Airwell johnson JOAU-ZCY218-H11 Service Manual Download Page 77

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Re-installation while the outdoor unit need to be repaired

Installation

Be sure to check the gas leakage.

7. Re-installation while the outdoor unit need to be repaired

7.1. Evacuation for

the whole system

Procedure:

1). Confirm that both the 2-way and 3-way valves are set to the opened position.

2). Connect the vacuum pump to 3-

way valve’s service port.

3). Evacuation for approximately one hour. Confirm that the compound meter indicates -0.1Mpa.

4). Close the valve (Low side) on the charge set, turn off the vacuum pump, and confirm that the gauge

needle does not move (approximately 5 minutes after turning off the vacuum pump).

5). Disconnect the charge hose from the vacuum pump.

Summary of Contents for johnson JOAU-ZCY218-H11

Page 1: ...DCD Indoor Units Outdoor Units JOSI DKH009 N11 JOAU ZCY218 H11 JOSI DKH012 N11 JOSI DBC012 N11 JOSI DAQ012 N11 JOSI DCD012 N11 JOAU ZCY327 H11 JOSI DKH018 N11 JOAU ZCY430 H11 JOAU ZCY536 H11 REFRIGERANT REFRIGERANT R410A HEATPUMP REFRIGERANT SM ZCY DCI 1 A 1 GB March 2016 ...

Page 2: ...Information 1 Part 2 Indoor Units 11 Part 3 Outdoor Units 46 Part 4 Installation 68 Part 5 Electrical Control System 79 The specifications designs and information in this book are subject to change without notice for product improvement ...

Page 3: ...General Information General Information 1 Part 1 General Information 1 Model Lists 2 2 External Appearance 3 2 1 Indoor Units 3 2 2 Outdoor Units 3 3 Product specification 4 ...

Page 4: ...0Hz 1Ph Four way cassette compact JOSI DBC012 N11 12000 220 240V 50Hz 1Ph Duct JOSI DCD012 N11 12000 220 240V 50Hz 1Ph Console JOSI DAQ012 N11 12000 220 240V 50Hz 1Ph 1 2 Outdoor Units Universal Outdoor unit Model Compressor type Compressor Brand Power supply JOAU ZCY218 H11 Twin rotary GMCC 220 240V 50Hz 1Ph JOAU ZCY327 H11 Twin rotary GMCC 220 240V 50Hz 1Ph JOAU ZCY430 H11 Twin rotary GMCC 220 2...

Page 5: ...External Appearance General Information 3 2 External Appearance 2 1 Indoor Units DKH Duct Four way cassette Compact Console 2 2 Outdoor Units ...

Page 6: ...or type model Twin Rotary DC Inverter Fan type quantity Axial x 1 Fan speeds H L RPM 750 Air flow H L m3 hr 2500 Sound power level 4 H L dB A 65 Sound pressure level 5 H L dB A 55 Dimensions WxHxD mm 845x700x320 Weight kg 48 Package dimensions LxWxH mm 965x395x755 Packaged weight kg 52 Stacking height units 2 levels Refrigerant type R410A Refrigerant charge standard connecting tubing length kg 10m...

Page 7: ...l Twin Rotary DC Inverter Fan type quantity Axial x 1 Fan speeds H L RPM 800 Air flow H L m3 hr 3500 Sound power level 4 H L dB A 68 Sound pressure level 5 H L dB A 58 Dimensions WxHxD mm 900x860x315 Weight kg 62 Package dimensions LxWxH mm 1043x395x915 Packaged weight kg 67 Stacking height units 2 levels Refrigerant type R410A Refrigerant charge standard connecting tubing length kg 10m 2 4 Additi...

Page 8: ... Twin Rotary DC Inverter Fan type quantity Axial x 1 Fan speeds H L RPM 800 Air flow H L m3 hr 3800 Sound power level 4 H L dB A 70 Sound pressure level 5 H L dB A 58 Dimensions WxHxD mm 900x860x315 Weight kg 65 Package dimensions LxWxH mm 1043x395x915 Packaged weight kg 69 Stacking height units 2 levels Refrigerant type R410A Refrigerant charge standard connecting tubing length kg 10m 2 4 Additio...

Page 9: ...odel Twin Rotary DC Inverter Fan type quantity Axial x 1 Fan speeds H L RPM 850 Air flow H L m3 hr 5500 Sound power level 4 H L dB A 70 Sound pressure level 5 H L dB A 60 Dimensions WxHxD mm 990x345x965 Weight kg 80 Package dimensions LxWxH mm 1120x435x1100 Packaged weight kg 91 Stacking height units 2 levels Refrigerant type R410A Refrigerant charge standard connecting tubing length kg 10m 3 Addi...

Page 10: ...rain tube I D mm ODΦ17 5 ODΦ17 5 Dimensions WxHxD mm 715x250x188 800x275x188 Net Weight kg 6 5 7 4 Package dimensions LxWxH mm 775x260x324 865x265x350 Packaged weight kg 8 2 9 5 Operation control type Remote control Remote control Model Indoor Unit JOSI DKH018 N11 Installation Method of Pipe Flared Characteristics Units Cooling Heating Capacity 4 kW 5 0 1 8 6 1 5 0 1 4 6 7 Power supply V 220 240 P...

Page 11: ...H M L VL RPM 810 780 680 530 1200 1070 1000 Heating H M L VL RPM 810 780 680 530 1200 1070 1000 Air flow 1 H M L VL m3 hr 700 640 560 440 560 440 410 External static pressure Min Pa 0 25 0 40 Sound power level 2 dB A 58 58 Sound pressure level 3 H M L VL dB A 44 40 36 41 39 36 Moisture removal l hr 1 5 1 5 Condensate drain tube I D mm ODФ16 ODΦ25 Dimensions WxHxD mm 700 600 210 700x210x635 Net Wei...

Page 12: ... VL RPM 830 720 660 Air flow 1 H M L VL m3 hr 800 710 560 External static pressure Min Pa 0 Sound power level 2 dB A 55 Sound pressure level 3 H M L VL dB A 44 41 38 Moisture removal l hr 1 5 Condensate drain tube I D mm ODΦ25 Dimensions WxHxD mm 570x260x570 Net Weight kg 16 Package dimensions LxWxH mm 655x655x290 Packaged weight kg 19 Frame dimensions WxHxD mm 647x50x647 Frame net weight kg 2 5 F...

Page 13: ...Indoor Units Indoor Units 11 Part 2 Indoor Units DKH Type 12 Light Commercial 22 ...

Page 14: ...DKH Type 12 Indoor Units DKH Type 1 Function 13 2 Dimensions 14 3 Wiring Diagrams 15 4 Exploded View and Spare Part list 16 ...

Page 15: ...er Ico Filter O Vitamin C Filter O 3M HAM Filter O Bio Filter O Golden Fin O Ionizer O 1W Standby Louver Position Memory Function Refrigerant Leakage Detect Self diag Function Hydrophilic Aluminum Fin PTC Heating Belt O Filter 2 ways of drainage O optional function ...

Page 16: ...nsions W D H Model L mm R mm H mm Dimension of installation hole mm JOSI DKH009 N11 100 95 45 65 JOSI DKH012 N11 JOSI DKH018 N11 110 100 45 Model W D H JOSI DKH009 N11 715 188 250 JOSI DKH012 N11 800 188 275 JOSI DKH018 N11 940 205 275 ...

Page 17: ...Wiring Diagrams Indoor Units 15 3 Wiring Diagrams JOSI DKH009 N11 JOSI DKH012 N11 JOSI DKH018 N11 ...

Page 18: ...Exploded View and Spare Part list 16 Indoor Units 4 Exploded View and Spare Part list Exploded View of indoor unit JOSI DKH009 N11 ...

Page 19: ...1 12 12122000000350 Bearing sleeve 1 13 12622000000006 Bearing pedestal 1 14 12100102000036 Cross flow window rotor 1 15 12122000005105 Wind Guide Assembly 1 16 12122000004172 Chassis Assembly 1 16 1 11002010000143 stepper motor 1 17 12122000000445 Pipe Pressing Board 1 18 12222000000024 Installation Plate 1 19 17222000A18108 Electronic control box assembly 1 19 1 12122000007835 Electrical Control...

Page 20: ...Exploded View and Spare Part list 18 Indoor Units Exploded View of indoor unit JOSI DKH012 N11 ...

Page 21: ...ng pedestal 1 14 12100102000022 Cross flow Window Rotor 1 15 12122000005123 Wind Guide Assembly 1 16 12122000004342 Chassis Assembly 1 16 1 11002010000143 stepper motor 1 17 12122000000445 Pipe Pressing Board 1 18 12222000000012 Installation Plate 1 19 17222000A18111 Electronic control box assembly 1 19 1 12122000004586 Electrical Control Box 1 19 2 12122000004565 Electrical Control Box 1 19 3 171...

Page 22: ...Exploded View and Spare Part list 20 Indoor Units Exploded View of indoor unit JOSI DKH018 N11 ...

Page 23: ...12 12122000000350 Bearing sleeve 1 13 12622000000006 Bearing pedestal 1 14 12100102000072 Cross flow window rotor 1 15 12122000006245 Wind Guide 1 16 12122000004388 Chassis Assembly 1 16 1 11002010000143 stepper motor 1 17 12122000000445 Pipe Pressing Board 1 18 12222000000011 Installation Plate 1 19 17222000A18109 Electronic control box assembly 1 19 1 12122000004586 Electrical Control Box 1 19 2...

Page 24: ...Light Commercial 22 Indoor Units Light Commercial 1 Features 23 2 Dimensions 32 3 Service Space unit mm 35 4 Wiring Diagrams 37 5 Exploded View and Spare Part list 40 ...

Page 25: ... design affords comfortable feeling Compact design The body size is 570 260 570mm it s just smaller than the ceiling board so it s very easy for installation and will not damage the decoration The panel size is 647 50 647mm The hooks are designed in the four corners of the body which can save installation space ...

Page 26: ...E box is simply and safely built inside the indoor unit It s convenient for installation and maintenance Can check the control part easily you only need to open the air return grille Fresh air intake function Fresh air fulfills air quality more healthy and comfortable ...

Page 27: ...s Light Commercial 25 Air passage function Reserves the space for air outlet from the side of indoor unit It s availed to connect air duct from the two sides to the nearby small rooms Dimension Φ75mm Fresh Air ...

Page 28: ... air inlet frame from rear and bottom is same it s very easy to move the cover from bottom to rear side or from rear to the bottom in order to matching the installation condition Fresh air intake function Install one duct from the reserved fresh air intake to outdoor Continually inhale the fresh air to improve the quality of the indoor air fulfills air quality more healthy and comfortable Front Bo...

Page 29: ...the filter from the indoor unit for cleaning even the filter is installed in rear side or bottom side Replace the motor or centrifugal fan Remove the ventilated panel firstly Remove a half of blower housing and take out the motor with centrifugal fan Directly remove two bolts and then replace the motor or centrifugal fan easily ...

Page 30: ...e of an on off controller or a central controller to realize remote on off control function or group control function Built in drain pump Optional Built in drain pump can lift the water to 750mm upmost It s convenient to install drainage piping under most space condition Motor Blower Housing Ventilated Panel Remote on off ports Central control ports ...

Page 31: ...oard with a receiver in the E box Move out the display and fix it in other place even in the distance of 10m The unit will realized remoter control The wired controller and the display board can display the error code or production code when the chips detect some failure 750mm upmost Wired Controller Standard Remote Controller Optional ...

Page 32: ... Consumes up to 30 less energy than non inverter units DC inverter compressor indoor fan motor adopts DC motor 2 Achieves set temperature more quickly air supplying from top and bottom or from top only air inlet from four directions Display ...

Page 33: ...efficiency filter built in Formaldehyde nemesis filter active carbon and biological anti virus filter is optional 6 Comfort flexible air blow vertical auto swing and wide angle louvers ensure that warm air reaches the furthest corners of the room and increase the air flow coverage Low noise operation lowest to 23Db Low starting power and precise room temperature adjustment 7 Powerful mode can be s...

Page 34: ...Dimensions 32 Indoor Units 2 Dimensions 2 1 Four way cassette type compact 2 2 A5 Duct H G E F A B D C ...

Page 35: ...al 33 L M Model Outline dimension mm Air outlet opening size Air return opening size Size of outline dimension mounted plug A B C D E F G H I J K L M JOSI DCD012 N11 700 210 635 570 65 493 35 119 595 200 80 740 350 2 3 Console ...

Page 36: ...Dimensions 34 Indoor Units ...

Page 37: ...mmercial 35 3 Service Space unit mm 3 1 Four way cassette compact 3 2 A5 Duct Ensure enough space required for installation and maintenance All the indoor units reserve the hole to joint the fresh air pipe The hole size as following ...

Page 38: ...Service Space unit mm 36 Indoor Units 3 3 Console ...

Page 39: ... 0 0 F ON OFF 16 31 0 F OFF ON 32 47 0 F ON ON 48 63 SW1 1 SW1 2 Anti Cold Air Setting OFF OFF Fan OFF when ICT 24 Default ON OFF Fan OFF when ICT 15 OFF ON Fan OFF when ICT 8 ON ON Reserved SW6 1 SW6 2 Temp Compensation Heating OFF OFF 6 Default ON OFF 4 OFF ON 2 ON ON Reserved Auto Restart With Auto Restart Default W O Auto Restart SW3 OFF ON Fan Status When Thermo OFF FAN ON Default FAN OFF ON ...

Page 40: ...Wiring Diagrams 38 Indoor Units JOSI DCD012 N11 JOSI DAQ012 N11 ...

Page 41: ...Exploded View and Spare Part list 40 Indoor Units 1 Exploded View and Spare Part list Exploded View of indoor unit JOSI DBC012 N11 ...

Page 42: ...on Hanger 1 12 12122500000330 Sealing board for Pipe Tie in Subassembly 1 13 12222500000197 Joint board of Evaporator 1 14 12222500000199 Motor Installing Foundation 1 15 11002015000069 Brushless DC Motor 1 16 12100103000089 Centrifugal Fan 1 17 12122500000425 Air Guide Coil 1 18 17222500000377 E Parts Box assembly 1 18 1 12222500000165 Welding Parts of Electrical Control Box 1 18 2 12122500000029...

Page 43: ...Exploded View and Spare Part list 42 Indoor Units Exploded View of indoor unit JOSI DCD012 N11 ...

Page 44: ...12 3 201600320001 Copper nut 1 12 4 201670190020 Input pipe assembly 1 12 4 1 201600320000 Copper nut 1 13 201270290034 Evaporator right support board assembly 1 14 202440500004 Pipe temperature sensor assembly 1 15 202285190003 Water collector 1 16 201270290090 Right clapboard assembly 1 16 1 201270890021 Hook 2 17 203370190015 Electronic control box assembly 1 17 1 201270290163 Electronic contro...

Page 45: ...Exploded View and Spare Part list 44 Indoor Units Exploded View of indoor unit JOSI DAQ012 N11 ...

Page 46: ...1310072 Ambient temperature sensor assembly 1 9 5 202301400072 Wire joint 1 9 7 201244090002 Electronic control box seal plate 1 9 8 201144090008 Installation plate of electric parts 1 9 9 201344090004 Display board assembly 1 9 10 2013440A0029 Main control board assembly 1 9 11 201244090004 Fixing board of electronic control box I 1 9 14 201344090029 Auxiliary electric heater control board 1 10 2...

Page 47: ... Units Part 3 Outdoor Units 1 Dimensions 47 2 Service Space 51 3 Refrigeration Cycle Diagram 52 4 Wiring Diagrams 54 5 Indoor units combination 56 6 Operation Limits 57 7 Sound Levels 58 8 Exploded View and Spare Part list 59 ...

Page 48: ...Dimensions Outdoor Units 47 1 Dimensions JOSI DAQ012 N11 560 W1 H 6 D1 335 D2 360 845 W 313 D3 335 D1 R6 R5 A1 22 A2 50 B1 120 110 B2 700 W2 73 58 58 58 110 H1 H2 200 7 243 6 L1 L2 ...

Page 49: ...Dimensions 48 Outdoor Units JOAU ZCY327 H11 900 W 590 W1 860 H 12 D2 355 D1 333 302 D3 333 D1 50 97 90 B2 B1 8 A2 55 55 55 55 55 110 62 W2 H1 H2 R6 238 4 285 7 L1 L2 ...

Page 50: ...Dimensions Outdoor Units 49 JOAU ZCY430 H11 900 W 590 W1 860 H 12 D2 355 D1 333 302 D3 333 D1 50 97 90 B2 B1 8 A2 55 55 55 55 55 55 55 110 62 W2 H1 H2 R6 238 4 285 7 L1 L2 ...

Page 51: ...Dimensions 50 Outdoor Units JOAU ZCY536 H11 ...

Page 52: ...Service Space Outdoor Units 51 2 Service Space More than 60cm More than 30cm More than 60cm More than 200cm Air inlet Air inlet More than 30cm Air outlet Wall or obstacle Maintain channel ...

Page 53: ... B LIQUID VALVE B GAS VALVE B Accumulator T2B A Evaporator temp sensor outlet T2B B 3 2 Refrigeration cycle diagram of inverter 1 drive 3 type LIQUID VALVE A GAS VALVE A HEAT EXCHANGE EVAPORATOR HEAT EXCHANGE CONDENSER Compressor 4 WAY VALVE COOLING HEATING T2 Evaporator temp sensor middle T1 Room temp sensor T3 Condenser temp sensor T5 Discharge temp sensor T4 Ambient temp sensor INDOOR OUTDOOR E...

Page 54: ...ressure switch T2B A Evaporator temp sensor outlet T2B B T2B C T2B D 3 4 Refrigeration cycle diagram of inverter 1 drive 5 type LIQUID VALVE A GAS VALVE A HEAT EXCHANGE EVAPORATOR HEAT EXCHANGE CONDENSER COOLING HEATING T2 Evaporator temp sensor middle T1 Room temp sensor T3 Condenser temp sensor T4 Ambient temp sensor INDOOR OUTDOOR EXV A CAPILIARY A CHECK VALVE CAPILIARY TUBE EXV B CAPILIARY B L...

Page 55: ...Wiring Diagrams 54 Outdoor Units 4 Wiring Diagrams JOAU ZCY218 H11 JOAU ZCY327 H11 ...

Page 56: ...Wiring Diagrams Outdoor Units 55 JOAU ZCY430 H11 JOAU ZCY536 H11 ...

Page 57: ...mbination for JOAU ZCY430 H11 JOAU ZCY430 H11 Two IDU Three IDU Four IDU 9 18 9 9 9 9 12 12 9 9 9 9 12 18 9 9 12 9 12 18 9 9 9 12 18 18 9 9 18 12 12 12 5 4 Indoor unit combination for JOAU ZCY536 H11 JOAU ZCY536 H11 Two IDU Three IDU Four IDU Five IDU 18 18 9 9 18 12 12 12 9 9 9 9 9 9 12 12 9 12 12 18 9 9 9 9 9 9 9 9 12 18 9 12 12 12 12 18 9 9 9 12 9 9 12 18 12 12 12 12 9 9 9 9 12 9 9 12 12 12 9 1...

Page 58: ... above conditions certain safety protection features may come into operation and cause the unit to operate abnormally 2 The room relative humidity should be less than 80 If the air conditioner operates beyond this figure the surface of the air conditioner may attract condensation Please set the vertical air flow louver to its maximum angle vertically to the floor and set HIGH fan mode 3 The optimu...

Page 59: ...tdoor Units 7 Sound Levels H 1 0m Outdoor Unit Microphone Note H 0 5 height of outdoor unit Model Noise Power dB A Noise level dB A JOAU ZCY218 H11 65 60 JOAU ZCY327 H11 68 61 JOAU ZCY430 H11 70 62 JOAU ZCY536 H11 70 64 ...

Page 60: ...Exploded View and Spare Part list Outdoor Units 59 8 Exploded View and Spare Part list Exploded View of outdoor unit JOAU ZCY218 H11 ...

Page 61: ... Valve plate 1 201257190109 21 1 Wire joint 1 202301450157 6 Chassis assembly 1 201257090054 21 2 Terminal board 1 201257190117 7 Rear right clapboard assembly 1 201257190099 22 Liquid valve assembly 1 201657090490 9 Water collector 1 201157090005 22 1 Liquid valve 2 201600740097 10 Front right clapboard assembly 1 201248100389 22 2 Electronic expansion valve assembly 2 201601300554 11 Front panel...

Page 62: ...Exploded View and Spare Part list Outdoor Units 61 Exploded View of outdoor unit JOAU ZCY327 H11 ...

Page 63: ...0554 11 Front panel 1 201248200103 24 Liquid valve assembly 1 201657390000 12 Air outlet grille 1 2011482A0001 24 1 Liquid valve 1 201600740091 Round sticker of air outlet grille 1 2011374A0005 24 2 Electronic expansion valve assembly 1 201601300554 13 Axial flow fan 1 201100300527 25 4 ways valve assembly 1 201657190430 14 Brushless DC Motor 1 202400300047 25 1 Gas valve 3 201600720091 15 Support...

Page 64: ...Exploded View and Spare Part list Outdoor Units 63 Exploded View of outdoor unit JOAU ZCY430 H11 ...

Page 65: ...720091 Round sticker of air outlet grille 1 2011374A0005 25 2 4 ways valve 1 201600600119 13 Axial flow fan 1 201100300527 26 Capillary assembly 1 201657390066 14 Brushless DC Motor 1 202400300047 27 Compressor 1 201400601740 15 Supporter assembly of fan motor 1 201257190071 29 Discharge temperature sensor assembly 1 202448200000 16 Rear supporter 1 201248200095 30 Cover of inductance 1 2012483900...

Page 66: ...Exploded View and Spare Part list 66 Outdoor Units Exploded View of outdoor unit JOAU ZCY536 H11 ...

Page 67: ...bly 1 201601300554 11 Air outlet grille 1 2011487A0003 28 liquid valve assembly 1 201657290021 Round sticker of air outlet grille 1 2011374A0005 28 1 Liquid valve 1 201600740091 12 Front panel 1 201248700072 28 2 Electronic expansion valve assembly 1 201601300554 13 Rear supporter 1 2012487G0011 29 liquid valve assembly 1 201657190373 14 Top cover assembly 1 201257190096 29 1 Liquid valve 1 201600...

Page 68: ...2 Connecting the cables 69 3 Pipe length and the elevation 69 4 Installation for the first time 71 5 Adding the refrigerant after running the system for many years 74 6 Re installation while the indoor unit need to be repaired 75 7 Re installation while the outdoor unit need to be repaired 77 ...

Page 69: ...se and switch 3 Pipe length and the elevation Maximum piping length and height difference 1 drive 2 1 drive 3 1 drive 4 1 drive 5 Max length for all rooms m 30 45 60 75 Max length for one IU m 20 25 30 30 Max height difference between IU and OU m OU higher than IU 10 10 10 10 OU lower than IU 15 15 15 15 Max height difference between IUs m 10 10 10 10 Additional refrigerant charge 1 drive 2 1 driv...

Page 70: ...ion pipe diameter mm inch Model Pipe diameter mm inch 7K9K12K Liquid 6 35 1 4 Liquid 6 35 1 4 Gas 9 52 3 8 Gas 9 52 3 8 18K Liquid 6 35 1 4 Liquid 6 35 1 4 Gas 12 7 1 2 Gas 12 7 1 2 Outdoor unit union diameter mm inch Indoor unit A B C D Liquid 6 35 1 4 Gas 9 52 3 8 ...

Page 71: ... the 2 way and 3 way valves are set to the closed position 2 Connect the charge hose with the push pin of handle lo to the 3 way valves gas service port 3 Connect the charge hose of handle hi connection to the vacuum pump 4 Fully open the handle Lo of the manifold valve 5 Operate the vacuum pump to evacuate 6 Make evacuation for 30 minutes and check whether the compound meter indicates 0 1Mpa If t...

Page 72: ...e valves on the charging cylinder and the charge set Purge the air by loosening the flare nut on the 2 way valve approximately 45 for 3 seconds then closing it for 1 minute repeat 3 times After purging the air use a torque wrench to tighten the flare nut on the 2 way valve 4 Check the gas leakage Check the flare connections for gas leakage 5 Discharge the refrigerant Close the valve on the chargin...

Page 73: ...se Open the valve at the bottom of the cylinder and press the check valve on the charge set to purge the air be careful of the liquid refrigerant 3 Put the charging cylinder onto the electronic scale and record the weight 4 Operate the air conditioner at the cooling mode 5 Open the valves Low side on the charge set and charge the system with liquid refrigerant 6 When the electronic scale displays ...

Page 74: ...on the charge set to purge the air be careful of the liquid refrigerant 3 Put the charging cylinder onto the electronic scale and record the weight 4 Operate the air conditioner at the cooling mode 5 Open the valves Low side on the charge set and charge the system with liquid refrigerant 6 When the electronic scale displays the proper weight refer to the gauge and the pressure of the low side disc...

Page 75: ...handle lo to the 3 way valves gas service port 3 Air purging of the charge hose Open the handle Lo valve of the manifold valve slightly to purge air from the charge hose for 5 seconds and then close it quickly 4 Set the 2 way valve to the close position 5 Operate the air conditioner at the cooling cycle and stop it when the gauge indicates 0 1MPa 6 Set the 3 way valve to the closed position immedi...

Page 76: ...n closing it for 1 minute repeat 3 times After purging the air use a torque wrench to tighten the flare nut on the 2 way valve 4 Check the gas leakage Check the flare connections for gas leakage 5 Discharge the refrigerant Close the valve on the charging cylinder and discharge the refrigerant by loosening the flare nut on the 2 way valve approximately 45 until the gauge indicates 0 3 to 0 5 Mpa 6 ...

Page 77: ...oth the 2 way and 3 way valves are set to the opened position 2 Connect the vacuum pump to 3 way valve s service port 3 Evacuation for approximately one hour Confirm that the compound meter indicates 0 1Mpa 4 Close the valve Low side on the charge set turn off the vacuum pump and confirm that the gauge needle does not move approximately 5 minutes after turning off the vacuum pump 5 Disconnect the ...

Page 78: ... record the weight 4 Open the valves Low side on the charge set and charge the system with liquid refrigerant If the system cannot be charge with the specified amount of refrigerant or can be charged with a little at a time approximately 150g each time operating the air conditioner in the cooling cycle however one time is not sufficient wait approximately 1 minute and then repeat the procedure 5 W...

Page 79: ...Electrical Control System Electrical Control System 79 Part 5 Electrical Control System 1 Electrical Control Function 80 2 Troubleshooting 94 ...

Page 80: ...door fan speed keeps too low for certain time the unit will stop and the LED will display the failure 1 2 6 Zero crossing detection error protection only for JOSI DKH009 N11 If AC detects time interval is not correct for continuous 240s the unit will stop and the LED will display the failure The correct zero crossing signal time interval should be between 6 13ms 1 2 7 Inverter module protection Th...

Page 81: ...er than HEAT_F4 the frequency will not be limited After 10s of the compressor start if the current IHEAT the AC will display the failure for 30 seconds and stop The AC will restart 3 minutes later 1 2 9 Indoor outdoor units communication protection If the indoor units cannot receive the feedback signal from the outdoor units for 2 minutes the AC will stop and display the failure 1 2 10 Oil return ...

Page 82: ...es The compressor will run at corresponding frequency according to the gross amendatory capacity demand Frequency COOL_F0 COOL_F1 COOL_F2 COOL_F15 COOL_F16 Amendatory capacity demand 0 1 2 15 16 Meanwhile the maximum running frequency will be adjusted according to the outdoor ambient temp 43 41 38 T4LimFre1_ADD No limit T4LimFre2_ADD T4LimFre3_ADD 42 39 37 49 46 T4LimFre4_ADD T4LimFre5_ADD 48 45 1...

Page 83: ...PD_ADD DC_FAN_SSLOW_SPD_ADD 1 3 2 3 Indoor fan running rules For Cassette A5 In cooling mode indoor fan runs all the time and the speed can be selected as high medium low and auto The auto fan 3 5 3 0 High Low 1 0 Medium 1 5 For DKH HND Console In cooling mode indoor fan runs all the time and the speed can be selected as high medium low and auto When the compressor is running the indoor fan is con...

Page 84: ...ill release and the compressor will restart after 3 minutes 1 3 2 5 Evaporator low temperature protection When T2B 0 for 250 seconds the indoor unit has no capacity demand and resume till T2B 10 When T2 4 the indoor has no capacity demand and resume till T2 8 1 3 3 Heating Mode 1 3 3 1 Compressor running rules The compressor will run at corresponding frequency according to the gross amendatory cap...

Page 85: ...ID_SPD_ADD 1 3 3 3 Indoor fan running rules For DKH HND Console In heating mode indoor fan can be selected as high medium low auto and silent The anti cold wind function has the priority When the compressor is running the indoor fan is controlled as below If the compressor stops caused by the room temperature rising the indoor fan will be forced to run 127 seconds with breeze During this period th...

Page 86: ...iority 1 3 3 5 Defrosting mode Condition of defrosting If any one of the following items is satisfied AC will enter the defrosting mode After the compressor starts up and keeps running mark the minimum value of T3 from the 10th minutes to 15th minutes as T30 1 If the compressor cumulate running time is up to 29 minutes and T3 TCDI1 T3 T30SUBT3ONE T30 2 If the compressor cumulate running time is up...

Page 87: ...en with remote controller and the setting temperature can be changed between 17 30 In auto mode the machine will choose cooling heating or fan only mode according to ΔT ΔT T1 Ts ΔT T1 Ts Running mode ΔT 1 Cooling 1 ΔT 1 Fan only ΔT 1 Heating Indoor fan will run at auto fan of the relevant mode The louver operates same as in relevant mode If the machine switches mode between heating and cooling the...

Page 88: ...e the AC current operation mode Suppose AC is off now it will not start up firstly after setting the timer off function And when reaching the setting time the timer LED will be off and the AC running mode has not been changed 1 3 6 7 The setting time is relative time 1 3 7 Economy function 1 3 7 1 The sleep function is available in cooling heating or auto mode 1 3 7 2 Operation process in sleep mo...

Page 89: ...perature 1 3 10 5 The slave forced cooling units will not be controlled by other signals 1 3 11 Drain pump control For Cassette Adopt the water level switch to control the action of drain pump Main action under different condition every 5 seconds the system will check the water level one time 1 When the A C operates with cooling including auto cooling and forced cooling mode the pump will start ru...

Page 90: ...oom temperature steady at 8 and prevents household things freezing when the house is unoccupied for a long time in severe cold weather 1 3 14 Mode conflict The indoor units cannot work cooling mode and heating at same time Heating mode has a priority 1 Definition Cooling mode Heating Mode Fan Off Cooling mode No Yes No No Heating Mode Yes No Yes No Fan No Yes No No Off No No No No No No mode confl...

Page 91: ... will show 18 B indoor unit evaporator outlet temp T2BB 19 C indoor unit evaporator outlet temp T2BC 20 D indoor unit evaporator outlet temp T2BD 21 E indoor unit evaporator outlet temp T2BE 22 A indoor unit room temp T1A If the temp is lower than 0 degree the digital display tube will show 0 If the temp is higher than 50 degree the digital display tube will show 50 If the indoor unit is not conne...

Page 92: ...y T3 Bit2 Frequency limit caused by T5 Bit1 Frequency limit caused by current Bit0 Frequency limit caused by voltage 43 Average value of T2 Sum T2 value of all indoor units number of indoor units in good connection 44 Outdoor unit fan motor state Off 0 High speed 1 Med speed 2 Low speed 3 Breeze 4 Super breeze 5 45 The last error or protection code 00 means no malfunction and protection The follow...

Page 93: ... 3 1 1 3 1 2 0 b c d e f 2 Capacity area a b c d e f Norm value N 3 2 1 5 1 0 5 0 1 3 12 4 Number of indoor unit Display Number of indoor unit 1 1 2 2 3 3 4 4 5 5 1 3 12 5 Opening degree of electronic expansion valve Actual opening degree equals the display data times 4 ...

Page 94: ...air control feature is activated in heating operation OPERATION indication lamp This lamp illuminates when the air conditioner is in operation TIMER indication lamp Lights up during Timer operation Temperature indicator Displays the temperature settings when the air conditioner is operational Displays the malfunction code 2 1 2 Icon explanation on indoor display board Duct Temporary button Operati...

Page 95: ...lternative displays between running frequency and RO each displays 0 5s In low ambient cooling mode the LED displays LC or alternative displays between running frequency and LC each displays 0 5s In forced cooling mode the LED displays FC or alternative displays between running frequency and FC each displays 0 5s When PFC module protection occurs three times within 15 minutes the LED displays E6 o...

Page 96: ... protection P4 5 Inverter compressor drive protection P5 6 Mode conflict P6 7 Low pressure protection O light X off flash For Cassette Duct NO MALFUNCTION RUN Timer DEF Alarm DISPLAY DIGITAL TUBE 1 Open or short circuit of T1 temperature sensor X X X E0 2 Open or short circuit of T2 temperature sensor X X X E1 3 Indoor outdoor units communication error X X X E2 4 Full water malfunction X X X E3 5 ...

Page 97: ...ication malfunction between indoor and outdoor units X X 4 Outdoor fan speed has been out of control X O 5 Indoor EEPROM malfunction X 6 IPM module protection X 7 Open or short circuit of T3 or T4 temperature sensor or Outdoor unit EEPROM parameter error 8 Voltage protection O 9 Inverter compressor drive protection X 10 Indoor fan Speed has been out of control O 11 Mode conflict X O O light X off ...

Page 98: ...sensor or connector of sensor is defective F3 No C Indoor unit coil outlet temperature sensor or connector of sensor is defective F4 No D Indoor unit coil outlet temperature sensor or connector of sensor is defective F5 No E Indoor unit coil outlet temperature sensor or connector of sensor is defective P1 High pressure protection For JOAU ZCY430 H11 JOAU ZCY536 H11 P2 Low pressure protection For J...

Page 99: ...unit 2 4 1 1 Indoor EEPROM malfunction If the EEPROM chip is welded on PCB replace the PCB directly Otherwise check whether the EEPROM chip plugged in PCB well Yes No Yes Insert the EEPROM well Replace the indoor PCB Shut off the power supply and turn it on 1 minute later Is it still displaying the error code ...

Page 100: ... S and N Refer PIC 1 Turn on all indoor unit by remote controller Is all indoor unit display Turn off the all indoor units Is IPM power LED or operating LED lamp On Refer PIC2 Yes A Is all the wiring between terminal and Indoor PCB connect ok No Yes A No Reconnect the wiring Is indoor units number correct Check on the outdoor check point 2 for dual zone 3 for tri zone 4 for qua zone Refer PIC 4 Ye...

Page 101: ...Troubleshooting Electrical Control System 101 Pic 2 IPM For dual tri zone Self Check Operating els Pic 1 check Vs is it m between po value ...

Page 102: ...102 Electrical Control System Self Check Power Operating els PIC3 Main board LED when power on and unit standby Pic 2 IPM For qua zone PIC 4 check point button Press 1 time for check how many indoor units are connected ...

Page 103: ...s No Correct the connections No Yes Check whether the main PCB is normal through index 2 Yes Yes Check whether the fan motor is normal through index 1 Yes Replace the fan motor Replace the main PCB The malfunction is solved No No If the malfunction is still existing replace the main PCB No Index 1 1 Indoor AC fan motor Measure the resistance value of each winding by using the tester For the defini...

Page 104: ...or 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 have problems and need to be replaced 2 Indoor DC fan motor control chip is inside 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 r...

Page 105: ...Vs Vm 280V 380V 2 3 Black GND 0V 4 White Vcc 14 17 5V 5 Yellow Vsp 0 5 6V 6 Blue FG 14 17 5V For Duct Cassette NO Color Signal Voltage 1 Red Vs Vm 192V 380V 2 3 Black GND 0V 4 White Vcc 13 5 16 5V 5 Yellow Vsp 0 6 5V 6 Blue FG 15V For console NO Color Signal Voltage 1 Red VDC 310V 2 3 White Vcc 15V 4 Blue FG 15V 5 Yellow Vsp 0 7 5V 6 Black GND 0V ...

Page 106: ... Replace indoor or outdoor PCB Replace the sensor Check the resistance value of the sensor via Appendix 1 Is it normal No 2 4 1 5 Full water malfunction If the water level switch is inserted well No Insert the water level switch well If the water level switch is broken Yes Replace the water level switch If the water pump is normal No Replace the water pump Yes No Yes Check PCB board or replace the...

Page 107: ...door unit 2 4 2 1 Outdoor EEPROM malfunction ODU E0 If the EEPROM chip is welded on PCB replace the PCB directly Otherwise check whether the EEPROM chip plugged in PCB well Yes No Yes Insert the EEPROM well Replace the outdoor main board Outdoor EEPROM malfunction ...

Page 108: ...re at least one LED in the IPM board light Check the signal wire between the IPM module and the main board is it connected good Reconnect and retry Is error still display Replace IPM board and then check whether the system can run normally Replace the electric control box No No No No Yes Trouble is solved No Yes Replace outdoor main board and then check whether the system can run normally No Yes Y...

Page 109: ... and N L2 is about 220 240VAC Check the power supply Check whether the voltage of IPM board P and N is normal DC277 356V for 18 27KBtu h DC277 410V for 36KBtu h Replace bridge rectifiers and then check whether the system can run normally Replace IPM board and then check whether the system can run normally Replace outdoor main board Yes No No No No Yes Trouble is solved Yes Yes ...

Page 110: ... operates normally Find out the cause and have it solved For example check whether the fan is blocked or the bearing is broken Check the wires of fan motor Are all the connections good No Yes No Correct the connections No Yes Check whether the main PCB is normal through index 2 Yes Yes Check whether the fan motor is normal through index 1 Yes Replace the fan motor Replace the main PCB The malfunct...

Page 111: ... 2 3 Black 4 White 5 Yellow 6 Blue Index2 1 Outdoor DC fan motor control chip is inside 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 have problems and need to be replaced DC motor voltage input and output NO Color Signal Voltage 1 Red Vs Vm 140...

Page 112: ...board No Replace high pressure protector Yes Judge 2 Whether the high pressure protector is broken Check whether the refrigerant system is ok Judge 3 Check whether the outdoor ambient temperature is higher than 50 No Stop the unit Yes Judge 4 Check whether the outdoor unit is bad ventilation No Make the outdoor unit ventilate well Yes Judge 5 Check whether the heat exchanger is dirty Clean the hea...

Page 113: ...refrigerant system is ok Judge 3 Check whether the outdoor ambient temperature is too low No Stop the unit Yes Method Connect the pressure gauge to the gauge joint of the system check whether the pressure is lower than 0 14MPa No Leak hunting Charge nitrogen or refrigerant to the system if the leakage is serious there will be distinct gas leakage cici sound if the leakage is slight use the suds mi...

Page 114: ...eck whether the outdoor ambient temperature is higher than 50 No Stop the unit Yes Judge 3 Check whether the outdoor unit is bad ventilation No Make the outdoor unit ventilate well Yes Judge 5 The refrigerant pipe is blocked No Let the refrigerant out then use the high pressure nitrogen or refrigerant to blow pipe vacuumize and charge the refrigerant again Yes Judge 4 Check whether the heat exchan...

Page 115: ...on is right between compressor discharge temp sensor and PCB according to wiring diagrams Method Check whether the resistance of compressor discharge temp sensor is right refer to the Appendix 2 No Yes Yes Trouble is solved No Judge The discharge temp sensor is broken Check whether the refrigerant is leak Correct the wiring connection Stop leaking and add refrigerant Replace the compressor dischar...

Page 116: ...han 65 C Yes Judge 1 Check whether the outdoor ambient temperature is higher than 50 No Judge 3 The refrigerant pipe is blocked Let the refrigerant out then use the high pressure nitrogen or refrigerant to blow pipe vacuumize and charge the refrigerant again Yes Judge 2 Check whether the heat exchanger is dirty No Clean the heat exchanger Yes Replace outdoor main board Yes Check whether the resist...

Page 117: ...ork normally No Replace the compressor check whether the system can work normally Check whether the lines in E part box are connected tightly Yes Connect it tightly check ok or not No No Yes No Replace the bridge rectifiers Check whether the bridge rectifiers are normal Use the multimeter to measure the resistance between each two terminals check whether there is the condition that value of resist...

Page 118: ...12 N11 JOSI DKH018 N11 Indoor fan motor RPG20E WZDK20 38G WZDK30 38G Model JOSI DCD012 N11 JOSI DBC012 N11 JOSI DAQ012 N11 Indoor fan motor WZDK27 38GS WZDK37 38G RD 280 20 8A Outdoor unit Model JOAU ZCY218 H11 JOAU ZCY327 H11 JOAU ZCY430 H11 Compressor DA150S1C 20FZ DA250S2C 30MT DA250S2C 30MT Outdoor fan motor WZDK50 38G WZDK72 38G WZDK72 38G Model JOAU ZCY536 H11 Compressor TNB306FPGMC L Outdoo...

Page 119: ...rature sensor from PCB measure the resistance value with a tester Temperature Sensors Room temp T1 sensor Indoor coil temp T2 sensor Outdoor coil temp T3 sensor Outdoor ambient temp T4 sensor Compressor discharge temp T5 sensor Measure the resistance value of each winding by using the multi meter ...

Page 120: ... 4 44 0000 36 6 13059 76 1 34105 116 0 40060 3 41 5878 37 5 87359 77 1 29078 117 0 38991 2 39 8239 38 5 62961 78 1 25423 118 0 37956 1 37 1988 39 5 39689 79 1 21330 119 0 36954 0 35 2024 40 5 17519 80 1 17393 120 0 35982 1 33 3269 41 4 96392 81 1 13604 121 0 35042 2 31 5635 42 4 76253 82 19958 122 0 3413 3 29 9058 43 4 57050 83 16448 123 0 33246 4 28 3459 44 4 38736 84 13069 124 0 32390 5 26 8778 ...

Page 121: ...37 3 74 8 358 114 2 489 5 234 9 35 35 78 75 8 084 115 2 422 4 222 8 36 34 32 76 7 82 116 2 357 3 211 4 37 32 94 77 7 566 117 2 294 2 200 7 38 31 62 78 7 321 118 2 233 1 190 5 39 30 36 79 7 086 119 2 174 0 180 9 40 29 15 80 6 859 120 2 117 1 171 9 41 28 81 6 641 121 2 061 2 163 3 42 26 9 82 6 43 122 2 007 3 155 2 43 25 86 83 6 228 123 1 955 4 147 6 44 24 85 84 6 033 124 1 905 5 140 4 45 23 89 85 5 ...

Page 122: ...22 Electrical Control System 2 Compressor checking Measure the resistance value of each winding by using the tester Position Resistance Value DA150S1C 20FZ DA250S2C 30MT TNB306FPGMC L Blue Red 0 95Ω 20 0 55Ω 20 0 53Ω 20 ...

Page 123: ...resistance between P and UVWN UVW and N Digital tester Normal resistance value Digital tester Normal resistance value Red Black Several MΩ Red Black Several MΩ P N U N U V V W W Red 4 Indoor AC Fan Motor Measure the resistance value of each winding by using the tester Position Resistance Value RPG20E TongDe RPG20E Weilng Black Red 415Ω 8 20 387Ω 8 20 Red Yellow 396Ω 8 20 378Ω 8 20 Yellow Blue 396Ω...

Page 124: ...SERVICE MANUAL Multi Splits Series ...

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