electricity remains in capacitors even when the power supply is off. Ensure the capacitors are fully discharged before troubleshooting. Test the voltage between P and N on back of the main PCB with multimeter.
2. General Troubleshooting 2.1 Error Display (Indoor Unit) When the indoor unit encounters a recognized error, the operation lamp will flash in a corresponding series, the timer lamp may turn on or begin flashing, and an error code will be displayed.
2.2 Error Display (For 18K And Above 18K Outdoor Unit) There are 2 LED lights (RED color and GREEN color) welded in outdoor main board. After power on, LED show different actions when encounter different problems. No.
3. Complain Record Form Complain Record Form Request No.: Date: Installation Date: Service Date: Customer Information Name Telephone No. Home Address Email Product Information Indoor Unit Model Outdoor Unit Model Serial No. of indoor unit Serial No.
Parameter Checking information by Remote controller Displaying code Displaying code meaning T1 Room temperature T2 Indoor coil temperature T3 Outdoor coil temperature T4 Ambient temperature Tb Outlet temperature of indoor coil TP Discharge temperature TH Sunction temperature FT Targeted Frequency Fr Actual Frequency IF Indoor fan speed OF Outdoor fan speed LA EXV opening steps CT Compressor continuous running time ST Causes of compressor stop.
4. Information Inquiry • To enter information inquiry status, complete the following procedure within ten seconds: • Press LED(or DO NOT DISTURB) 3 times. • Press SWING(or AIR DIRECTION) 3 times. • Finish 1 and 2 within 10 seconds, you will hear beeps for two seconds, which means the unit goes into parameter checking mode. • Use the LED(or DO NOT DISTURB) and SWING(or AIR DIRECTION) buttons to cycle through information displayed. • Pressing LED(or DO NOT DISTURB) will display the next code in the sequence.
Displayed code T1 Room temperature T2 Indoor coil temperature T3 Outdoor coil temperature T4 Ambient temperature Tb Outlet temperature of indoor coil TP Discharge temperature TH Suction temperature FT Targeted frequency Fr Actual frequency IF OF Displayed value Explanation Indoor fan speed Meaning Additional Notes 1. All displayed temperatures use actual values. 2. All temperatures are displayed in °C regardless of remote used.
Displayed code Explanation Displayed value Meaning Additional Notes A0 A1 0 1 2 3 0-FF 4 5 6 L Reserved 2-28 5-20 - 5-25 A U T A 5 T Troubleshooting 10 -
5. Error Diagnosis and Troubleshooting Without Error Code WARNING Be sure to turn off unit before any maintenance to prevent damage or injury. 5.1 Remote maintenance SUGGESTION: When troubles occur, please check the following points with customers before field maintenance. No.
5.
Test method / remedy ☆ ☆ Troubleshooting 13 ☆ Turn the AC later Turn the AC later Turn off SILENCE function.
Shipping plates remain attached Interference from cell phone towers and remote boosters The air inlet or outlet of either unit is blocked Heavy load condition Possible causes of trouble Bad airproof Others Loosen hold down bolts and / or screws 1.
Test method / remedy ☆ ☆ Condenser (Outdoor) fan will not start ☆ ☆ Unit runs, but shortly stops ☆ ☆ Compressor short-cycles due to overload ☆ ☆ ☆ ☆ Troubleshooting 15 Check resistance with multimeter ☆ Evaporator (indoor) fan will not start ☆ ☆ Check resistance with multimeter Compressor and condenser (outdoor) fan will not start Replace the stepping motor ☆ Test voltage ☆ Test continuity of coil & contacts Compressor will not start but fans run Test continuity of coil & contacts ☆ ☆
Test method / remedy ☆ Troubleshooting 16 ☆ ☆ ☆ ☆ Rectify piping so as not to contact each other or with external plate ☆ Choose AC of lager capacity or add the number of AC Compressor is noisy ☆ ☆ ☆ Remove them ☆ ☆ ☆ ☆ ☆ Contact of piping with other piping or external plate Poor choices of capacity Shipping plates remain attached Loosen hold down bolts and / or screws Heavy load condition Poor installation of feeler bulb Leaking power element on expansion valve Expansion valve or capill
6. Quick Maintenance by Error Code If you do not have the time to test which specific parts are faulty, you can directly change the required parts according the error code. You can find the parts to replace by error code in the following table.
7. Troubleshooting by Error Code 7.1 E0 / F4 (EEPROM parameter error diagnosis and solution) Description: Indoor or outdoor PCB main chip does not receive feedback from EEPROM chip. Recommended parts to prepare: • Indoor PCB • Outdoor PCB Troubleshooting and repair: Shut off the power supply and turn it on 2 minutes later. Is it still displaying the error code? NO The unit is operating normally. YES Replace the indoor main PCB(E0) /outdoor main PCB(F4).
7.2 E1 (Indoor and outdoor unit communication error diagnosis and solution) Description: Indoor unit can not communicate with outdoor unit Recommended parts to prepare: • Indoor PCB • Outdoor PCB • Reactor Troubleshooting and repair: Power off, then restart the unit after 2 minutes. Does a problem remain? NO The unit is operating normally YES Measure Vs. (Vs is the voltage between S and N of outdoor unit.
Remarks: • Use a multimeter to test the DC voltage between 2 port(or S or L2 port) and 3 port(or N or S port) of outdoor unit. The red pin of multimeter connects with 2 port(or S or L2 port) while the black pin is for 3 port(or N or S port) . • When AC is normal running, the voltage will move alternately between -25V to 25V. • If the outdoor unit has malfunction, the voltage will move alternately with positive value. • While if the indoor unit has malfunction, the voltage will be a certain value.
7.3 E2 (Zero crossing detection error diagnosis and solution) Description: When PCB does not receive zero crossing signal feedback for 4 minutes or the zero crossing signal time interval is abnormal. Recommended parts to prepare: • Connection wires • PCB Troubleshooting and repair: Check the connections and power supply. Is it normal? NO Correct the connections. Turn on the unit when the power supply is good. YES Indoor main PCB is defective. Replace indoor main PCB.
7.4 E3 / F5 (Fan speed is operating outside of normal range diagnosis and solution) Description: When indoor / outdoor fan speed keeps too low or too high for a certain time, the unit will stop and the LED will display the failure. Recommended parts to prepare: • Connection wires • Fan assembly • Fan motor • PCB Troubleshooting and repair: Power off, then restart the unit after 2 minutes. Does a problem remain? NO The unit is operating normally YES Shut off the power supply, Rotate the fan by hand.
Index: 1. Indoor or Outdoor DC Fan Motor(control chip is in fan motor) Power on and when the unit is in standby, measure the voltage of pin1-pin3, pin4-pin3 in fan motor connector. If the value of the voltage is not in the range showing in below table, the PCB must has problems and need to be replaced. • DC motor voltage input and output (voltage: 220-240V~): No. Color Signal Voltage 1 Red Vs/Vm 280V~380V 2 --- --- --- 3 Black GND 0V 4 White Vcc 14-17.5V 5 Yellow Vsp 0~5.
3. Indoor AC Fan Motor Power on and set the unit running in fan mode at high fan speed. After running for 15 seconds, measure the voltage of pin1 and pin2. If the value of the voltage is less than 100V(208~240V power supply) or 50V (115V power supply), the PCB must has problems and need to be replaced.
7.5 E4/E5/F1/F2/F3 (Open circuit or short circuit of temperature sensor diagnosis and solution) Description: If the sampling voltage is lower than 0.06V or higher than 4.94V, the LED will display the failure. Recommended parts to prepare: • Connection wires • Sensors • PCB Troubleshooting and repair: Check the connection between temperature sensor and PCB. Is it properly wired? NO Ensure proper connections. YES Measure the resistance value of the sensor.
7.6 E7 (Indoor PCB / Display board communication error diagnosis and solution) Description: Indoor PCB does not receive feedback from the display board.
7.7 EC (Refrigerant Leakage Detection diagnosis and solution) Description: Define the evaporator coil temperature T2 of the compressor just starts running as Tcool. In the beginning 5 minutes after the compressor starts up, if T2 < Tcool-1°C(1.8°F) does not keep continuous 4 seconds and compressor running frequency higher than 50Hz does not keep for 3 minutes, and this situation happens 3 times, the display area will show “EC” and AC will turn off.
7.8 F0 (Overload current protection diagnosis and solution) Description: An abnormal current rise is detected by checking the specified current detection circuit. Recommended parts to prepare: • Outdoor PCB • Connection wires • Compressor Troubleshooting and repair: Check the power supply. Is it in working order? NO Stop the unit. YES Check system for blockages. Do any exist? Clear the blockage. Yes No Check the compressor resistance values.
7.9 P0(IPM malfunction or IGBT over-strong current protection diagnosis and solution) Description: When the voltage signal the IPM sends to the compressor drive chip is abnormal, the display LED shows “P0” and the AC turn off. Recommended parts to prepare: • Connection wires • IPM module board • Outdoor fan assembly • Compressor • Outdoor PCB Troubleshooting and repair: Check the wiring between PCB and compressor. YES Does an error exist? Ensure proper connections or replace the wires and connectors.
7.10 P1(Over voltage or too low voltage protection diagnosis and solution) Description: Abnormal increases or decreases in voltage are detected by checking the specified voltage detection circuit. Recommended parts to prepare: • Power supply wires • IPM module board • PCB • Reactor Troubleshooting and repair: Check the power supply. Is it in working order? NO Turn off the unit. YES Check the connections and wires. Are they in working order? Ensure proper connections or replace the wires.
7.11 P2(High temperature protection of IPM module diagnosis and solution) Description: If the temperature of IPM module is higher than a certain value, the LED will display the failure. Recommended parts to prepare: • Outdoor PCB • IPM module board Troubleshooting and repair: Check the fastening screws on the PCB and IPM radiator. Are they fixed tightly? YES Replace the outdoor control PCB. NO Tighten the screws and apply silicon grease.
7.12 P4(Inverter compressor drive error diagnosis and solution) Description: An abnormal inverter compressor drive is detected by a special detection circuit, including communication signal detection, voltage detection, compressor rotation speed signal detection and so on. Recommended parts to prepare: • Connection wires • IPM module board • Outdoor fan assembly • Compressor • Outdoor PCB Troubleshooting and repair: Check the wiring between the PCB and compressor.
8. Check Procedures 8.1 Temperature Sensor Check WARNING Be sure to turn off all power supplies or disconnect all wires to avoid electric shock. Operate after compressor and coil have returned to normal temperature in case of injury. 1. Disconnect the temperature sensor from PCB (Refer to Chapter 5&6. Indoor&Outdoor Unit Disassembly). 2. Measure the resistance value of the sensor using a multi-meter. 3. Check corresponding temperature sensor resistance value table (Refer to Chapter 8. Appendix).
Resistance Value KSK103D33UEZ3 KSN140D21UFZ KTM240D57UMT 2.02Ω 1.28Ω 0.62Ω Blue-Red Blue-Black Red-Black Note: The picture and the value are only for reference, actual condition and specific value may vary.
8.3 IPM Continuity Check WARNING Electricity remains in capacitors even when the power supply is off. Ensure the capacitors are fully discharged before troubleshooting. 1. Turn off outdoor unit and disconnect power supply. 2. Discharge electrolytic capacitors and ensure all energy-storage unit has been discharged. 3. Disassemble outdoor PCB or disassemble IPM board. 4. Measure the resistance value between P and U(V, W, N); U(V, W) and N.
Appendix Contents i) Temperature Sensor Resistance Value Table for T1, T2, T3, and T4 (°C – K).......2 ii) Temperature Sensor Resistance Value Table for TP (for some units)(°C --K)......3 iii) Pressure On Service Port........................................................................................
i) Temperature Sensor Resistance Value Table for T1,T2,T3 and T4 (°C – K) °C °F K Ohm °C °F K Ohm °C °F K Ohm °C °F K Ohm -20 -4 115.266 20 68 12.6431 60 140 2.35774 100 212 0.62973 -19 -2 108.146 21 70 12.0561 61 142 2.27249 101 214 0.61148 -18 0 101.517 22 72 11.5 62 144 2.19073 102 216 0.59386 -17 1 96.3423 23 73 10.9731 63 145 2.11241 103 217 0.57683 -16 3 89.5865 24 75 10.4736 64 147 2.03732 104 219 0.56038 -15 5 84.
ii) Temperature Sensor Resistance Value Table for TP(for some units) (°C --K) °C °F K Ohm °C °F K Ohm °C °F K Ohm °C °F K Ohm °C °F K Ohm °C °F K Ohm °C °F K Ohm °C °F K Ohm -20 -4 542.7 20 68 68.66 60 140 13.59 100 212 3.702 -19 -2 511.9 21 70 65.62 61 142 13.11 101 214 3.595 -18 0 483 22 72 62.73 62 144 12.65 102 216 3.492 -17 1 455.9 23 73 59.98 63 145 12.21 103 217 3.392 -16 3 430.5 24 75 57.37 64 147 11.79 104 219 3.
iii) Pressure On Service Port Cooling chart(R410A): °F(°C) BAR PSI MPa ODU(DB) 0(-17) 5(-15) 15 (-9.44) 45 (7.22) 75 (23.89) 85 (29.44) 95 (35) 105 (40.56) 115 (46.11) 120 (48.89) 70/59 (21.11/15) 6.4 6.5 7.3 8.0 8.2 7.8 8.1 8.6 10.1 10.6 75/63 (23.89/17.22) 6.7 6.8 7.9 8.6 8.6 8.3 8.7 9.1 10.7 11.2 80/67 (26.67/19.44) 7.1 7.2 8.5 9.5 9.3 8.9 9.1 9.6 11.2 11.9 90/73 (32.22/22.78) 7.7 7.8 9.6 10.5 10.3 9.5 10.0 10.6 12.4 13.0 70/59 (21.
Heating chart(R410A): °F(°C) BAR PSI MPa ODU(DB/WB) 57/53 (13.89/11.67) 47/43 (8.33/6.11) 37/33 (2.78/0.56) 27/23 (-2.78/-5) 17/13 (-8.33/10.56) 0/-2 (-17/-19) -17/-18 (-27/-28) 55(12.78) 30.3 28.5 25.3 22.8 20.8 18.5 16.5 65(18.33) 32.5 30.0 26.6 25.4 23.3 20.5 19.0 IDU(DB) 75(23.89) 33.8 31.5 27.8 26.3 24.9 21.5 20.0 55(12.78) 439 413 367 330 302 268 239 65(18.33) 471 435 386 368 339 297 276 75(23.89) 489 457 403 381 362 312 290 55(12.78) 3.
System Pressure Table-R410A Pressure Temperature Pressure Temperature Kpa bar PSI °C °F Kpa bar PSI °C °F 100 1 14.5 -51.623 -60.921 2350 23.5 340.75 38.817 101.871 150 1.5 21.75 -43.327 -45.989 2400 24 348 39.68 103.424 200 2 29 -36.992 -34.586 2450 24.5 355.25 40.531 104.956 250 2.5 36.25 -31.795 -25.231 2500 25 362.5 41.368 106.462 300 3 43.5 -27.351 -17.232 2550 25.5 369.75 42.192 107.946 350 3.5 50.75 -23.448 -10.
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