Johnson Controls DCP18CSB21S Installation And Maintenance Manual Download Page 4

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Table of contents

Table of Contents

2. Installation

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Installation

- Checking Parts

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Selection of Installation Location

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Electric Connection Requirement

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Installation of Indoor Unit

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Installation of Outdoor Unit

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Vacuum Pump

Leak Detection

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Post

Installation

Testing

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3. Maintenance

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.1 Precautions before Maintenance

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.2 Error Code List

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.3 Troubleshooting for Main Malfunction

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.4 Troubleshooting for Normal Malfunction

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Appendix:

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Appendix 1: Reference Sheet of Celsius and Fahrenheit

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Appendix 2: Configuration of Connection Pipe

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Appendix 3: Pipe

xpanding Method

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Appendix 4: List of Resistance for Temperature Sensor

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.1 Installation Dimension Diagram

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Installation

Procedures......

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Customer Service, Technical Support

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Summary of Contents for DCP18CSB21S

Page 1: ...ING UNITS READ AND UNDERSTAND THIS MANUAL BEFORE USING THIS INVERTER DRIVEN AIR CONDITIONING UNIT KEEP THIS MANUAL FOR FUTURE REFERENCE INDOOR UNIT DHP18NWB21S DCP18NWB21S DHP24NWB21S DCP24NWB21S OUTDOOR UNIT DHP18CSB21S DCP18CSB21S DHP24CSB21S DCP24CSB21S Type Model Model Type IMPORTANT ...

Page 2: ...2 P5415467 ...

Page 3: ...d advanced information to maintain and service this inverter driven cooling or heat pump air conditioning unit which you operate as well for other models This inverter driven cooling or heat pump air conditioning unit has been designed for a specific temperature range For optimum performance and long life operate this unit within range limits This manual should be considered as a permanent part of...

Page 4: ...ation Testing 8 3 Maintenance 9 3 1 Precautions before Maintenance 9 3 2 Error Code List 10 3 3 Troubleshooting for Main Malfunction 13 3 4 Troubleshooting for Normal Malfunction 27 Appendix 29 Appendix 1 Reference Sheet of Celsius and Fahrenheit 29 Appendix 2 Configuration of Connection Pipe 29 Appendix 3 Pipe Expanding Method 30 Appendix 4 List of Resistance for Temperature Sensor 31 2 1 Install...

Page 5: ...orrectly injuries may occur due to a falling unit Use appropriate Personal Protective Equipment PPE such as gloves and protective goggles and where appropriate have a gas mask nearby Also use electrical protection equipment and tools suited for electrical operation purposes Keep a quenching cloth and a fire extinguisher nearby during brazing Use care in handling rigging and setting of bulky equipm...

Page 6: ...sure the condensate hose discharges water properly If connected incorrectly it may cause leaks Do not install the unit in any place where oil can seep onto the units such as table or seating areas in restaurants and so forth For these locations or social venues use specialized units with oil resistant features built into them In addition use a specialized ceiling fan designed for restaurant use Th...

Page 7: ...son Controls Johnson Controls uses only refrigerants that have been approved for use in the unit s intended home country or market Johnson Controls distributors similarly are only authorized to provide refrigerants that have been approved for use in the countries or markets they serve The refrigerant used in this unit is identified on the unit s faceplate and or in the associated manuals Any addit...

Page 8: ...gas and liquid valves otherwise these devices will be damaged It is closed before shipment If the arrangement for outdoor units is incorrect it may cause flowback of the refrigerant and result in failure of the outdoor unit The refrigerant system may be damaged if the slope of the piping connection kit exceeds 15o Electrical Precautions Take the following precautions to reduce the risk of electric...

Page 9: ... source completely before attempting any maintenance for electrical parts Check to ensure that no residual voltage is present after disconnecting the power source Do not clean with or pour water into the controller as it could cause electric shock and or damage the unit Do not use strong detergent such as a solvent Clean with a soft cloth Check that the ground wire is securely connected Do not con...

Page 10: ... At least 72 At least 6 At least 6 Space to the wall S p a c e t o t h e o b s t r u c t i o n r o o l f e h t o t e c a p S Space to the obstruction Condensate pipe Space to the wall Space to the obstruction Space to the obstructio Space to the obstruction At least 24 At least 12 At least 24 At least 12 At least 78 A t l e a s t 1 1 8 1 ...

Page 11: ...tape 4 Electroprobe 7 Electronic leakage detector 10 Pipe pliers pipe cutter 2 Screw driver 5 Universal meter 8 Vacuum pump 11 Pipe expander pipe bender 3 Impact drill drill head electric drill 6 Torque wrench open end wrench inner hex wrench 9 Manifold gauge 12 Soldering appliance refrigerant container ...

Page 12: ...it Make the bound pipes pass through the wall hole and then connect outdoor unit Arrange the pipes Vacuum pumping and leakage detection Check after installation and test operation Finish installation Note This flow is only for reference Please find more detailed installation steps in this manual Select outdoor unit installation location Mount support of outdoor unit select it according to the actu...

Page 13: ... with a specialized grounding device by an authorized professional Please make sure it is always grounded effectively otherwise it may cause electric shock 2 The yellow green wire in air conditioner is grounding wire which can t be used for other purposes 3 The grounding resistance should comply with national electric safety regulations 4 The unit must be positioned so that the plug is accessible ...

Page 14: ...nnect the Pipe of Indoor Unit 1 Aim the pipe joint at the corresponding bellmouth As shown in Fig 5 2 Pretighten the union nut by hand 3 Adjust the torque force by referring to the following Place the open end wrench on the pipe joint and place the torque wrench on the union nut Tighten the union nut with torque wrench As show in Fig 6 4 Wrap the indoor pipe and joint of connection pipe with insul...

Page 15: ...onnection pipe power cord and condensate hose with the band As shown in Fig 14 2 Reserve a certain length of condensate hose and power cord for installation when binding them When binding to a certain degree separate the indoor power and then separate the condensate hose As shown in Fig 15 3 Bind them evenly 4 The liquid pipe and gas pipe should be bound separately at the end 9 Hang the Indoor Uni...

Page 16: ...ire and power cord to the wiring terminal according to the color fix them with screws As shown in Fig 23 6 Neaten the Pipes 1 The pipes should be placed along the wall bent reasonably and hidden if possible Min semidiameter of bending the pipe is 3 15 16inch 2 If the outdoor unit is higher than the wall hole you must set a U shaped curve in the pipe before pipe goes into the room in order to preve...

Page 17: ...d in water 1 Use Vacuum Pump 1 Remove the valve caps on the liquid valve and gas valve and the nut of refrigerant charging vent 2 Connect the charging hose of manifold gauge to the refrigerant charging vent of gas valve and then connect the other charging hose to the vacuum pump 3 Open the piezometer completely and operate for 10 15min to check if the pressure of manifold gauge remains in 14 5ISP ...

Page 18: ...tenance is needed follow the steps below to discharge electricity of electrolytic capacitor after power off 1 Open the top cover of outdoor unit and then remove the cover of the electric box 2 After finishing discharging electricity measure the voltage between points A and B with universal meter to make sure if electricity discharging is completed in order to prevent electric shock If the voltage ...

Page 19: ...ro cross direction U8 Off 3s and blink 17 times The complete unit stops 1 Power supply is abnormal 2 Detection circuit of indoor control mainboard is abnormal 13 cooling dehumidifying except the indoor fan motor is running others will stop to run heating all stop running ...

Page 20: ...s the normal state Off 3s and blink once during blinking ON 10s and Off 05s Defrosting will occur in heating mode Compressor will operate while indoor fan will stop Complete unit current detection malfunction Off 3s and blink 13 times U5 ...

Page 21: ...12 Installation and Maintenance ...

Page 22: ...d broken Malfunction diagnosis process Is the wiring terminal between the temperature sensor and the controller loose or poorly contacted Start Insert the temperature sensor tightly Yes Yes Yes Yes Yes Yes No No No No No No Is malfunction eliminated Is malfunction eliminated Is malfunction eliminated Replace it with a temperature sensor with the same model Make the parts upright Is there short cir...

Page 23: ...main board that is of the same model Replace a new main board that is of the same model It s the malfunction of main board Then check whether the voltage between terminal 2 and terminal 3 of the motor interface is 15VDC Connect power and restart the unit Test whether the voltage between terminal 1 and terminal 2 of motor interface is within 280 310VDC Then check whether there is voltage between te...

Page 24: ...inboard is defined abnormal Malfunction diagnosis process Start Is there jumper cap on the mainboard Is the jumper cap inserted correctly and tightly Replace the jumper cap with the same model Appearance of the jumper cap Assemble the jumper cap with the same model Insert the jumper cap tightly Is malfunction eliminated Is malfunction eliminated Is malfunction eliminated Replace the mainboard with...

Page 25: ...play board Main board of IDU matches with that of ODU Communication cord is damaged Replace IDU s main board Malfunction eliminated End Connect the line according to wiring diagram Match correctly according to product specification Replace communication cord Replace ODU s main board Malfunction eliminated Malfunction eliminated Malfunction eliminated yes yes yes yes yes yes yes no no no no no no n...

Page 26: ...6 Both ends of electrolytic capacitor C47 C47 12V power DC 12V 13V Test 7 Both ends of electrolytic capacitor C60 C60 5V power DC 5V Test 8 Both ends of electrolytic capacitor C73 C73 3 3V power DC 3 3V Test 9 Between S and T Communication circular current DC 56V Test 10 Between point N and GND C50 to N terminal ground signal receiving terminal of outdoor unit Jumping between 0V and 3 3V Test 11 U...

Page 27: ...t with the voltage testing circuit on control panel AP1 Replace the control panel AP1 Measure the AC voltage between terminalL andN on wiring board XT power supply Voltage within 210VAC 250VAC Shut down the power and repair the power supply to restore the range 210VAC 250VAC power on and restart the unit Is the fault eliminated Shut down the power and wait 20 minutes or use DC voltmeter to measure...

Page 28: ...or COMP is well connected If they are loosened If the connection sequence is correct Is voltage input in the normal range Test the voltage between L N of wiring board XT by DC voltage meter If coil resistance of compressor is normal Is compressor coil insulating to copper pipe well If the work load of unit is heavy If radiating of unit is well If the refrigerant charging is appropriate Malfunction...

Page 29: ...ltage between the two ends of capacitor C2 until the voltage is lower than 20V Replace the capacitor C2 Then energize and start the unit Replace the control panel AP1 Take corrective actions according to Technical Service Manual and then energize and start the unit If there is any abnormality described above Replace the control panel AP1 If the connection between AP1 and COMP is unsecure or the co...

Page 30: ...ck if fan terminal OFAN is connected well 2 Test if resistance value of any two terminals is less than 1k with ohmic meter If the indoor and outdoor fan work well After the unit de energized for 20 min Replace control board AP1 If the radiating of outdoor and indoor unit is well Improve the radiating environment of unit Replace outdoor fan Y Replace fan capacitor C1 Anti high temperature overload ...

Page 31: ...UVW is well connected and connection sequence is correct Replace control board AP1 Replace the compressor If malfunction is removed If the stop time of compressor is more than 3 min N If the stop time is not enough and the high and low pressure of system is not balanced please start it after 3 min Improve the connection situation of control board AP1 and compressor COMP connect it with wiring diag...

Page 32: ...rmally If the stop time of compressor is more than 3min Synchronism after energize the unit and start it Connect wire well Synchronism occurred during operation Replace control board AP1 If the radiating of unit is well Remove malfunction Improve the radiating of unit clean heat exchanger and increase ventilation Replace fan capacitor C1 Replace outdoor fan Y N N N Y Y N Replace control board AP1 ...

Page 33: ...g diagram Replace EKV coil of electron expansion valve If the wiring terminal FA of electron expansion is well connected Remove malfunction The resistance value of first 4 l e ad an d th e fifth lead is similar less than 100 After the unit de energized for 20 min Remove malfunction Y N N N If the overload protector SAT is well connected N Under ambient temperature test the resistance of overload p...

Page 34: ... Check communication circuit of outdoor unit Problem of communication circuit Check built in wiring of indoor and outdoor unit Connection correct Malfunction of circuit is detected with control board AP1 voltage Check connection wire of indoor and outdoor unit with circuit diagram Check connection wire of indoor and outdoor unit with circuit diagram If the unit is operation normal before malfuncti...

Page 35: ...ber jumping Outdoor unit malfunction Test voltage value with Test 13 position in diagram with voltage meter Number jumping Test voltage value with Test 11 position in diagram with voltage meter Number jumping Test voltage value with Test 12 position in diagram with voltage meter Y Y Y Y Number jumping The circuit of outdoor unit communication is normal Y N N N N End ...

Page 36: ...ethod for details Malfunction of compressor Compressor doesn t operate Refer to point 5 of maintenance methods for details 3 4 Troubleshooting for Normal Malfunction 1 Air conditioning unit doesn t start 2 Poor cooling heating of air conditioning unit 3 Horizontal louver doesn t swing Possible Causes Discriminating Method Air Conditioner Status Troubleshooting No power supply or poor connection fo...

Page 37: ...densate pipe Replace condensate pipe Wrapping is not tight Water leaking from the pipe connection place of indoor unit Wrap it again and bundle it tightly 5 Compressor doesn t operate Possible causes Discriminating method air conditioner status Troubleshooting Wrong wire connection or poor connection Check the wiring status according to circuit diagram Connect wires according to wiring diagram to ...

Page 38: ...ttle Liquid pipe inch Gas pipe inch Cooling only oz ft Cooling and heating oz ft Ф1 4 Ф3 8or Ф1 2 0 2 0 2 Ф1 4 or Ф3 8 Ф5 8 or Ф3 4 0 2 0 2 Ф1 2 Ф3 4 or Ф7 8 0 3 1 3 Ф5 8 Ф1 or Ф1 1 4 0 7 1 3 Ф3 4 2 7 2 7 Ф7 8 3 8 3 8 Cooling capacity Max length of connection pipe Max height difference 5000 Btu h 1465 W 49 21ft 16 40ft 7000 Btu h 2051 W 49 21ft 16 40ft 9000 Btu h 2637 W 49 21ft 32 81ft 12000 Btu h...

Page 39: ...llowing steps A Cut the pip Confirm the pipe length according to the distance of indoor unit and outdoor unit Cut the required pipe with pipe cutter B Remove the burrs Remove the burrs with shaper and prevent the burrs from getting into the pipe C Put on suitable insulating pipe D Put on the union nut Remove the union nut on the indoor connection pipe and outdoor valve install the union nut on the...

Page 40: ...8 233 6 0 717 24 8 60 23 95 9 779 165 2 2 28 235 4 0 697 26 6 57 18 96 8 9 382 167 2 206 237 2 0 678 28 4 54 31 98 6 9 003 168 8 2 133 239 0 66 30 2 51 59 100 4 8 642 170 6 2 064 240 8 0 642 32 49 02 102 2 8 297 172 4 1 997 242 6 0 625 33 8 46 6 104 7 967 174 2 1 933 244 4 0 608 35 6 44 31 105 8 7 653 176 1 871 246 2 0 592 37 4 42 14 107 6 7 352 177 8 1 811 248 0 577 39 2 40 09 109 4 7 065 179 6 1...

Page 41: ...3 04 165 2 3 04 235 4 0 93 26 6 76 24 96 8 12 51 167 2 94 237 2 0 904 28 4 72 41 98 6 12 168 8 2 844 239 0 88 30 2 68 79 100 4 11 52 170 6 2 752 240 8 0 856 32 65 37 102 2 11 06 172 4 2 663 242 6 0 833 33 8 62 13 104 10 62 174 2 2 577 244 4 0 811 35 6 59 08 105 8 10 2 176 2 495 246 2 0 77 37 4 56 19 107 6 9 803 177 8 2 415 248 0 769 39 2 53 46 109 4 9 42 179 6 2 339 249 8 0 746 41 50 87 111 2 9 05...

Page 42: ... 77 49 19 147 2 10 54 217 4 3 04 8 6 323 9 78 8 47 08 149 10 18 219 2 2 955 10 4 306 2 80 6 45 07 150 8 9 827 221 2 872 12 2 289 6 82 4 43 16 152 6 9 489 222 8 2 792 14 274 84 2 41 34 154 4 9 165 224 6 2 715 15 8 259 3 86 39 61 156 2 8 854 226 4 2 64 17 6 245 6 87 8 37 96 158 8 555 228 2 2 568 19 4 232 6 89 6 36 38 159 8 8 268 230 2 498 21 2 220 5 91 4 34 88 161 6 7 991 231 8 2 431 23 209 93 2 33 ...

Page 43: ...34 ...

Page 44: ...Product improvement specifications and appearance in this manual are subject to change without prior notice Johnson Controls Inc USA LIT 12012174 ...

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