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DuctlessAire DA-09, Service Manual

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Service Manual

1 

Service Manual

 

Mini-Splits 

Summary of Contents for DA-09

Page 1: ...Service Manual 1 Service Manual Mini Splits ...

Page 2: ...1 7 Sleep function 15 1 8 Anti mildewing operation function 15 1 9 Remember function at the time of power failure 15 2 Pre Installation Requirements 22 2 1 Unit sized correctly and applied correctly 22 2 2 Electrical Requirements 22 2 3 Breaker Size 22 2 4 Line Set Lengths and Sizes 20 2 5 Indoor Unit Positioning 21 2 6 Outdoor Unit Positioning 21 3 Installation Tips 21 3 1 R410A Refrigerant 24 3 ...

Page 3: ...e Manual 3 3 3 Number of Electrical Interconnect Wires 26 3 4 Service Valves 27 3 5 Adding Refrigerant Charge 28 3 6 Condensate Piping 28 4 Common Technical Problems 29 5 Unit Fault Codes 36 6 Maintenance 45 ...

Page 4: ...size Do not exceed this sizing guideline Installing large capacity systems in small rooms will lead to short cycling of the compressor as the supply airflow from the unit to bounces back into the return air stream of the unit If using the larger capacity units Supply air is discharged at a velocity of approximately 6ft per second With a small room where the opposite wall to the unit is less than 1...

Page 5: ... the floor so that the airflow from the unit is unimpeded Sensible Heat and Humidity DuctlessAire units are designed to provide an approximate SHR of 0 66 Be aware that low humidity conditions will further reduce unit performance requiring either additional higher fan speeds to be programmed into the unit or introduction of some latent load into the room e g Use of a humidifier Compressor Run Time...

Page 6: ...ssor which can damage the valve plate wash oil from the bearing services and eventually cause the Compressor to fail A Wind Baffle will provide cooling operation down to an Ambient of 0 DegF Wind Baffles are field fabricated drawings are available on request from DuctlessAire 1 2 Commercial Offices Shops Churches etc Sizing Again Sizing and Location of the Mini Split to the room is EXTREMELY IMPOR...

Page 7: ... 4 weeks of operation more frequently in areas subject to dirtier conditions e g Warehouse offices etc Condensers located inside the Building Especially with Warehouse or additional office space the condensers can be installed inside the building this provides two specific issues to address 1 Lower ambient these units are rated at 95 DegF ambient if the ambient in the building does not rise above ...

Page 8: ... For optimum unit operation the High Wall Indoor unit should be mounted a minimum of 6 feet from the floor A minimum height of 4 feet must be maintained for correct unit operation Ensure air flow is never directly straight onto areas where people may sit or congregate as the temperature difference between Supply and Return air will be approximately 35 DegF Outdoor unit location The Outdoor units a...

Page 9: ...Sun Rooms are different in their application as they by definition have a large solar gain and therefore can require cooling in cold ambient temperatures Therefore as per Computer room and Commercial applications it is mandatory to install the ICM 326H low ambient control and a crankcase heater on the system Indoor unit Location For optimum unit operation the High Wall Indoor unit should be mounte...

Page 10: ...oller plus a Crankcase Heater either a Mars 32342 or Raychem CCH 1 or 2 bellyband types MUST be installed For cooling operation below 32 DegF and down to a minimum of 0 DegF DuctlessAire recommends that Wind Baffles be installed on both the Coil Inlet and Fan Outlet of the Outdoor unit Please contact DuctlessAire directly for details of the design requirements for the Wind Baffles We also recommen...

Page 11: ...ely strap the probe to the bend or tube and insulate to ensure accurate temperature sensing Wiring Wiring should be in accordance with the diagrams on the following pages DO NOT deviate from the wiring shown if in doubt please call Technical Support for assistance Please note on Heat Pump units the bypass connection must be wired from the Reversing Valve to the ICM controller to ensure that the Ou...

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Page 15: ...ource of heat baseboard electric or hydronic or other type be used when the temperature falls below 24 DegF Warm Start In Heat Pump operation the Indoor fan motor will only start operating when the indoor coil temperature has reached 86 DegF Then the fan will start operating in an ultra low speed mode increasing in fan speed back to the selected speed on the remote control as the Indoor coil tempe...

Page 16: ...g Defrost the Indoor fan motor will stop so that cold air is not blown into the room The Outdoor fan motor will also stop to speed up the defrost process After defrost has finished the compressor will stop to equalize pressures A single blink of the operating light shows that unit is in defrost Defrost Initiation and Termination Come into the defrosting status state only meet one of the following ...

Page 17: ...the unit will exit the defrosting status A When the sensor temperature of the outdoor coil pipes is above 59DegF programmable data 29 the unit will exit the defrosting status B When the defrosting time is longer than fifteen minutes the unit will exit the defrosting status Reversing Valve The reversing or 4 way valve is energized for HEATING in a DuctlessAire unit If the unit does not produce heat...

Page 18: ...itioning will come back to the operation status the same as the status before the sleep the indoor blower will still be operating according to the set wind speed that is set during the sleep The unit can be shut down through pressing down the ON OFF key on the remote controller and the sleep setting will also be canceled at the same time B Pressing down the Sleep key on the remote controller to se...

Page 19: ...wo hours and it will keep the same value from that time on D Set the sleep in the heating mode it will be Ts 1 after one hour it will be Ts 3 after two hours it will be Ts 5 after three hours and it will keep the same value from that time on E Set the sleep in the dehumidify mode the unit will keep on the operation according to the dehumidify mode but the sleep and screen closing will be execute F...

Page 20: ...mation mode then the air conditioning will execute the anti mildewing operation function The compressor and indoor blower will be operated according to the curve in the start up period that is shown in the following figure the indoor blower is in the operation status of low wind speed the air flap will be closed thirty seconds after it has been operated according to the original status the outdoor...

Page 21: ... again after the power failure then the immediate start up should be selected when the timing off function is set if the power is supplied again after the power failure then the immediate shut down should be selected D When the sleep function is set because this sleep function has no timing off operation if the power is supplied again after the power failure then the start up should be selected an...

Page 22: ...d Control voltage for the Outdoor unit There is NO 24V AC wiring on these units therefore all the electrical wiring between the units MUST be a minimum of 14 AWG The Outdoor unit MUST be fed with power from a Breaker and or Local Disconnect The Outdoor unit MUST provide power for the Indoor unit Do not install local disconnects or J boxes adjacent to the Indoor unit as this can cause mis wiring an...

Page 23: ... 4 50ft 20ft DA 12 1 2 1 4 50ft 20ft DA 18 5 8 3 8 50ft 20ft DA 24 5 8 3 8 50ft 20ft All of the units have the expansion device located in the Outdoor unit therefore both the Suction and the Liquid line MUST be insulated separately 2 5 Indoor Unit Positioning High Wall units must be mounted high on the wall use a height of 6 to 8 feet with nothing that would restrict airflow in front of the indoor...

Page 24: ...All valve and electrical connections are on the RHS of the Outdoor unit when looking at the condenser fan 3 Installation Tips Tools required for installing a DuctlessAire Mini Split 10 or 12 Crescent wrenches x 2 Small Electrical Screwdriver Tool to help knockout the cable entry holes Refrigerant Gauges and 5 16 Gauge Adaptor Vacuum Pump and Vacuum gauge Digital Refrigerant scale to weigh in extra...

Page 25: ...he best method of ensuring a perfectly dry system 5 In order to prevent confusion with what type of refrigerant is used in the system DuctlessAire uses a 5 16 Schrader connection on the Suction line to attach a gauge set to Therefore an adaptor is required to connect to a standard US gauge set It is always a good practice to insulate the flare nuts to prevent loosening as the system operates this ...

Page 26: ...nals at both the Indoor and Outdoor units require the use of a small bladed electrical screwdriver to access the terminal screws 3 3 Number of Electrical Interconnect Wires If a question on the wiring occurs the IOM manual contains the unit wiring diagrams Model Number of Interconnect Wires including Ground 9 12000btu Cooling Only 4 18 24btu Cooling Only 4 9 12000btu Heat Pump 6 18 24000btu Heat P...

Page 27: ... the Outdoor unit To do this it is very important that the SUCTION SERVICE VALVE MUST BE OPENED FIRST This will allow the refrigerant to flood the system without passing through the capillary tube If the Liquid service valve is opened first it is possible to log Oil in the capillary tube especially if the outdoor temperature is low If this happens the unit will drop into a vacuum immediately on st...

Page 28: ...000 12000btu Models Add 0 3 oz ft of R410A over 25ft 18000 24000btu Models Add 0 5 oz ft of R410A over 25ft Added Charge required for a line set of Unit 30ft 35ft 40ft 45ft 50ft 9000 12000btu 1 5oz 3 0oz 4 5oz 6 0oz 7 5oz 18000 24000btu 2 5oz 5 0oz 7 5oz 10 0oz 12 5oz Remember the Schrader connection for these R410A units is a 5 16 size not the standard this distinguishes the system from an R22 sy...

Page 29: ...Technical questions that are asked of our Technical Support staff By having these available it may help diagnose a problem before calling No Fault The possible reason Solution 01 Not cooling well The room is too large the window or door is not closed Close the window and door Too many persons or too much heat source in room Reduce the heat source The installed position of outdoor unit isn t good H...

Page 30: ... out Blockage in airinlet or air outlet Clear the obstacles Air mixed in refrigerant refill the refrigerant after vacuumizing outdoor temperature is above 109 DegF The indoor or outdoor fan motor is running slow Change this indoor or outdoor fan motor The compressor suction or venting capability is very poor Change the compressor or outdoor unit 4 way valve slight mixes up Change the 4 way valve 0...

Page 31: ...h Check Repair and replace The refrigerant leaked completely refill up refrigerant after checking the leak source The system blocked completely Check capillary tube strainer etc repair or replace them 03 Not heating well The room is too large the window or door is not closed Close the window and door The set temperature is too low Heighten the set temperature The air filter is dirty Clean this fil...

Page 32: ...r or outdoor motor speed is lower Replace this fan motor The compressor suction or venting capability is very poor Replace the compressor 4 way valve slight mixes up Let the four way valve moving continually Replace the four way valve if it can t move The capillary valve has been blocked Replace the capillary valve 04 Cannot heat The fan doesn t run motor or capacitor of fan failed Poor contact fo...

Page 33: ...ough Check Repair and replace The refrigerant leaked refill up refrigerant after checking the leak source and welding the leak point vacuumizing The system blocked completely Check capillary tube strainer etc repair or replace them The compressor failed Replace compressor The compressor is blocked Knock the compressor With wooden hammer repeatedly or shunt another capacitor if can not shart change...

Page 34: ... line supply voltage is too low install voltage regulator The capacitor of compressor failed Replace the capacitor The PCB failed Check Repair and replace the PCB The compressor locked Replace the compressor The compressor open circuit or short circuit Replace the compressor The overload protector has been damaged Replace the overload protector 05 The AC can t turn on No power in AC power connecti...

Page 35: ... window failure Repair or replace this receiving head or window poor contact for socket connector of PCB Check Repair or replace this PCB The transformer damaged Replace the transformer The PCB damaged and no output Replace the PCB 08 Unit suddenly doesn t work after running some time Power failure fuse of power supply burn out Replace this fuse poor contact for the plug Check repair and replace t...

Page 36: ... on disconnecting valve The system is blocked For example the strainer or connect pipe Replace this parts which blocked The compressor failed Replace the compressor The indoor fan is not running Check one by one change fan motor capacitor or pcb 10 Noise and vibration is existent during running electromagnetic noise from compressor Replace the compressor resonance between the compressor and other ...

Page 37: ...ross flow fan broke Replace the bearing The cross flow fan collides with the foam or sponge Reconfigure or cut out some foam or sponge The pipe of outdoor unit contact with crust Adjust the pipes and keep them away more than 3 from the metallic or plastic parts The noise come from synchronous motor stepper motor capacitance transformer reactor Replace the faulted parts the indoor and outdoor air c...

Page 38: ... 226 3 275 3 323 18 0 4 28 722 29 497 30 271 38 100 4 3 117 3 165 3 213 17 1 4 27 42 28 147 28 873 39 102 2 3 012 3 06 3 107 16 3 2 26 186 26 868 27 55 40 104 2 912 2 959 3 006 15 5 25 017 25 657 26 297 41 105 6 2 815 2 861 2 908 14 6 8 23 908 24 509 25 11 42 107 4 2 722 2 768 2 814 13 8 6 22 857 23 421 23 985 43 109 2 2 633 2 678 2 724 12 10 4 21 859 22 389 22 918 44 111 2 547 2 592 2 637 11 12 2...

Page 39: ...6 7 55 7 653 70 157 8 1 137 1 168 1 199 15 59 7 169 7 266 7 363 71 159 6 1 105 1 135 1 165 16 60 8 6 9 6 991 7 082 72 161 4 1 074 1 103 1 133 17 62 6 6 644 6 729 6 814 73 163 2 1 043 1 072 1 101 18 64 4 6 398 6 478 6 558 74 165 1 014 1 043 1 071 19 66 2 6 163 6 238 6 313 75 166 8 0 986 1 014 1 042 20 68 5 938 6 008 6 078 76 168 6 0 959 0 986 1 014 21 69 8 5 723 5 789 5 854 77 170 4 0 932 0 959 0 9...

Page 40: ...ow 14DegF display at on state flicker 1 3 SEC anti cold wind 1 Normal during heating mode 2 It will be removed when the coil pipe temperature sensor reaches certain temperature E1 display at off state display at on off state Outdoor temp sensor fault 1 Check whether the resistance of the sensor is normal when it is abnormal the sensor should be replaced 2 Check whether there is short circuit or op...

Page 41: ...ted circuit is damaged the electric control board should be replaced E2 display at off state flicker 2 4 SEC display at on off state room temp sensor fault 1 Check whether the resistance of the sensor is normal when it is abnormal the sensor should be replaced 2 Check whether there is short circuit or open circuit in the wire of the sensor and whether the plug is connected well whether there is we...

Page 42: ...y at off state flicker 3 5 SEC display at on off state coil temp sensor fault 1 Check whether the resistance of the sensor is normal when it is abnormal the sensor should be replaced 2 Check whether there is short circuit or open circuit in the wire of the sensor and whether the plug is connected well whether there is welding off or rosin joint on the electric control board if there is any it shou...

Page 43: ...tance and operation current of the compressor are normal 2 Check whether the high and low pressure is normal when the unit is running 3 Check whether the coil pipe sensor is normal whether the contact of the inserter on the circuit board is well the coil pipe temperature sensor is fixed whether there is water in the fixed clap the evaporation of the indoor unit is well the key is to check the evap...

Page 44: ...cleaned when it is too dirty 5 Check whether the capacitance of the outdoor motor and the fan is damaged it should be replaced when it is damaged 6 If the above items are normal the electric control board should be replaced E5 PG motor display at off state flicker 5 7 SEC display at off state no feedback signal of indoor fan 1 Check whether two sets of plugs on the outlet end of the motor have loo...

Page 45: ...con and other components on the electric control board have damaged replace the controllable silicon or electric control board when they are damaged E6 PG motor display at off state flicker 6 8 SEC display at off state no over zero signal 1 Firstly check whether the indoor fan is normal 2 Check whether the signal outputting from the integrated chip of the electric control board is normal the elect...

Page 46: ...ration current of the compressor are normal 2 Check whether the high and low pressure is normal when the unit is running 3 Check whether the indoor and outdoor wiring is right when it is wrong connect them again according to the circuit diagram 4 Check whether the contact of the inserter on the circuit board and the connection are well otherwise repair 5 Check whether the signal feedback wire is d...

Page 47: ... signal feedback wire in the terminal inserts firmly which is between the indoor PCB and the display board E8 display at off state flicker 8 10 SEC display at off state frost protection ov er heat protection 1 Check whether the filter of the indoor unit is dirty or blocked and clean if it is dirty 2 Check whether the indoor fan is running normally and replace the motor if it is abnormal 3 Check wh...

Page 48: ... Continuous Fan All Mini Splits feature continuous Indoor fan operation when the unit is powered and turned on the Indoor fan does not cycle with the compressor as is common with the standard US style systems The reason for this is While the system is on the fan slowly moves air throughout the conditioned space monitoring the temperature of the air returning to the fan coil This action provides ac...

Page 49: ...ergy and costing more 500W x 20minutes 166W consumed per hour versus 40W for the DuctlessAire unit But the constant fan operation does have one drawback the unit air filters work harder and therefore clog up faster than on a regular central unit Therefore DuctlessAire recommends that in ALL applications the 2 large Air Filters be cleaned MONTHLY This is very important especially with the lower air...

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