SERVICE MANUAL AIR CONDITIONER Electrolux Home Products Italy S.p.A. Corso Lino Zanussi, 30 I - 33080 Porcia – PN Fax: + 39 0434 394096 SOE Edition: 07-2012 Rev 0.
010-10 ADL 2/62 599 73 60-74
Index 1. Safety Precautions: refer to Page 3. 2. ESD Requirements: refer to Pages 4 & 5. 3. Specifications: refer to Pages 6 to 7. 4. Component Overview: refer to Pages 8 & 9. 5. Dimention: refer to Pages 10 & 11. 6. Installation Brief: refer to Pages 12 to 15 7. Electrical Functions: refer to Pages 16 to 23. 8. Schematic Diagram: refer to Pages 24 to 27. 9. Troubleshooting: refer to Pages 28 to 52. 10. Disassembly Precedure: refer to Pages 53 to 60.
1. Safe Electrical Working Practices: Isolate Power Before Attempting to Service any Appliance. Remove Power cord, Fuse or Switch off the Circuit Breaker. Always check appliance with multimeter to ensure the power is disconnected. If you have to work on a live appliance all precautions must be taken. Use only Insulated tools and equipment. Wear insulated shoes. No water on the floor or working space. Reduce the amount of exposed skin, by covering your arms and legs.
2.
210-10 ADL 6/62 599 75 60-77
3.
Model of Outdoor Unit EXH09HL1WE CHINA RESOURCES(SHENYANG) SANYO COMPRESSOR CO. LTD EXH12HL1WE CHINA RESOURCES(SHENYANG) SANYO COMPRESSOR CO. LTD C-6RZ110H1A C-6RZ110H1A A A W FV50S Rotary 33 4.59 800 FV50S Rotary 33 4.59 800 1nt11l-3979 1nt11l-3979 ºC Electron expansion valve 16～30 Electron expansion valve 16～30 Compressor Manufacturer/Trademark Outdoor Unit Compressor Model Compressor Oil Compressor Type L.R.A.
Connectio n Pipe Ambient temp (cooling) Ambient temp (heating) Condenser Form Pipe Diameter Rows-fin Gap Coil Length (LXDXW) Fan Motor Speed Output of Fan Motor Fan Motor RLA Fan Motor Capacitor Air Flow Volume of Outdoor Unit Fan Type Fan Diameter Defrosting Method Climate Type Isolation Moisture Protection Permissible Excessive Operating Pressure for the Discharge Side Permissible Excessive Operating Pressure for the Suction Side Sound Pressure Level (H/M/L) Sound Power Level (H/M/L) Dimension (WXHXD) Di
4.
Display Panel(indoor unit) (10)Heating indicator: This indicator illuminates when the air conditioner is in HEAT mode. (11)Cooling indicator: This indicator illuminates when the air conditioner is in COOL mode (12)LED indicator (13)Power indicator: This indicator illuminates when the air conditioner is connected to the power supply.
5. Dimensions Indoor Unit Unit：mm Models W(R) D H EXH09HL1W EXH12HL1W 896 205 316 210-10 ADL H1 267 12/62 H2 H3 Q Q1 S S1 35 34.
EXH09HL1W (outdoor) & EXH12HL1W(outdoor) 210-10 ADL 13/62 599 75 60-77
6.
Installation Site Instructions Proper installation site is vital for correct and efficient operation of the unit. Avoid the following sites where: ●strong heat sources, vapours, flammable gas or volatile liquids are emitted. ●high-frequency electro-magnetic waves are generated by radio equipment, ●welders and medical equipment. ●salt-laden air prevails (such as close to coastal areas). ●the air is contaminated with industrial vapours and oils. ●the air contains sulphures gas such as in hot spring zones.
Piping Length, Elevation, Flare Work & Torque Settings Piping Model Standard Length (m) Max Elevation (m) Max Length (m) Additional Refrigerant (g/m) GAS LIQUID EXH09HL1W 3/8 9.52mm 1/4 6.00mm 5 10 20 20 EXH12HL1W 3/8 9.52mm 1/4 6.00 mm 5 10 20 20 Flaring work. Firmly hold copper pipe in a die in the dimension shown in The table below . A(mm) OUTER DIAMETER(mm) Max. Min. 6,00 1,3 0,7 9,52 1,6 1,0 12,70 1,8 1,0 16 2,4 2,2 Connection Adjustment 1.
Electrical Work: CAPACITY POWER SUPPLY INPUT RATED AMP Switch/Fuse CABLE SIZE EXH09HL1W EXH12HL1W 220-240V~/50Hz 16A/16A 1.5 mm (power cord) 2 1.5 mm (connecting cable) 2 Connect the Cable to the Indoor Unit（instruction manual） 1.The inside and outside connecting cable can be connected without removing the front panel. 2. Connecting cable between indoor unit and outdoor unit shall be approved polychloroprene sheathed flexible cord,type designation H07RN-F or heavier cord. 3.
7. Electronic Function 1.Temperature Parameters ◆Indoor preset temperature (Tpreset) ◆Indoor ambient temperature (Tamb.) 2.Basic Functions (The temperature in this manual is expressed by Centigrade. If Fahrenheit is used, the switchover between them is Tf=TcX1.8+32.) Once the unit is energized, the compressor shall never be restarted except 3mins interval at least. For the first energization, if the unit is at off status before power failure, the compressor can be restarted without 3-min delay.
(3) Heating Mode (this mode isn’t available for cooling only unit) ①Heating Conditions and Process When Tamb. ≤Tpreset+2℃, the unit operates in cooling mode. Compressor and outdoor fan operate and indoor fan operates according to cold air prevention. When Tamb.≥Tpreset+5℃, compressor and outdoor fan stop operation, while indoor fan operates according to blowing residual heat. When Tpreset+2℃＜Tamb.＜Tpreset+5℃, the unit operate at previous running status.
(4) Fan Mode In fan mode, indoor fan operates at set fan speed, while compressor and outdoor fan all stop operation. In fan mode, the temperature setting range is 16～30℃. Display is displaying operation icon and set temperature. (5) Auto Mode In auto mode, the system will select the operation mode (cooling, hearing of fan mode) according to the change of ambient temperature automatically. The display displays operation icon, actual operation mode and set temperature.
(7)SAVE Function ① In cooling mode, if press IONFilter+clock buttons on remote controller simultaneously, the controller will enter into SAVE mode. In SAVE mode, if press IONFilter+clock buttons on remote controller simultaneously again, SAVE function won’t be set again. ②If remote controller is set to display set temperature, dual-8 nixie tube display “SE”.
Timer Change Although timer has been set, the unit still can be turned on/off by pressing ON/OFF button of the remote controller. You can also set the timer once again, and then the unit will operate according to the last setting. If timer ON and timer OFF are set at the same time during operation of the unit, the unit will keep operating at current status till OFF time reaches. If timer ON and timer OFF are set at the same time at unit OFF, the unit will keep off status till ON time reaches.
When Tpreset＜Tamb.＜Tpreset＋3℃, indoor fan operates at medium speed; When Tpreset-2＜Tamb.≤Tpreset, indoor fan operates at low fan speed; When Tamb. ≤Tpreset-2℃, indoor fan operates at quiet mode. ③Auto fan speed is not available in drying mode Note: high speed, medium speed and low speed is to “notch 5”, “notch “3” and “notch 1” respectively. As for the switchover among high speed, medium speed and low speed, the unit should operates at every speed for 3minutes and 3s at least.
(9) Control of Left&Right Swing After energization, swing will be restored to the starting point firstly and then stop at the middle position. When setting left&right swing, swing blade has 7 statuses: left position ①, secondary left position ②, middle position ③, secondary right position ④, right position ⑤, swing between ①and ⑤, stop position. If left&right swing is set when turning on the unit, swing motor will drive blade to swing between left and right.
(14) Fahrenheit Display Function Niexie tube displays current set temperature. If the remote control signal is Fahrenheit, the temperature will be display by Fahrenheit. Set temperature range is 16~30℃（61-86℉）. Under auto mode, nixie tube displays 25℃（77℉）in cooling and fan, and 20℃（68℉） in heating. Cooling only controller only displays 25℃（77℉）.
8.Schematic Diagram 8.
8.
●BOTTOM VIEW 210-10 ADL 28/62 599 75 60-77
Outdoor Unit ●TOP VIEW SN Interface name 1 Input of neutral wire of power 6 2 Input of live wire of power 7 3 Communication interface 8 4 5 / Interface 1 of electric reactor Interface 2 of electric reactor / SN 9 10 Interface name Interface of fan Neutral wire of electric heater of chassis Neutral wire of electric heater of compressor Neutral wire of 4-way valve Live wire of 4-way valve / / SN Interface name 11 Live wire of electric heater 12 Input of overload 13 Temp sensor 14 15
9. Troubleshooting Safety Please insure stored voltage is discharged/removed from all relevant high voltage capacitors, by the use of a 25 to 40 watt incandescent globe. As illustrated below.
Diagnosis and Solution: Error Code Display of lamp (the times of blinking) Display of indoor unit Running Anti-freezing protection E2 2 System block or refrigerant leakage Compressor exhaust high temperature protection AC over-current protection E3 3 E4 4 7 P48 5 P45 Name of malfunction Indoor Cooling Page NO.
Function of Indoor Controller: 1.
2. Diagram of Display When the Unit is Standby 3. Troubleshooting of Indoor Unit 3.
3.2 Each Troubleshooting and Schematic Diagram 3.2.1 Firstly, check if power supply is normal Check if power supply is normal and the voltage is between 165V~235V. 3.2.2 Refer to Malfunction Code Table and confirm the malfunction according to malfunction code displayed on indoor unit. F1,F2 Malfunctions Malfunction of indoor ambient temperature sensor: F1 is displayed; COOL LED lamp is off for 3s and blinks once; (That the LED lamp is on for 0.5s and off for 0.5s is a blink.
F1,F2 Malfunctions: Flowchart： Start Is the wiring terminal between temperature sensor and the controller loosened or poorly contacted? Yes Insert the temperature sensor tightly No Malfunction is eliminated No Is there short circuit due to tri-pover of the parts? Yes Make the parts upright No Malfunction is eliminated No Is the temperature sensor normal according to the Resistance Table? Yes No Replace it with a temperature sensor of the same model Yes Yes No Replace the controller with one
H6 Malfunction (2) Malfunction of Indoor Motor There is no feedback from indoor motor: H6 is displayed and LED lamp is off for 3s and blinks for 11 times. (That the LED lamp is on for 0.5s and off for 0.5s is a blink.) Interface of DC motor； 1.VDC DC power supply，normal working voltage: 280~310VDC； 2.Reference voltage point of GND DC motor； 3.Control voltage of Vcc DC motor: 15VDC； 4.Vsp voltage value is proportional to rotational speed； 5.
H6 Malfunction Flowchart： 210-10 ADL 37/62 599 75 60-77
C5 Malfunction (3) Malfunction of Jumper Cap Malfunction of Jumper Cap: C5 is displayed; Operation LED lamp is off for 3s and blinks for 15 times. (That the LED lamp is on for 0.5s and off for 0.5s is a blink.) Function of jumper cap: determine swing angle of different models and rotational speed of indoor fan.
C5 Malfunction Flowchart： C5 is displayed on the unit.
E6 Malfunction (4) Communication Malfunction between Indoor and Outdoor Units Communication malfunction between indoor and outdoor units: E6 is displayed and operation LED lamp is off for 3s and blinks for 6 times. (That the LED lamp is on for 0.5s and off for 0.5s is a blink.) When communication between indoor and outdoor units is normal, communication LED lamp of indoor unit blinks ( off for 0.5s and on for 0.5s).
4. Cautions: (1) Before replacing indoor mainboard, check if the substituted mainboard is qualified. The following tests shall be done: a. Test if protective tube FUSE1 is open-circuit. If so, replace it with a protective tube of same model. b. Energize the unit to test if the buzzer will sound. If not, this mainboard of the indoor unit can’t be used. c. Equip the display and energize the unit to test if the display is normal. If not, that mainboard of indoor unit can’t be used.
Detection point 5 Detection point 6 210-10 ADL Detection point 3 Detection point 2 Detection point 7 42/62 Detection point 10 Detection point 8 Detection point 4 Detection point 1 Detection point 9 599 75 60-77
3. Troubleshooting of Outdoor Unit 3.1 Firstly, check if power supply is normal Check if power switch is turned on and the voltage is between 165V~253V. 3.
# Example of LED sequence: Single fault code sequence. Mutable fault code sequence. (2) Low Voltage protection PL is displayed on indoor unit Yellow LED lamp of outdoor unit blinks for 12 times # Check voltage of power supply. (3) High voltage protection PH is displayed on indoor unit Yellow LED lamp of outdoor unit blinks for 13 times. # Check voltage of power supply.
(4) Communication Malfunction E6 is displayed on indoor unit Green LED lamp of outdoor unit doesn’t blink. # If there is no LED lamp blinking, 1. Measure voltage between N1 (neutral wire ) and 3 (live wire) on patching board of outdoor electric box by AC voltage grade of universal meter. If it is found that there is voltage, check if there is electricity for patching board of indoor unit. If there is no electricity, check if wiring of indoor unit is correct. Otherwise replace controller of indoor unit. 2.
(6) Over current protection E5 is displayed on indoor unit Yellow LED lamp of outdoor unit blinks for 5 times #It indicates that the current of the complete unit is too large. Check if voltage of power supply is normal. (7) EEPROM Reading and Writing Malfunction EE is displayed on indoor unit Yellow LED lamp of outdoor unit blinks for 11 times # Check if EEPRPM is assembled correctly. Position of EEPROM (8) Outdoor Ambient Temp.
(11) PFC Over Current Protection HC is displayed on indoor unit Yellow LED lamp of outdoor unit blinks for 14 times # Check if the power supply voltage is normal # Check if there is short circuit between any two pins. If so, IGBT is damaged. Replace the IGBT and turn on the unit again. If IGBT is still burnt out, the PFC drive circuit is damaged, replace the mainboard. # Check if voltage of PFC is normal (15V). If not, check switch power module.
(13) Mismatching of indoor and outdoor unit LP is displayed on indoor unit Yellow LED lamp of outdoor unit blinks for 16 times # Check if jumper cap of indoor unit is applicable. Needle stand of jumper cap (14) Low Pressure Protection (refrigerant leak) (not applicable to this model) E3 is displayed on indoor unit Red LED lamp of outdoor unit blinks for 9 time # Check if refrigerant leaks and if connecting pipe is correctly connected.
(17) Discharge Temperature Protection E4 is displayed on indoor unit Yellow LED lamp of outdoor unit blinks for 7 times When TBdischarge≥98℃, the frequency is prohibited to increase; When TBdischarge≥103℃, the compressor operates at decreased frequency; When TBdischarge≥110℃, the compressor stops operation; When TBdischarge≤90, when compressor has stopped operation for 3min, it will resume operation. # Check if discharge temperature meets the above conditions of protection.
(19) Power Protection L9 is displayed on indoor unit Yellow LED lamp of outdoor unit blinks for 9 times When Pc≥1900w, if Pc≤1800w for continuous 3min, the unit will resume normal operation; When PcB≥2000w, the unit will operate at decreased frequency; When Pc≥2100w, compressor stops operation. # Check if power of compressor meets the conditions mentioned above. Decrease the frequency so as to reduce the power to less than 1800w for 3min. Then check if the compressor resumes operation.
After replacing outdoor controller, the malfunction still exists: In that case, check if communication wire, temp sensor, fan, compressor or 4-way valve is normal. Communication wire: Check if communication wire, live wire and neutral wire are incorrectly connected, or wiring terminal is poorly connected. If the communication wire is prolonged, check if the joint is well connected. Temperature sensor: measure resistances to ground of the 3.3V(detection point 6) and IPM15V(detection point 3).
Appendix Appendix 1: Resistance Table of Ambient Temperature Sensor for Indoor and Outdoor Units（15K） Resistance Resistance Temp（℃） Resistance（kΩ） Temp（℃） Temp（℃） Temp（℃） （kΩ） （kΩ） -19 138.1 20 18.75 59 3.848 98 Resistance （kΩ） 1.071 -18 128.6 21 17.93 60 3.711 99 1.039 -17 121.6 22 17.14 61 3.579 100 1.009 -16 115 23 16.39 62 3.454 101 0.98 -15 108.7 24 15.68 63 3.333 102 0.952 -14 102.9 25 15 64 3.217 103 0.925 -13 97.4 26 14.36 65 3.105 104 0.898 -12 92.
Appendix 2: Resistance Table of Outdoor and Indoor Tube Temperature Sensors（20K） Resistance Resistance Resistance Temp（℃） Temp（℃） Temp（℃） Temp（℃） （kΩ） （kΩ） （kΩ） Resistance （kΩ） -19 181.4 20 25.01 59 5.13 98 1.427 -18 171.4 21 23.9 60 4.948 99 1.386 -17 162.1 22 22.85 61 4.773 100 1.346 -16 153.3 23 21.85 62 4.605 101 1.307 -15 145 24 20.9 63 4.443 102 1.269 -14 137.2 25 20 64 4.289 103 1.233 -13 129.9 26 19.14 65 4.14 104 1.198 -12 123 27 18.
Temp（℃） -29 -28 210-10 ADL Appendix 3: Resistance Table of Outdoor Discharge Temperature Sensor（50K） Resistance Temp Resistance Temp Resistance Temp Resistance（kΩ） （kΩ） （℃） （kΩ） （℃） （kΩ） （℃） 853.5 10 98 49 18.34 88 4.754 799.8 11 93.42 50 17.65 89 4.609 -27 750 12 89.07 51 16.99 90 4.469 -26 703.8 13 84.95 52 16.36 91 4.334 -25 660.8 14 81.05 53 15.75 92 4.204 -24 620.8 15 77.35 54 15.17 93 4.079 -23 580.6 16 73.83 55 14.62 94 3.958 -22 548.9 17 70.
10. Disassembly Procedure Indoor disassembly: Procedure Steps 1. Before disassembly 2. Remove panel panel Remove the clamps on left and right side of the panel, to separate the panel and front case. displayer Remove the screws fixing display, to remove the display. screw 3.
Steps Procedure 4. Remove guide louver axial bushing guide louver Pushing out the axial bushing in middle of the guide louver, slightly bend the guide louver to remove it. 5. Remove front case assy Remove the screws fixing front case. Loosen the clamps on front case.
6. Remove electric box assy electric box cover 1 Loosen the clasp of electric box cover; remove the electric box cover; remove the tube temperature sensor; remove the 3 earthing wire screws of earthin g screw scre w evaporator and then remove the connection screw of electric box and chassis. indoor tube temp. sensor clamp Remove the 2 connection screws of electrostatic deduster and evaporator and then remove the screw electrostatic deduster.
Steps Procedure 7. Remove connection pipe clamp and evaporator assy screw connection pipe clamp evaporator assy Remove the screws fixing connection pipe clamp, to remove the clamp. Remove the two screws connecting evaporator angle support and chassis, screw remove the screws fixing evaporator assy and motor clamp, loosen the clamp, slightly regulate the evaporator connection pipe position, to remove the evaporator. clamp 8.
Outdoor disassembly: Steps Procedure 1. Remove top cover Remove the screws fixing right handle and valve cover, to remove them. screw Remove the screws fixing left & right side of top cover, to remove the top cover. top cover screw 2. Remove panel assy panel assy Remove the screws connecting panel assy, chassis and motor support, to remove the panel assy.
3. Remove left and right side plate assy right side plate assy Remove the screws connecting right side plate and evaporator, electric box assy and valve support, to remove the right side plate assy. screw Left side plate assy Remove the screws connecting left side plate and evaporator to remove the left side plate assy. screw 4.
5. Remove motor and motor support Remove the screw nut fixing motor, to remove the motor motor; remove the screws connecting motor support and chassis, to remove the motor support. motor support screw nut 6. Remove electric box assy electric box cover Remove the screw fixing electric box cover, to remove the electric box cover.
Steps Procedure 7. Remove four-way valve assy Remove the screw on electromagnetic loop, to four-way valve assy remove the loop. Welding cut the spot weld of four-way valve, to remove the four-way valve assy. (Release the refrigerant clearly before welding cutting) spot weld 8. Remove bid and small valve Remove the screw fixing big and small valve, to small valve screw remove the valves. big valve 9.
