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54

Troubleshooting Outdoor Components

Liquid Line Temperature Sensors

These sensors are a negative coefficient thermistor that decrease in resistance as the temperature increases. The 

sensors are used to monitor the temperature of the refrigerant leaving the EEV to maintain a correct superheat 

operation. Please refer to the troubleshooting section for error codes generated by a sensor fault. Temperature 

sensors and locations will vary depending on models.

All manuals and user guides at all-guides.com

Summary of Contents for RIO09HP115V1A

Page 1: ...allation Service Troubleshooting Models RIO09HP115V1A RIO12HP115V1A RIO09HP230V1A RIO09HP230V1B RIO12HP230V1A RIO12HP230V1B RIO18HP230V1A RIO24HP230V1A All manuals and user guides at all guides com a l l g u i d e s c o m ...

Page 2: ...Maintenance Electrical Schematics OutdoorCircuitBoard Troubleshooting Indoor Components TroubleshootingOutdoorComponents Fault Codes Status Displays Troubleshooting Flow Charts Disassembly of Indoor Units Disassembly of 9 000 12 000 btuh Outdoor Systems Disassembly of 18 000 and 24 000 btuh Outdoor systems Appendix 1 3 Temperature Sensor Resistance Tables 3 4 5 7 8 9 13 14 15 16 21 22 25 26 29 30 ...

Page 3: ...ury or death Refer to your local and national codes for proper grounding Have the unit properly grounded with all connections tight Loose connections can cause overheating and a possible fire hazard Safety Precautions Warnings Warning Warning Caution Never install the unit in a place where a combustible gas might leak or it may lead to fire or explosion Make a proper provision against noise when t...

Page 4: ...uh AC Cooling Only HP Heat Pump HC Heat Cool 230V 208 20V 60Hz 1PH 115V 115V 60Hz 1PH Style Color Designation Revision Level S System O Outdoor H Indoor High Wall D Indoor Duct C Indoor Cassette F Indoor Floor Ceiling Product Catalog Number Nomenclature Example RIO24HP230V1AH All manuals and user guides at all guides com ...

Page 5: ...55 Net Gross Weight Indoor lbs 19 26 19 26 Net Gross Weight Outdoor lbs 75 84 75 84 Condenser Coil Type Refrigerant Charge oz R410a 37 5 R410a 41 1 Line Set Size Liq Suction 1 4 3 8 1 4 3 8 Pre Charged Lineset Ft Feet 25 25 Additional Refrigerant charge additional feet oz 0 2 0 2 Max Total Piping Length Feet 66 66 Max Elevation Feet 33 33 MCA Amps 13 15 MOCP Breaker Size Amps 20 25 Wire Size to Ou...

Page 6: ...ations Compressor Type DC Inverter driven Twin Rotary Sound Pressure Outdoor dBA 49 52 Net Gross Weight Indoor lb 19 25 20 27 Net Gross Weight Outdoor lb 64 73 68 77 Condenser Coil Type Refrigerant Charge oz R410a 26 1 R410a 35 3 Line Set Size Liq Suction 1 4 3 8 1 4 3 8 Pre Charged Lineset Ft Feet 25 25 Additional Refrigerant charge additional feet oz 0 2 0 2 Max Total Piping Length Feet 50 50 Ma...

Page 7: ... Specifications Compressor Type DC Inverter driven Twin Rotary Sound Pressure Outdoor dBA 56 53 Net Gross Weight Indoor lb 27 35 33 44 Net Gross Weight Outdoor lb 106 117 115 126 Condenser Coil Type Refrigerant Charge oz R410a 45 9 R410a 54 7 Line Set Size Liq Suction 1 4 1 2 1 4 1 2 Pre Charged Lineset Ft Feet 25 25 Additional Refrigerant charge additional feet oz 0 2 0 2 Max Total Piping Length ...

Page 8: ...e fault The indoor unit contains a digital display which will indicate the current fault The evaporator swing motors fan motors and circuit board are also components of the indoor unit The indoor units have a on off switch to bypass the remote control if lost or batteries fail This will be explained later in this service manual The systems require R410A and are pre charged for 25 of lineset Please...

Page 9: ...it Heat Exchanger Heat Exchanger Inverter Compressor Temperature Sensor 4 way Compressor Refrigeration Components Refrigeration Cycles and Components Accumulator Discharge Sensor Temperature Sensor Strainer Electronic Expansion Valve All manuals and user guides at all guides com ...

Page 10: ...es 4 way valve Electronic expansion valve Strainer Cooling Mode Temperature Sensor Refrigeration Cycles and Components Cooling Mode 4 way valve Inverter Compressor Discharge Silencer Discharge Temperature Sensor Strainer Temperature Sensor All manuals and user guides at all guides com ...

Page 11: ...ill be in a low pressure temperature saturated state This cold saturated refrigerant will move through the coil absorbing heat This liquid will flash to a vapor and will be superheated to about 10 degrees F Since this tubing is cold it must be insulated F The superheated vapor will be returned to the outdoor unit s 4 way valve G The refrigerant will flow to the accumulator not all models will have...

Page 12: ...hanger Heat Exchanger Inverter Compressor Accumulator not on all sizes 4 way valve Electronic expansion valve Filter Temperature Sensor Heating Mode 4 way valve Discharge Silencer Discharge Temperature Sensor Temperature Sensor All manuals and user guides at all guides com ...

Page 13: ...sure liquid and will maintain the proper superheat E The cold refrigerant will travel through the outdoor coil evaporator and will pickup heat from the outdoor air This will cause the cold saturated refrigerant to flash to a saturated mixture which will be superheated to 10 degrees F F The superheated vapor will travel through the 4 way valve to the accumulator which will prevent liquid floodback ...

Page 14: ... Swing Motor Ambient Temperature Sensor Indoor Unit Components RIO 12 000 btuh model Other RIO models may very slightly Indoor Circuit Board Fan Motor Note Component locations may vary depending on models All manuals and user guides at all guides com ...

Page 15: ...dels may very slightly Compressor 4 Way Valve Capacitors AP1 Board Exhaust Temp Sensor Outdoor Fan Note Component locations may vary depending on models Crankcase Heater Expansion Valve Outdoor Sensor mounted on outside of coil Outdoor Tube Sensor All manuals and user guides at all guides com ...

Page 16: ...ng The following will occur 6 minutes after the compressor has been operating in the cooling or dry mode If the evaporator temperature drops below 360 F the compressor will operate at a reduced frequency If the evaporator is below 300 F for 3 minutes the compressor will stop 30 seconds later the outdoor fan will stop In cooling mode the indoor fan and swing motor will remain on If the evaporator t...

Page 17: ...ation and the indoor evaporator coil temperature is 1080 F the indoor fan will operate at its preset condition If the indoor ambient temperature is 90 F and 20 F of the preset temperature the unit will run in its original mode of operation If the compressor is running and the mode is changed from heating to cooling the compressor will stop the 4 way valve will be de energized 2 minutes later the o...

Page 18: ...bient 140 F Toutdoortube Tcompensation Toutdoorambient 37 F 3 During defrost if run time for the compressor does not reach 3 minutes the defrost cycle will not start for the next 2 hours At that time the compressor stops operation and 30 seconds later the outdoor fan will stop 30 seconds after this the 4 way reversing valves will de energized Following another 30 second delay the compressor will i...

Page 19: ...pressor in a safety and reliable operating range A If Itotal 13a an increase in frequency will be allowed B If Itotal 15a increasing the frequency is not allowed C If Itotal 17a the compressor will decrease its frequency D If Itotal 19a the compressor will stop and the indoor fan will stop after 30 seconds 4 Fan Mode Under this mode the fan will run at the preset speed and the outdoor fan compress...

Page 20: ...has been off for at least 3 minutes the compressor will resume operation 4 Compressor High Pressure Protection Not available on 115v 9k 12k models When the high pressure switch is detected for 6 seconds or more the compressor will stop and can only be started by powering off the unit Dirty coils refrigerant overcharge and outdoor fan problems can cause this fault 5 Compressor Phase lacking Protect...

Page 21: ...gnals for a 3 minutes communication fault will occur and the whole system will stop and a E6 will be displayed on the front panel of the indoor unit Protection Functions Basic Protection Functions All manuals and user guides at all guides com a l l g u i d e s c o m ...

Page 22: ...tton 13 Sleep Button 14 Light Button Press mode and buttons to switch between Fahrenheit Centigrade Press to lock control Note This remote control is used in other models and some features may or may not be available Consult the owners manual for specific features for your model There should be no obstructions between the remote control and the indoor unit for proper operation Keep the remote from...

Page 23: ...wn swing icon 21 Left right swing icon 22 Set time icon 23 Digital display 24 Fan speed icon Replacing Batteries 1 Locate the battery cover on the back of the remote 2 Slide the cover downward 3 Make sketch of battery polarities then replace with two AAA batteries 4 Replace cover All manuals and user guides at all guides com ...

Page 24: ...to start or stop up down swing function The remote controller defaults to simple swing condition Press button and button at the same time at unit OFF to switch between simple swing and static swing blinks for 2 seconds In static swing condition pressing button the swing angle up down louver positions If the unit is turned off during swing operation the louver will stop at present position 7 Health...

Page 25: ...ton within 5 seconds during HOUR ON OFF blinking TIMER setting will be canceled 12 Turbo Button Boost the cooling or heating airflow allowing the unit to reach the preset temperature in the shortest amount of time 13 Sleep Button Press this button to go into the SLEEP operation mode Press it again to cancel this function This function is available in COOL HEAT Only for models with heating function...

Page 26: ...dry nitrogen with a pressure regulator for pressurizing unit Pressurize with 150 psi of dry nitrogen Apply soap and water to check whether the joints are leaky A leak detector may also be used for a leakage test Hint You may want to perform leak testing and evacuation before wiring to save time electrical connections can be completed while your vacuum pump is running Step 3 System Evacuation Note ...

Page 27: ...dequate for up to a total length of refrigerant line as indicated in the chart below Additional refrigerant will need to be added for total lengths over the listed length Confirm the following chart with your installation manual for additional charge amounts RIO09HP115V 1A RIO12HP115V 1A RIO09HP230V 1A 1B RIO12HP230V 1A 1B Additional Charge 0 2 oz ft 0 2 oz ft 0 2 oz ft 0 2 oz ft Max Length withou...

Page 28: ...1 4 adapter may be required to connect hose to port Check to insure that the liquid and gas valves are closed on the unit Close all valves on your gauge set then connect the vacuum pump to your gauge set Pump down lineset and indoor unit This step will be repeated for all zones 4 Zero charging scale Place the refrigerant tank on the charging scale Open the tank valve turn on the scale then zero th...

Page 29: ...ference 6 Charge to the correct weight If the scale was zeroed with the refrigerant tank on the scale the amount added to the system will be a negative amount since it was removed from the tank After the proper amount of refrigerant has been weighed in close the manifold valve 7 Remove refrigerant tank Close the tank valve then carefully remove the hose and adapter Replace the charging port cap ba...

Page 30: ...t 4 Be sure to leave enough space to allow access for routine maintenance Refer to unit installation specifications for clearances Select a place more than 3 feet away from any TV or other electrical appliances Indoor Unit 1 Select a suitable site where proper drainage will occur 2 Select a site where there is sufficient ventilation 3 Select a site where there is no obstruction blocking the inlet ...

Page 31: ...ately 132 pounds 5 Refer to specific models for dimensional data Mounting Plate Installation 1 The piping can exit the indoor unit from either side see pictured below 2 Drill a 2 1 2 diameter hole at a slightly downward angle to the outdoor side 3 Note The outdoor hole should be approximately 1 4 lower than the indoor hole 4 Insert the piping hole sleeve into the hole to prevent the piping and wir...

Page 32: ...rom the outside through the wall sleeve 2 Bend the indoor lineset Note a tube bender will speed up the process 3 Carefully remove flare nut from indoor coil Listen for holding charge from indoor unit No charge may indicate a leak and should be tested 4 Use a flaring tool if necessary to create the flare connect tubing tightening to the torque listed below Install Line Set Tubing Size Torque foot p...

Page 33: ...ave liquid and gas valves closed 1 After no leaks have been detected connect a vacuum pump to the outdoor unit 2 Connect appropriate hoses to manifold gauge vacuum pump and unit refrigeration connections 3 Evacuate the system until the micron gauge reads no higher than 350 microns 4 Close valve to vacuum pump if pressure does not rise above 500 microns after one minute the evacuation should be com...

Page 34: ...all local electrical codes for electrical wiring Connect the Outdoor Wiring Installation 115 volt unit shown 240 Volt unit 1 Remove the handle on the right side plate of the outdoor unit 2 Connect wiring from indoor unit to 1 2 3 ground being careful to match color code of indoor connections Repeat this for each indoor unit 3 Connect power wiring form outdoor disconnect to L1 L2 and ground 4 Check...

Page 35: ...the front panel as shown on the picture 2 The first stage filter can be cleaned with a vacuum cleaner or by washing with a mild soap and 113º F water 3 The 2nd filter can be washed use a vacuum cleaner to clean any dust lint etc 4 Throughly dry filters before replacing in unit All manuals and user guides at all guides com ...

Page 36: ...hange without notice please refer to the one supplied with the unit Indoor Board Symbol Color Symbol Symbol Color Symbol WH White BN Brown UE Yellow BU Blue RD Red BK Black YEGN Yellow Green Protective Earth All manuals and user guides at all guides com a l l g u i d e s c o m ...

Page 37: ...th the unit Outdoor Unit 9K 12K 115V Symbol Parts Name Symbol Parts Name N L Neutral Wire 110v Live Wire WH White 4YV 4 Way Valve YE Yellow EKV Electric Expansion Valve RD Red L Reactor BN Brown COMP Compressor BU Blue Protective Earth BK Black SAT Overload YEGN Yellow Green All manuals and user guides at all guides com ...

Page 38: ...Electrical Schematics 9K 12K 230V These circuit diagrams are subject to change without notice please refer to the one supplied with the unit Indoor Board 9 12k All manuals and user guides at all guides com ...

Page 39: ...39 Electrical Schematics These circuit diagrams are subject to change without notice please refer to the one supplied with the unit Outdoor Unit 9K 12K 230V All manuals and user guides at all guides com ...

Page 40: ...40 Electrical Schematics These circuit diagrams are subject to change without notice please refer to the one supplied with the unit 18K Indoor Unit All manuals and user guides at all guides com ...

Page 41: ...41 Electrical Schematics 24K Indoor Unit All manuals and user guides at all guides com a l l g u i d e s c o m ...

Page 42: ...42 Electrical Schematics 24K Indoor Unit All manuals and user guides at all guides com ...

Page 43: ...43 Electrical Schematics These circuit diagrams are subject to change without notice please refer to the one supplied with the unit 18K 24K All manuals and user guides at all guides com ...

Page 44: ...44 Electrical Schematics These circuit diagrams are subject to change without notice please refer to the one supplied with the unit 18K 24K All manuals and user guides at all guides com ...

Page 45: ...45 AP 1 Circuit Board Compressor Wires Thermistor wires 4 Way Valve Compressor Heater Band N2 Voltage Terminal Printed Circuit Boards All manuals and user guides at all guides com ...

Page 46: ...c 161 vac 225 vac Brown Red 148 vac 184 vac 210 vac 340 vac White Red 123 vac 150 vac 180 vac 205 vac The following chart indicates approximate voltage measurements readings may vary slightly depending on models and should be used as a reference only Voltages should be taken with unit running PG Wire Connector Resistance ohms Brown White 97 Ω Brown Red 174 Ω White Red 78 Ω The following chart indi...

Page 47: ...check the condition of the indoor step swing motor resistance measurements may be compared to the following chart Resistance measurements must be taken with power off and the connector removed from the board The following charts indicate approximate readings and may vary with different models Turn power off and remove connector from circuit board All manuals and user guides at all guides com ...

Page 48: ...g mode using a digital thermometer record the temperature of the input line and the output line of the valve as indicated in the picture above With the compressor running the input side of the valve should have a higher reading then the output side indicating that the valve is metering If the temperature readings are the same the valve is fully open and the valve is not metering Since the pressure...

Page 49: ... readings First record the temperature of the compressor discharge tubing secondly record the temperature of the suction line tube There should be no more than a 10 degrees difference between the two readings The next set of readings will require recording the temperature of the tubing going to the condenser coil and the temperature of the tubing going to the accumulator Again if there should be l...

Page 50: ...1 0 38 15 57 134 6 4 139 109 228 2 0 779 6 42 8 36 32 58 136 4 3 99 110 230 0 0 758 7 44 6 34 58 59 138 2 3 848 111 231 8 0 737 8 46 4 32 94 60 140 0 3 711 112 233 6 0 717 9 48 2 31 38 61 141 8 3 579 113 235 4 0 697 Using a glass of ice water place the sensor into the glass with a digital thermometer Wait a few minutes for the reading to stabilize Compare the readings to the sensor tables in Appen...

Page 51: ...n the windings differ greatly the windings are bad If there is a reading from any wire to the chassis there is leakage in the windings Compressor Windings Red Yellow Blue Wires Reactor The reactor filters out electrical noise and transient voltage spikes to the control board There will be a reading of less than 1 Ω after the wires are removed There should be no reading from either reactor terminal...

Page 52: ...ted from circuit board The chart below will indicate the approximate resistance values in ohms This motor is a brush less DC motor readings may vary slightly for different models Plugging a known good motor in the board would provide a quick troubleshooting technique Motor Leads Red Yellow White Red 75 Ω 74 Ω Yellow 75 Ω 74 Ω White 74 Ω 74 Ω All manuals and user guides at all guides com ...

Page 53: ...essor Crankcase Heater Check Troubleshooting Outdoor Components Refrigerant Temperature Sensors These sensors are a negative coefficient thermistor that decrease in resistance as the temperature increases The sensors are used to monitor the temperature of the refrigerant Please refer to the troubleshooting section for error codes generated by a sensor fault Temperature sensors and locations will v...

Page 54: ...as the temperature increases The sensors are used to monitor the temperature of the refrigerant leaving the EEV to maintain a correct superheat operation Please refer to the troubleshooting section for error codes generated by a sensor fault Temperature sensors and locations will vary depending on models All manuals and user guides at all guides com ...

Page 55: ... Temperature 208 F Compressor will not rise above present level Exhaust Temperature 217 F Compressor will run at reduced frequency Exhaust Temperature 194 F Compressor off for 3 minutes minimum the compressor will restart Error Code F5 will be generated if the sensor is open or shorted Please refer to the troubleshooting section for more detailed information Exhaust Temperature Sensor All manuals ...

Page 56: ...ture increases This sensor will monitor the temperature of the outdoor air The reading will be used by the inverter board to adjust frequency calculations Error Code F3 will be generated if the sensor is open or shorted Please refer to the troubleshooting section for more detailed information All manuals and user guides at all guides com a l l g u i d e s c o m ...

Page 57: ... Precautions A large capacity electrolytic capacitor is used in the outdoor unit controller inverter Capacitor should be discharged before attempting to work on board Electrical shock hazard will be present even after unit is disconnecte3d from power source Confirmation Confirm that the unit has proper voltage within 10 of rated value Observe flashing LED of indoor outdoor unit for diagnostic info...

Page 58: ...operation comporessor and outdoor fan stop while indoor fan operates 1 Poor air return in indoor unit 2 Fan speed is abnormal 3 Evaporator is dirty 3 System block or refrigerant leakage E3 OFF 3S and blink 3 times OFF 3S and blink 9 times The Dual 8 Code Display will show E3 until the low pressure switch stop operation 1 Low pressure protection 2 Low pressure protection of system 3 Low pressure pr...

Page 59: ...g heatin operation all loads stop Replace outdoor control panel AP1 9 Limit decrease frequency due to high temperature of module EU OFF 3S and blink 6 times OFF 3S and blink 6 times All loads operate normally while operation frequency for compressor is decreased Discharging after the complete unit is de energized for 20 mins check whether the thermal grease on IPM module of outdoor control panel A...

Page 60: ...ng temperature Cooling drying internal fan motor stops operation while other loads stop operation heating AC stop operation 1 Loosening or bad contact of indoor evaporator temp sensor and mainboard terminal 2 Components on the mainboard fall down leads short cirtui 3 Indoor evaporator temp sensor damaged check temp sensor value chart for testing 4 Mainboard damaged 14 Outdoor ambient temperature s...

Page 61: ...vercurrent F8 OFF 3S and blink 8times OFF 3S and blink 1 time All loads operate normally while operation frequency for compressor is decreased The input supply voltage is too low System pressure is too high and overload 19 Decrease frequency due to high air discharge F9 OFF 3S and blink 9 times OFF 3S and blink twice All loads operate normally while operation frequency for compressor is decreased ...

Page 62: ... the control panel AP1 23 Compressor Min frequence in test state P0 during during Showing durin min cooling or min heating test 24 Compressor rated frequence in test state P1 during during Showing during nominal cooling or nominal heating test 25 Compressor maximum frequence in test state P2 during during Showing during max cooling or max heating test 26 Compressor intermediate frequence in test s...

Page 63: ...trol panel AP1 is sufficient and whether the radiator is inserted tightly If its no use please replace control panel AP1 31 Decrease frequency due to high temperature resistant during heating operation H0 OFF 3S and blink 10 times All loads operate normally while operation frequency for compressor is decreased Refer to the malfunction analysis overload high temperature resistant 32 Static dedustin...

Page 64: ...ectric heater stop operationg guide louver stops and present location 1 Bad contact of DC motor feedback terminal 2 Bad contact of DC motor control end 3 Fan motor is stalling 4 Motor malfunction 5 Malfunction of mainboard rev detecting circuit 38 H7 OFF 3S and blink 7 times During cooling and drying operation compressor will stop while indoor fan operate During heating operationg the complete uni...

Page 65: ...nd blink 11 times During cooling and drying operation compressor will stop while indoor fan operate During heating operationg the complete unit will stop operation Refer to the malfunction analysis 44 Malfunction of phase current detection circuit for compressor U1 OFF 3S and blink 13 times During cooling and drying operation compressor will stop while indoor fan will operate During heating operat...

Page 66: ... loosened or broken 3 4V is damaged please replace 4V 48 Zero crossing malfunction of outdoor unit U9 OFF 3S and blink 18 times During cooling operation compressor will stop while indoor fan will operate during heating the complete unit will stop operation Replace outdoor control panel AP1 49 Frequency limiting power OFF 3S and blink 13 times 50 Compressor running OFF 3S and blink once 51 The temp...

Page 67: ...Anti freezing protection normal disply of indoor unit IPM Protection Overcurrent Protection Exhaust Protection Overload protection of compressor Cooling dehumidfy or heating dropped frequency current Exhaust temp dropped frequency temperature Tube temp dropped frequency temperature T tube in dropped frequency temperature Outdoor condenser temp sensor malfunction Outdoor ambient temp sensor malfunc...

Page 68: ... temperature is too high Anti freezing protection E2 OFF 3s and blink twice n o n o During cooling and drying operation compressor and outdoor fan stop while indoor fan operates 1 Poor air return in indoor unit 2 Fan speed is abnormal 3 Evaporator is dirty High discharge temperature protection of compressor D4 OFF 3s and blink 4 times n o n During cooling and drying operation compressor and outdoo...

Page 69: ...nction analysis Circuit PG motor indoor fan has circuit malfunction by zero cross detection U8 OFF 3s and blink 17 times Operation of remote controller or control panel is available but the unit wont act Control board is damaged PG motor indoor fan motor does not operate H6 OFF 3s and blink 11 times The complete unit will stop operation Poor connection for PGF in circuit diagram Malfunction of ind...

Page 70: ...rol panel AP1 refer to the wiring diagram for indoor unit 2 Room temperature sensor is damaged please refer to the resistance table of temperature sensor Indoor evaporator temperature sensor is open short circuited F2 OFF 3s and blink twice During cooling and drying operation indoor unit will operate while other loads will stop During heating operation the complete unit will stop operation 1 Room ...

Page 71: ... F5 OFF 3s and blink 5 times o o During cooling and drying operation compressor will stop after operating for about 3 mins while indoor fan will operate During heating operation the complete unit will stop after operating for about 3 mins 1 Outdoor temperature sensor hasn t been connected well or is damaged Please check it by referring to the resistance table for temperature sensor 2 The head of t...

Page 72: ...ling and drying operation compressor will stop while indoor fan will operate During heating operating the complete unit will stop operation 1 Measure the voltage of position L and N on wiring board XT if the voltage is higher than 265VAC turn on the unit after the supply voltage is increased to the normal range 2 If the AC input is normal measure the voltage of electrolytic capacitor C on control ...

Page 73: ...nk 15 times o o o During cooling and drying operating the compressor will stop while indoor fan will operate During heating operation the complete unit will stop operating Refer to the malfunction analysis IPM protection loss of synchronism protection and overcurrent protection of phase current for compressor Defrosting H1 OFF 3s and blink once Defrosting will occur in heating mode Compressor will...

Page 74: ...operation compressor will stop while indoor fan will operate During heating operation the complete unit will stop operation Refer to the malfunction analysis IPM protection loss of synchronism protection and overcurrent protection of phase current for compressor PFC protection HC OFF 3s and blink 6 times o n During cooling and drying operation compressor will stop while indoor fan will operate Dur...

Page 75: ...ate During heating operation the complete unit will stop operation Refer to the malfunction analysis Malfunction of phase current detection circuit for compressor U1 OFF 3s and blink 13 times o n o During cooling and drying operation compressor will stop while indoor fan will operate During heating operation the complete unit will stop operation Replace outdoor control panel AP1 EEPROM malfunction...

Page 76: ...control panel AP1 Module high temperature protection P8 OFF 3s and blink 19 times n o n During cooling and drying operation compressor will stop while indoor fan will operate During heating operation the complete unit will stop After the complete unit is deenergized for 20 mins check whether the thermal grease on IPM Module of outdoor control panel AP1 is sufficient and whether the radiator is ins...

Page 77: ...creased to the normal range 2 If the AC input is normal measure the voltage of electrolytic capacitor C on control panel AP1 if its normal theres malfunction for the circuit please replace the control panel AP1 Limit decrease frequency due to high temperature of module EU n n n All loads operate normally while operation frequency for compressor is decreased Discharging after the complete unit is d...

Page 78: ...D Heating LED D40 D5 D41 D6 D42 D16 D43 D30 Zero crossing malfunction of outdoor unit U9 n n o During cooling operation compressor will stop while indoor fan will operate during heating the complete unit will stop operation Replace outdoor control panel AP1 Limit decrease frequency due to anti freezing FH n n n o All loads operate normally while operation frequency for compressor is decreased Poor...

Page 79: ...g Yes No Repair connections No Yes No Check connection on indoor board Yes Is system operating properly Replace indoor board Is system operating properly Yes No Yes Is the indoor control board fastened securely and wired correctly Are the input voltages within 10 of rated value Replace indoor motor Yes All manuals and user guides at all guides com ...

Page 80: ...ensor readings compare to the resistance table in the Appendix Insert the plug correctly Yes Is problem corrected No Replace sensor or correct wire problem Yes Is problem corrected No Replace the sensor with appropriate part number No Is problem corrected Yes Replace the controller with the same part number End Troubleshooting Yes Yes F1 F2 will relate to indoor sensor faults F4 F5 will relate to ...

Page 81: ...ter 3 minutes Are the wire connections on the compressor connected properly Eliminate the malfunction Yes No No Yes Reconnect the wires according to the wiring diagram No Yes Is the unit overcharged Eliminate the malfunction Charge the unit according to the Charging section of this manual Replace the outdoor main board Eliminate the malfunction Replace the compressor End Troubleshooting Yes Yes No...

Page 82: ...oling mode compressor will stop indoor fan will run Heating mode all units stop 1 Check the resistance of the compressor terminals and connections to the compressor 2 Check for overcharge of refrigerant 3 Check for correct voltage 4 Check for dirty coils and filters Troubleshooting Procedure for Synchronizing Fault after Unit is Started Yes Compressor Wires Desynchronizing of Compressor after Unit...

Page 83: ...f the compressor terminals and connections to the compressor 2 Check for overcharge of refrigerant 3 Check for correct voltage Troubleshooting Procedure for Synchronizing Fault During Operation Yes Wire per diagram Replace Fan Capacitor C1 Yes Fan Operating Properly Yes Replace Outdoor Fan Motor Yes Improve airflow Yes No Is unit overcharged Replace Control Board AP1 Correct voltage problem No Cha...

Page 84: ...ck the coil of the electronic expansion valve per instructions in this manual Replace if faulty Eliminate the malfunction Check the refrigerant status if there is leakage recharge according to this service manual End Troubleshooting Yes No Yes No Check the resistance between the two ends of the overload protector in ambient temperature Is the resistance below 1K Eliminate the malfunction Yes Repla...

Page 85: ...door main board End Troubleshooting Are all connections correct Did this correct the problem Yes Yes Yes No De energize check the wire connections of indoor and outdoor units and power to outdoor unit Correct connections The malfunction indoor unit resumes normal De energize change the communication wire of the working communication indoor unit and malfunctioning non communicating indoor unit then...

Page 86: ...the temperature sensor readings compare to the resistance table in the Appendix Insert the plug correctly Yes Is problem corrected No Replace sensor or correct wire problem Yes Is problem corrected No Replace the sensor with appropriate part number No Is problem corrected Yes Replace the controller with the same part number End Troubleshooting Yes Yes All manuals and user guides at all guides com ...

Page 87: ...nit on Measure within one minute after the louvers are opened whether the output voltage on the control terminal of the PG motor is 50 volts Replace indoor board No Possible causes 1 Fan motor locked 2 The control or feedback terminal of PG not connected properly 3 Damaged motor 4 Main board malfunction Replace indoor motor Yes Does fan turn freely Find obstruction OK OK Repair connections Yes OK ...

Page 88: ... damaged 4 Bad control board Start Troubleshooting Is there a jumper cap on the controller Install a matching jumper cap End Troubleshooting Yes No Re insert the jumper cap Is system operating properly No Yes Yes No Is the jumper cap inserted correctly Yes Is system operating properly Replace the jumper cap Is system operating properly Replace the main control board Yes No Yes All manuals and user...

Page 89: ... refrigerant charge Fault Status Possible Causes Start Troubleshooting Check if compressor s connection line is properly connected Yes Check if current value is higher than the protectors setting Adjust compressor s connection line No Replace overcurrent protector No Yes Is units high pressure normal Refer to high pressure protection error No Yes Check if unit voltage is normal Check connections c...

Page 90: ...eter to measure the voltage across the terminals of the electrolytic capacitor Yes Check if the inductor wiring is loose or induction is cut off No Shut down power and wait 20 minutes or connect a DC voltmeter to the electrolytic capacitor until the voltage is less than 20 v Voltage higher than 200v Yes End Troubleshooting Replace the inductor or reconnect wires No Is the malfunction corrected No ...

Page 91: ... mode all units stop Are the compressor terminal connected properly Yes Correct wiring problem No Replace Compressor Is the resistance normal No End Troubleshooting Yes Start Troubleshooting after unit is powered off for 3 minutes Test the isolation impedance between the three phases of the compressor and copper tubing No Check the compressor winding resistance Is the resistance above 500MΩ Replac...

Page 92: ...ng to the wring diagram No Yes Is the wiring of the electronic expansion valve connected well Check the coil of the electronic expansion valve per instructions in this manual Replace if faulty Eliminate the malfunction Check the refrigerant status if there is leakage recharge according to this service manual End Troubleshooting Yes No Yes No Check the resistance between the two ends of the overloa...

Page 93: ...ng cooling mode compressor will stop indoor fan will run Heating mode all units stop 1 Check the resistance of the compressor terminals and connections to the compressor 2 Check for overcharge of refrigerant 3 Check for correct voltage 4 Check for dirty coils and filters Troubleshooting Procedure for Synchronizing Fault after Unit is Started Yes Troubleshooting 18 000 24 000 Units Desynchronize Ma...

Page 94: ... connections to the compressor 2 Check for overcharge of refrigerant 3 Check for correct voltage Troubleshooting Procedure for Synchronizing Fault During Operation Yes Wire per diagram Replace Fan Capacitor C1 Yes Fan Operating Properly Yes Replace Outdoor Fan Motor Yes Improve airflow Yes No Is unit overcharged Replace Control Board AP1 Correct voltage problem No Charge per installation manual Ma...

Page 95: ...tdoor unit 5 Follow Troubleshooting procedure Start Troubleshooting Is outdoor temperature above 127 0 F Normal protection outdoor ambient is higher than normal parameters Yes Remove power then restart after 20 minutes Are indoor and outdoor coils clean and free from obstructions Are indoor and outdoor fans operating properly Replace AP1 control board End Troubleshooting Clean Coils 1 Check fan fo...

Page 96: ...tteries Remote controller malfunction Press the Auto button If no response check for proper voltage and connections If there is a response check for defective remote controller or indoor receiver Indoor receiver defective Circuit breaker tripping Breaker trips immediately Check for shorted wires reactor or AP2 board Breaker trips within minutes of turning on Individual components could be defectiv...

Page 97: ...rt it after 3 minutes Are the wire connections on the compressor connected properly Eliminate the malfunction Yes No No Yes Reconnect the wires according to the wiring diagram No Yes Is the unit overcharged Eliminate the malfunction Charge the unit according to the Charging section of this manual Replace the outdoor main board Eliminate the malfunction Replace the compressor End Troubleshooting Ye...

Page 98: ...ic expansion valve per instructions in this manual Replace if faulty Eliminate the malfunction Check the refrigerant status if there is leakage recharge according to this service manual End Troubleshooting Yes No Yes No Check the resistance between the two ends of the overload protector in ambient temperature Is the resistance below 1K Eliminate the malfunction Yes Replace outdoor main board Troub...

Page 99: ...acitor Outdoor Unit Are wires connected proper with no short circuits Are wires connected proper with no short circuits Remove the PFC Capacitor and test resistance of the two terminals Is the resistance about zero Replace the capacitor Yes Is problem corrected Yes No No Disconnect the reactor wires measure the resistance between the two terminals of the reactor Replace the reactor Yes Is problem ...

Page 100: ...of some indoor units Replace outdoor main board End Troubleshooting Are all connections correct Did this correct the problem Yes Yes Yes No De energize check the wire connections of indoor and outdoor units and power to outdoor unit Correct connections The malfunction indoor unit resumes normal De energize change the communication wire of the working communication indoor unit and malfunctioning no...

Page 101: ... Replace the outdoor main board Are all connections correct Did this correct the problem Yes No Correct connections No Are all connections correct Did this correct the problem Yes No Correct connections No No Is the connection wire broke Check to see if there is power input between the neutral wire and live wire of the outdoor main board Check the input power The malfunction indoor unit resumes no...

Page 102: ...Motor winding open Incorrect wiring or bad connection Compressor runs outdoor fan will not Replace capacitor Fan capacitor has open circuit or damaged Replace capacitor Check for proper voltage of power module replace module if input is OK and output is incorrect Repair connection wire per schematic Open or shorted capacitor Improper voltage Incorrect wiring or bad connection Outdoor fan runs comp...

Page 103: ...s Incorrect refrigerant charge Replace swing motor Repair connections Replace control board The toque of the swing motor not sufficient Poor or wrong connection The controller is damaged Indoor swing motor inoperative Correct wiring Replace control board Adjust temperature setting Incorrect power wiring Damaged main control board Improper setting of temperature Outdoor unit and indoor unit nor run...

Page 104: ...compressor and tighten screws Reroute and adjust the tubing Foreign object in indoor unit Compressor vibrating or shaking Outdoor tubing touching Abnormal sound and or shake Tighten and adjust Indoor fan loose or hitting sides Adjust plates isolate with insulation Inner plates touching Adjust louver Outdoor louver touching outer case Replace compressor Abnormal sound inside compressor All manuals ...

Page 105: ...eds Check fan settings and controller board Improper voltage Measure incoming power Should be within 10 of nameplate Incorrect refrigerant charge Refer to charging procedures check for leaks if charge is low Refrigerant must be weighed in by using a charging scale pressure charts are not available Poor component wiring connections Check U V W wire connections as well as all power connection to and...

Page 106: ...to lock open Step 1 Lift center of air filter outward Step 2 Remove air filter by pulling forward 1 Remove air filters 2 Remove filter Left and right filters are interchangeable To reinstall insert air filter along the guide Hold On Off button for 5 seconds to force a cooling operation for approximately 15 minutes All manuals and user guides at all guides com a l l g u i d e s c o m ...

Page 107: ... 12 000 btuh Other models may vary slightly Warning Wait 10 minutes after power is disconnected before starting disassembly Step 2 Lift front panel upward until it locks into place Slightly press left hinge inward to release from socket Step 3 Very carefully lift and slide cover to the left and remove All manuals and user guides at all guides com ...

Page 108: ... screws as shown in the figure at right Note Some models may only have 3 screws Step 2 Disengage the 3 hooks on the upper portion Step3 The front grille can now be separated from the main portion Note Disengage the hooks by pressing with a screw driver 4 Remove service cover 5 Remove front grille assembly Hold On Off button for 5 seconds to force a cooling operation for approximately 15 minutes Al...

Page 109: ...ng disassembly Step 2 Remove the temperature sensor Disconnect the connection wires Remove the screw from the evaporator Remove wires from terminals Note Take care not to lose the thermistor clip Pat attention to the mounting of the thermistor replace in exact manner Step 3 Remove the screw holding the electrical box to the chassis remove electrical box All manuals and user guides at all guides co...

Page 110: ...isassembly Step 1 Remove tubing clamp Step 2 Adjust the tubing slightly Step3 Loosen the screws in the right and the left which hold the evaporator assembly Remove the evaporator assembly 7 Remove tubing assembly Hold On Off button for 5 seconds to force a cooling operation for approximately 15 minutes All manuals and user guides at all guides com ...

Page 111: ... 000 btuh Other models may vary slightly Warning Wait 10 minutes after power is disconnected before starting disassembly Step 1 Remove motor blade and shaft cushion rubber base Step 2 Remove screws on cross flow blade and then remove the motor 9 Remove shaft cushion rubber base All manuals and user guides at all guides com a l l g u i d e s c o m ...

Page 112: ...it 10 minutes after power is disconnected before starting disassembly 1 Remove tubing assembly 2 Remove top panel 1 Remove top panel Remove the screws front right left then remove panel Warning Be sure to wait a minimum of 10 minutes after turning off all power supplies before disassembly All manuals and user guides at all guides com ...

Page 113: ...Warning Wait 10 minutes after power is disconnected before starting disassembly 3 Remove grille and front panel 1 Remove the 5 screws from the edge between right side board condenser and valve Lift to remove the right side panel 2 Loosen the 5 screws holding the front panel 4 Remove right side panel All manuals and user guides at all guides com ...

Page 114: ... tapping screws holding the motor support then lift out support 5 Remove fan motor and axial blade 6 Remove electric box 1 Loosen two screws 2 The partition plate has a hook on the lower side Lift and pull the partition plate to remove Disassembly of Outdoor Unit 9 000 12 000 btuh Warning Wait 10 minutes after power is disconnected before starting disassembly All manuals and user guides at all gui...

Page 115: ...t 10 minutes after power is disconnected before starting disassembly 1 Loosen the two screws 2 The partition plate has a hook on the lowers side Lift and pull the partition plate to remove 7 Remove the partition plate All manuals and user guides at all guides com ...

Page 116: ...e all refrigerant Disassembly of Outdoor Unit 9 000 12 000 btuh Warning Wait 10 minutes after power is disconnected before starting disassembly 2 Remove the 3 footing screws holding compressor then remove the compressor All manuals and user guides at all guides com a l l g u i d e s c o m ...

Page 117: ...int between the gas valve and condensor piping then remove gas valve Before appying heat to the btubing protect the gas valve by wraping in a wet cloth Remove screws holding liquid valve assembly unsolder the joint between the liquid valve and Y Type tubing then remove liquid valve Before appying heat to the btubing protect the liquid valve by wraping in a wet cloth All manuals and user guides at ...

Page 118: ...r then pull upward to remove Disassembly of Outdoor Unit 18 000 and 24 000 btuh Warning Wait 10 minutes after power is disconnected before starting disassembly 1 Remove top cover plate valve cover and handle Warning Be sure to wait a minimum of 10 minutes after turning off all power supplies before disassembly All manuals and user guides at all guides com ...

Page 119: ... Unit 18 000 and 24 000 btuh Warning Wait 10 minutes after power is disconnected before starting disassembly 2 Remove grille and front panel 1 Remove the screws holding the right side panel to the valve support and electric box then remove the panel 2 Loosen the screws holding the left side panel and remove panel 3 Remove right and left side panels All manuals and user guides at all guides com ...

Page 120: ...support then pull upward the support to remove Disassembly of Outdoor Unit 18 000 and 24 000 btuh Warning Wait 10 minutes after power is disconnected before starting disassembly 4 Remove the axial flow fan 1 Remove the screws holding the electric box sub assembly loosen the wire bundle pull wires off of terminals then remove the electric box 5 Remove the electric box All manuals and user guides at...

Page 121: ...d 24 000 btuh Warning Wait 10 minutes after power is disconnected before starting disassembly 6 Remove fireproof electric box and sound proof sponge 1 Remove the screws holding the isolation sheet then carefully remove Note Notice how sheet is positioned for aid in replacing 7 Remove isolation sheet All manuals and user guides at all guides com a l l g u i d e s c o m ...

Page 122: ... 9 Remove compressor 1 Remove the screws holding the 4 way valve coil Properly remove refrigerant protect valve from heat damage and remove valve 2 Unsolder the tubing connecting the compressor and condenser assembly then remove the 4 way valve 1 Remove the three foot nuts on compressor then carefully remove the compressor All manuals and user guides at all guides com ...

Page 123: ... the support 2 Carefully remove the chassis sub assembly and condenser sub assembly Disassembly of Outdoor Unit 18 000 and 24 000 btuh Warning Wait 10 minutes after power is disconnected before starting disassembly 10 Remove condenser sub assembly All manuals and user guides at all guides com ...

Page 124: ...1 103 6 21 2 66 88 46 114 8 6 278 98 208 4 1 071 5 23 0 63 46 47 116 6 6 038 99 210 2 1 039 4 24 8 60 23 48 118 4 5 809 100 212 0 1 009 3 26 6 57 18 49 120 2 5 589 101 213 8 0 98 2 28 4 54 31 50 122 0 5 379 102 215 6 0 952 1 30 2 51 59 51 123 8 5 197 103 217 4 0 925 0 32 0 49 02 52 125 6 4 986 104 219 2 0 898 1 33 8 46 6 53 127 4 4 802 105 221 0 0 873 2 35 6 44 31 54 129 2 4 625 106 222 8 0 848 3 ...

Page 125: ...19 63 71 159 8 2 523 123 253 4 0 532 20 68 0 18 75 72 161 6 2 439 124 255 2 0 519 21 69 8 17 93 73 163 4 2 358 125 257 0 0 505 22 71 6 17 14 74 165 2 2 28 126 258 8 0 492 23 73 4 16 39 75 167 0 2 206 127 260 6 0 48 24 75 2 15 68 76 168 8 2 133 128 262 4 0 467 25 77 0 15 77 170 6 2 064 129 264 2 0 456 26 78 8 14 36 78 172 4 1 997 130 266 0 0 44 27 80 6 13 74 79 174 2 1 933 131 267 8 0 433 28 82 4 1...

Page 126: ...1 2 89 17 46 114 8 8 37 98 208 4 1 427 5 23 0 84 61 47 116 6 8 051 99 210 2 1 386 4 24 8 80 31 48 118 4 7 745 100 212 0 1 346 3 26 6 76 24 49 120 2 7 453 101 213 8 1 307 2 28 4 72 41 50 122 0 7 173 102 215 6 1 269 1 30 2 68 79 51 123 8 6 905 103 217 4 1 233 0 32 0 65 37 52 125 6 6 648 104 219 2 1 198 1 33 8 62 13 53 127 4 6 403 105 221 0 1 164 2 35 6 59 08 54 129 2 6 167 106 222 8 1 131 3 37 4 56 ...

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Page 129: ...3 6 89 07 64 147 2 10 54 116 240 8 2 124 13 55 4 84 95 65 149 0 10 18 117 242 6 2 069 14 57 2 81 05 66 150 8 9 827 118 244 4 2 015 15 59 0 77 35 67 152 6 9 489 119 246 2 1 963 16 60 8 73 83 68 154 4 9 165 120 248 0 1 912 17 62 6 70 5 69 156 2 8 854 121 249 8 1 863 18 64 4 67 34 70 158 0 8 555 122 251 6 1 816 19 66 2 64 33 71 159 8 8 268 123 253 4 1 77 20 68 0 61 48 72 161 6 7 991 124 255 2 1 725 2...

Page 130: ...130 Gree Electric Appliances Inc C 2014 Cat No DFS RIO HP 2SM All manuals and user guides at all guides com ...

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