Johnson Controls DCP30CSB21S Installation And Maintenance Manual Download Page 30 | Manualshive

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Installation and Maintenance

5. Malfunction of Zero-crossing Inspection Circuit Malfunction of the IDU Fan Motor U8

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Summary of Contents for DCP30CSB21S

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 DHP30NWB21S DCP30NWB21S DHP36NWB21S DCP36NWB21S OUTDOOR UNIT DHP30CSB21S DCP30CSB21S DHP36CSB21S DCP36CSB21S Type Model Model Type IMPORTANT ...

Page 2: ...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 3: ...Installation Testing 8 3 Troubleshooting 9 3 1 Flashing LED of Indoor Outdoor Unit and Primary Judgment 9 3 2 How to Check Main Parts 18 3 3 Troubleshooting for Normal Malfunction 34 Appendix 36 Appendix 1 Reference Sheet of Celsius and Fahrenheit 36 Appendix 2 Configuration of Connection Pipe 36 Appendix 3 Pipe Expanding Method 37 Appendix 4 List of Resistance for Temperature Sensor 38 2 1 Instal...

Page 4: ...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 5: ...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 6: ...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 7: ...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 8: ...nel to the indoor or outdoor units without turning OFF the main power supply After ceasing operation be sure to wait at least five minutes before turning off the main power switch Otherwise water leakage or electrical breakdown may result Disconnect the power source completely before attempting any maintenance for electrical parts Check to ensure that no residual voltage is present after disconnec...

Page 9: ...h At least 5 7 8 inch 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 19 11 16 inch At least 11 7 8 inch At least 19 11 16 inch At least 11 7 8 inch At least 78 3 4 inch A t l e a s t 1 1 8 i n c h ...

Page 10: ...ectroprobe 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 11: ...nit 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 section Select outdoor unit installation location Install the outdoor unit mount select it according to the a...

Page 12: ...ly 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 5 An all pole disconnect switch having a contact separation of at least 1 8 inch in all poles should be connected i...

Page 13: ... Connect the Pipe of Indoor Unit LP WKH SLSH MRLQW DW WKH FRUUHVSRQGLQJ EHOOPRXWK V VKRZn LQ LJ 3UHWLJKWHQ WKH XQLRQ QXW by KDQG GMXVW WKH WRUTXH IRUFH E UHIHUULQJ WR WKH IROORZLQJ 3ODFH WKH RSHQ HQG ZUHQFK RQ WKH SLSH MRLQW DQG SODFH WKH WRUTXH ZUHQFK RQ WKH XQLRQ QXW 7LJKWHQ WKH XQLRQ QXW ZLWK WRUTXH ZUHQFK V VKRZn LQ LJ UDS WKH LQGRRU SLSH DQG MRLQW RI FRQQHFWLRQ SLSH ZLWK LQVXODWLQJ SLSH DQG W...

Page 14: ...onnect Wire of Indoor Unit 2SHQ WKH SDQHO UHPRYH WKH VFUHZ RQ WKH ZLULQJ FRYHU DQG WKHQ WDNH GRZQ WKH FRYHU V VKRZn LQ LJ 8 Bind up Pipe LQG XS WKH FRQQHFWLRQ SLSH SRZHU FRUG DQG condensate KRVH ZLWK WKH EDQG V VKRZn LQ LJ 5HVHUYH D FHUWDLQ OHQJWK RI condensate KRVH DQG SRZHU FRUG IRU LQVWDOODWLRQ ZKHQ ELQGLQJ WKHP KHQ ELQGLQJ WR D FHU WDLQ GHJUHH VHSDUDWH WKH LQGRRU SRZHU DQG WKHQ VHSDUDWH WKH c ...

Page 15: ...G ORFDWLRQ ZLWK H SDQVLRQ VFUHZV 5 Connect Outdoor Electric Wire HW WKH FRQQHFWLRQ ZLUH VOHHYH JR WKURXJK WKH WZR KROHV RI UHWDLQLQJ SODWH WLJKWHQ WKH FRQQHFWLRQ MRLQW RI VOHHYH DQG UHWDLQLQJ SODWH UHPRYH WKH ZLUH FOLS FRQQHFW WKH SRZHU FRQQHFWLRQ ZLUH DQG SRZHU FRUG WR WKH ZLULQJ WHUPLQDO DFFRUGLQJ WR WKH FRORU secure WKHP ZLWK VFUHZV L WKH SRZHU FRQQHFWLRQ ZLUH DQG SRZHU FRUG ZLWK ZLUH FOLS L WK...

Page 16: ...t be placed in water 1 Use Vacuum Pump 5HPRYH WKH YDOYH FDSV RQ WKH OLTXLG YDOYH DQG JDV YDOYH DQG WKH QXW RI UHIULJHUDQW FKDUJLQJ YHQW RQQHFW WKH FKDUJLQJ KRVH RI manifold gauge to the UHIULJHUDQW FKDUJLQJ YHQW RI JDV YDOYH DQG WKHQ FRQQHFW WKH RWKHU FKDUJLQJ KRVH WR WKH YDFXXP SXPS 2SHQ WKH manifold gauge FRPSOHWHO DQG RSHUDWH IRU PLQ WR FKHFN LI WKH SUHVVXUH RI manifold gauge remains in 03D ORV...

Page 17: ...protection overload 5 Overcurrent protection E5 OFF 3S and blink 5 times OFF 1S and blink 5 times During cooling and drying operation compressor and outdoor fan stop while indoor fan operates During heating operation all loads stop 1 Supply voltage is unstable 2 Supply voltage is too low and load is too high 3 Evaporator is dirty 6 Communi cation Malfunction E6 OFF 3S and blink Always 6 ON times D...

Page 18: ...r ambient temperature sensor is open short circuited F3 OFF 3S and blink 3 times OFF 1S and blink 6 times During cooling and drying operating compressor stops while indoor fan operates During heating operation the complete unit will stop operation Outdoor temperature sensor hasnt been connected well or is damaged Please check it by referring to the resistance table for temperature sensor 15 Outdoo...

Page 19: ...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 panel AP1 if its normal theres malfunction for the circuit please replace the control panel AP1 22 Voltage of DC bus bar is too low PL OFF 3S and blink 21 times OFF 1S and blink 12 times Durin...

Page 20: ...analysis of capacitor 29 Malfunction of module temperature sensor circuit P7 OFF 3S and blink 18 times During cooling and drying operation compressor will stop while indoor fan will operate During heating operation the complete unit will stop Replace outdoor control panel AP1 30 Module high temperature protection P8 OFF 3S and blink 19 times During cooling operation compressor will stop while indo...

Page 21: ...ol end 3 Fan motor is stalling 4 Motor malfunction 5 Malfunction of mainboard rev detecting circuit 38 Desynchro nizing of compressor H7 OFF 3S and blink 7 times During cooling and drying 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 over...

Page 22: ...nstable 46 Malfunction of complete units current detection U5 OFF 3S and blink 13 times During cooling and drying operation the compressor will stop while indoor fan will operate During heating operating the complete unit will stop operation Theres circuit malfunction on outdoor units control panel AP1 please replace the outdoor units control panel AP1 47 The four way valve is abnormal U7 OFF 3S a...

Page 23: ...cator Cool Indicator Heating Indicator Yellow Indicator Red Indicator Green Indicator 53 Normal communica tion 54 Defrosting OFF 3S and blink once during blinking ON 10s and OFF 0 5s OFF 0 5S and blink once OFF 1S and blink twice Defrosting will occur in heating mode Compressor will operate while indoor fan will stop operation It s the normal state 55 Malfunction of zero cross detection circuit U8...

Page 24: ...16 Installation and Maintenance Compressor starts normally ...

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Page 27: ...liminated Reinsert the wiring terminal of indoor fan It s the malfunction of main board Replace a new main board that is of the same model It s the malfunction of main board Replace a new 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 i...

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Page 31: ... Cut off power supply Check if connection line of IDU and ODU and the wire inside electric box are correctly connected Correct connection Main board matches with display 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 Rep...

Page 32: ... 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 If the fault is eliminated Shut down the power and wait 20 minutes or use DC voltmeter to measure th...

Page 33: ...igh resulting in that the system pressure is too high and exceeds the permissible range 4 If the charge volume of refrigerant is too much resulting in that the system pressure is too high 5 Other conditions resulting in that the system pressure becomes too high Take corrective actions according to Technical Service Manual and then energize and start the unit If there is any abnormality described a...

Page 34: ...re protection Is outdoor ambient temperature higher than 53 20 minutes after the complete unit is powered off Is heat dissipation of the indoor unit and outdoor unit abnormal Normal protection please operate it after the outdoor ambient temp erature is normalized Improve the heat dissipation environ ment of the unit Does the outdoor fan work normally 1 Check if the fan terminal OFAN is connected c...

Page 35: ...mpressor stopping enough time Fault diagnosis process Y N Y N N Y Y N Power on the unit Is stop time of the compressor longer than 3 minutes Restart it after 3 minutes Does startup fail Are the wires for the compressor connected correctly Is connection sequence right Connect the wires as per the connection diagram Replace the control panel AP1 If the fault is eliminated Replace the compressor End ...

Page 36: ...he compressor connected correctly Is connection sequence right Is the connection made in clockwise direction Connect the wires correctly Replace the control panel AP1 If the fault is eliminated Replace the compressor End Out of step occurs in operation Is the outdoor fan working normally Is the outdoor unit blocked by foreign objects Replace the control panel AP1 If the fault is eliminated Replace...

Page 37: ...s 20 minutes after the complete unit is powered off Is the terminal FA for the electronic expansion valve connected correctly Connect the wires correctly Resistances between the first four pins close to the terminal hole and the fifth pin are almost the same less than 100 ohm Replace the electronic expansion valve If the fault is eliminated If the fault is eliminated Replace the control panel AP1 ...

Page 38: ... Y Start Check wiring of the reactor L of the outdoor unit and the PFC capacitor Whether there is any damage or short circuit Replace it as per the wiring diagram and reconnect the wires If the fault is eliminated Disconnect the terminals for the reactor and measure the resistance between the two terminals of the reactor by an ohm gauge Whether there is any damage or short circuit Replace the reac...

Page 39: ...operate normally before the failure occurs The AP1 voltage detection circuit is at fault Check wiring inside of the indoor and outdoor units Are wires broken Check the communication circuit of the outdoor unit If the fault is eliminated The communication circuit is abnormal Replace the main board of the indoor unit End If the fault is eliminated Replace the main board AP1 of the outdoor unit If th...

Page 40: ...in board AP1 of the outdoor unit If the fault is eliminated Is the connection right Check the wiring of the indoor and outdoor units with reference to the wiring diagram Correctly connect the corresponding wires for the indoor and outdoor units with reference to the wiring diagram 9 Communication malfunction following AP1 for outdoor unit control board Mainly detect Detect the indoor and outdoor u...

Page 41: ...ouver is fully open Check if the capacity output of outdoor unit is equal to the capacity demand of indoor units Check if the indoor outdoor filters or radiating fins are dirty or blocked Clean the fins The system pipe is blocked Refer to the dial up of indoor and outdoor unit Measure the swing motor and signal input Measure the fan motor and signal input Remove the obstructions Cover up the front...

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Page 44: ...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 45: ...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 46: ...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 47: ...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 48: ...40 ...

Page 49: ...Product improvement specifications and appearance in this manual are subject to change without prior notice Johnson Controls Inc USA LIT 12012183 ...

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