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Johnson Controls DHR18CSB21S, Service Manual

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Johnson Controls DHR18CSB21S Service Manual Download Page 4

11

 FLOW CHART 

FOR

 TROUBLESHOOTING

 ........................................................................................... 

45

 

11

.1 Troubleshooting Flow Chart of Main Control Malfunction

 .................................................. 

45

 

11

.2 Troubleshooting Flow Chart of Drive Malfunction

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52

 

11

.3 Interface

 ............................................................................................................................................ 

57

 

11

.4 IPM, PFC Testing Method

 ............................................................................................................ 

63

 

12

 

DISASSEMBLY AND ASSEMBLY PROCEDURES FOR MAIN PARTS

..........................................

.65

 

12

.1 

Outdoor Unit

 ....................................................

................................................................................

 

65

 

12

.2 

Indoor Unit

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......................................................................

 

69

CUSTOMER SUPPORT

...........................................

........................................................................................

 

83

 

TABLE OF CONTENTS

 (cont'd)

Summary of Contents for DHR18CSB21S

Page 1: ...NITS DHR18CSB21S DHR24CSB21S DHR30CSB21S DHR36CSB21S DHR42CSB21S DHR48CSB21S INDOOR UNITS DUCT DHR18NDB21S DHR24NDB21S DHR30NDB21S DHR36NDB21S DHR42NDB21S DHR48NDB21S Type Model Model Type 03257 17 INDOOR UNITS CASSETTE DHR18NKB21S DHR24NKB21S DHR30NKB21S DHR36NKB21S DHR42NKB21S DHR48NKB21S Type Model INDOOR UNITS CEILING DHR18NCB21S DHR24NCB21S DHR30NCB21S DHR36NCB21S DHR42NCB21S DHR48NCB21S Type...

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: ...CONTROLLER 16 7 1 Display View 16 7 2 Operation View 18 8 SPECIAL FUNCTIONS SETTINGS 21 8 1 Setting of Filter Clean Reminder Function 21 8 2 Low Temperature Drying Function 23 8 3 Lock Function 23 8 4 Memory Function 24 8 5 Door Control Function Occupancy Function 24 8 6 Switch between Fahrenheit and Celsius 24 8 7 Ambient Temperature 24 8 8 Error Code Recall 25 8 9 Programming Function 25 9 1 Sma...

Page 4: ...ain Control Malfunction 45 11 2 Troubleshooting Flow Chart of Drive Malfunction 52 11 3 Interface 57 11 4 IPM PFC Testing Method 63 12 DISASSEMBLY AND ASSEMBLY PROCEDURES FOR MAIN PARTS 65 12 1 Outdoor Unit 65 12 2 Indoor Unit 69 CUSTOMER SUPPORT 83 TABLE OF CONTENTS cont d ...

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: ...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 10: ... MODELS LIST 1 1 Outdoor Unit Model Name Power Supply V Ph Hz Appearance DHR18CSB21S 208 230V 60Hz DHR24CSB21S 208 230V 60Hz DHR30CSB21S 208 230V 60Hz DHR36CSB21S 208 230V 60Hz DHR42CSB21S 208 230V 60Hz DHR48CSB21S 208 230V 60Hz ...

Page 11: ...08 230V 60Hz DHR24NKB21S 23800 27200 208 230V 60Hz DHR30NKB21S 28200 31200 208 230V 60Hz DHR36NKB21S 34000 41000 208 230V 60Hz DHR42NKB21S 39500 44000 208 230V 60Hz DHR48NKB21S 48000 54500 208 230V 60Hz Ceiling Type DHR18NCB21S 17100 19100 208 230V 60Hz DHR24NCB21S 23800 27200 208 230V 60Hz DHR30NCB21S 28200 31200 208 230V 60Hz DHR36NCB21S 34000 41000 208 230V 60Hz DHR42NCB21S 39500 44000 208 230V...

Page 12: ...Service Manual 3 2 Nomenclature ...

Page 13: ...e Pa InWg 0 30 0 0 12 0 75 0 0 3 0 75 0 0 3 Sound Pressure Level SS H M L dB A 40 39 36 28 47 46 44 40 47 46 44 40 Air Filter PP PPKZ PPKZ Condensate Piping mm inch Φ30 1 5 φ1 18 0 06 Φ20 1 2 φ0 79 0 05 Φ20 1 2 φ0 79 0 05 Outline Dimensions W H D mm inch 1037 266 721 40 8 10 5 28 4 1279 268 558 50 4 10 6 22 0 1279 268 558 50 4 10 6 22 0 Net Weight kg lb 33 0 72 8 34 0 75 0 35 0 77 2 Outdoor Unit D...

Page 14: ...25 0 0 5 Sound Pressure Level SS H M L dB A 53 52 48 44 53 52 48 44 55 53 49 45 Air Filter PPKZ PPKZ PPKZ Condensate Piping mm inch Φ20 1 2 φ0 79 0 05 Φ20 1 2 φ0 79 0 05 Φ20 1 2 φ0 79 0 05 Outline Dimensions W H D mm inch 1226 290 775 48 3 11 4 30 5 1226 290 775 48 3 11 4 30 5 1340 350 750 52 8 13 8 29 5 Net Weight kg lb 46 0 101 4 46 0 101 4 56 0 123 5 Outdoor Unit DHR36CSB21S DHR42CSB21S DHR48CS...

Page 15: ... 44 37 47 46 42 38 49 48 45 40 Air Filter PP ABS PP ABS PP Condensate Piping mm inch Φ25 1 5 φ0 98 0 06 Φ25 1 5 φ0 98 0 06 Φ25 1 5 φ0 98 0 06 Outline Dimensions W H D mm inch 665 240 596 26 2 9 4 23 5 917 240 840 36 1 9 4 33 1 917 320 840 36 1 12 6 33 1 Net Weight kg lb 20 0 44 1 27 0 59 5 32 0 70 6 Outdoor Unit DHR18CSB21S DHR24CSB21S DHR30CSB21S Power Supply V Ph Hz 208 230V1Ph 60Hz 208 230V1Ph ...

Page 16: ...6 43 53 52 47 41 Air Filter ABS PP ABS PP ABS PP Condensate Piping mm inch Φ25 1 5 φ0 98 0 06 Φ25 1 5 φ0 98 0 06 Φ25 1 5 φ0 98 0 06 Outline Dimensions W H D mm inch 917 320 840 36 1 12 6 33 1 917 320 840 36 1 12 6 33 1 910 290 910 35 8 11 4 35 8 Net Weight kg lb 32 0 70 6 32 0 70 6 43 0 94 8 Outdoor Unit DHR36CSB21S DHR42CSB21S DHR48CSB21S Power Supply V Ph Hz 208 230V1PH 60Hz 208 230V1Ph 60Hz 208...

Page 17: ... 42 38 32 49 48 46 40 49 46 44 38 Air Filter PP PP PP Condensate Piping mm inch Φ17 1 75 φ0 67 0 07 Φ17 1 75 φ0 67 0 07 Φ17 1 75 φ0 67 0 07 Outline Dimensions W H D mm inch 1220 225 700 48 0 8 9 27 6 1220 225 700 48 0 8 9 27 6 1420 245 700 55 9 9 6 27 6 Net Weight kg lb 39 0 86 0 40 0 88 2 48 0 105 8 Outdoor Unit DHR18CSB21S DHR24CSB21S DHR30CSB21S Power Supply V Ph Hz 208 230V1Ph 60Hz 208 230V1Ph...

Page 18: ...5 700 66 9 9 6 27 6 Net Weight kg lb 48 0 105 8 50 0 110 3 59 0 130 1 Outdoor Unit DHR36CSB21S DHR42CSB21S DHR48CSB21S Power Supply V Ph Hz 208 230V1Ph 60Hz 208 230V1Ph 60Hz 208 230V1Ph 60Hz Heat Exchanger Cross Fin Coil Cross Fin Coil Cross Fin Coil Compressor Type Rotary Rotary Rotary Power Input W 4150 4150 4580 Refrigerant R410A Control Electronic Expansion Valve Electronic Expansion Valve Ele...

Page 19: ...Model Power Supply Fan Motor FLA Fuse Breaker Capacity Minimum Circuit Ampacity Maximum Overcurrent Protection V Ph Hz A A A A DHR18NDB21S 208V 230V1Ph 60Hz 0 6 5 15 1 15 DHR24NDB21S 208V 230V1Ph 60Hz 1 3 5 15 2 15 DHR30NDB21S 208V 230V1Ph 60Hz 1 3 5 15 2 15 DHR36NDB21S 208V 230V1Ph 60Hz 2 1 5 15 3 15 DHR42NDB21S 208V 230V1Ph 60Hz 2 1 5 15 3 15 DHR48NDB21S 208V 230V1Ph 60Hz 4 0 5 15 5 15 DHR18NKB2...

Page 20: ...en connecting a wired zone controller to an indoor unit use 18AWG stranded cabling not exceeding 98 feet 4 PIPING DIAGRAM Indoor Unit Outdoor Unit TH OE TH D Condenser Strainer with Service Port 4 Way Valve Muffler TH C Low Pressure Switch Accumulator High Pressure Switch Compressor Suction Service Valve with Service Port TH IE Evaporator TH E Cooling Heating TH OE Outdoor Environment Thermal Bulb...

Page 21: ...RATION FLOWCHART 5 1 Cooling Dry Operation Comp starts after 3min delay Temp of indoor Set temp Comp stop for 3 min N Y N Y Y N Indoor fan run Comp and outdoor fan run Comp and outdoor fan stop Power On Set controller to cool or dry mode ...

Page 22: ...ing Operation Comp starts after 3min delay N Y N Y Y N Power On Comp and outdoor fan run Temp of indoor Set temp Comp and outdoor fan stop Comp stop for 3 min Indoor unit running in heat mode Indoor fan starts only with hot coil ...

Page 23: ...s it once more and the unit will be turned off When turning off the unit the Sleep function will be canceled but the current time is still displayed MODE button By pressing this button Auto Cool Dry Fan Heat mode can be selected Auto mode is default after power on Under the Auto mode the setpoint temperature will not be displayed Under the Heat mode the initial value is 28 C 82 F under other modes...

Page 24: ...SWING function applicable for some Fan Coil Units When the wireless remote controller is energized initially with the unit under the OFF status it should be set by pressing the button and the SWING button simultaneously with the symbol blinking twice Then after the unit is turned on this function can be activated by pressing the SWING button with the displayed symbol indicating swing function is o...

Page 25: ...applicable to all models TIMER OFF button By pressing this button it is available to go to the TIMER OFF setting state with the same setting method as that of the TIMER ON in which case the OFF symbol blinks TURBO button In the Cool or Heat mode pressing this button can activate or deactivate the TURBO function When the TURBO function is activated its symbol will be displayed when the running mode...

Page 26: ...d down swing function 3 Air exchange function 4 Sleep function 5 Auto mode 6 COOL mode 7 DRY mode 8 FAN mode 9 HEAT mode 10 Health function 11 I Demand function 12 Vacation function 13 Status display of main and secondary wired zone controller 14 Shield function This button disables temperature adjustment On Off function mode change and the Energy Save function 3 ...

Page 27: ... function 19 Ambient setting temperature 20 Electric heater 21 Blow function Coil drying function 22 Defrosting function Heat Pump only 23 Filter cleaning reminder 24 Timer Setting 25 Keycard control Motion Sensor Activation 26 Quiet function 27 Lock function 7 2 Operation View 7 2 1 Wired Zone Controller Buttons Figure 2 3 3 Wired zone controller buttons ...

Page 28: ...me time for 5s to enter lock state All wired zone controller buttons are locked out when lock is turned on Repress and buttons for 5s to quit lock state 4 Mode and 5 Function Programming function Unit controller address Pressing Mode and Function buttons at the same time with the unit turned off puts the controller into Program Mode to allow confirmation setting of the unit controller address See ...

Page 29: ...of Wired Zone Controller Indoor Unit Address 7 2 3 1 Setting and Confirmation of Address Under off state of the unit press Function and Mode buttons at the same time for 5s to enter setting interface of wired controller s address In this case LCD displays address number Then press or button to adjust address and then press Enter Cancel button to confirm The address setting is related to the settin...

Page 30: ...wired zone controllers one should be the main and the other should be the secondary Setting of main secondary wired zone controller s address is shown as Figure 2 3 5 below Figure 2 3 5 Enquiry and setting of main secondary wired zone controller s address 8 SPECIAL FUNCTIONS SETTINGS 8 1 Setting of Filter Clean Reminder Function When unit is on press Function button to switch to filter clean remin...

Page 31: ... unit There are 4 types of situations 1 Clean Reminder is off Timer zone shows 00 2 Low particulate the former digit in timer zone shows 1 while the latter one shows 0 which indicates the accumulated operating time is 5500hr Each time the latter digit increases 1 the accumulated operating time increases 500hr When it reaches 9 it means the accumulated operating time is 10000hr 3 Medium particulate...

Page 32: ... reached in unit on or off state will blink every 0 5s for reminder Press Function button to switch to icon and press and button to adjust the level Then press Enter Cancel button so the accumulated operating time won t be cleared If the adjusted level is higher than the present accumulated operating time the icon won t blink any more if the adjusted level is lower than the present accumulated ope...

Page 33: ... room card is inserted or not the ON OFF of unit can be controlled If long distance monitoring or centralized control information is received when the room card is not inserted icon is cleared When the card is reinserted door control function is judged to be turned on If long distance monitoring or centralized control information is received when the room card is inserted the indoor unit will main...

Page 34: ...yed code is the most recent 8 9 Programming Function Under off state of the unit press Function and Timer buttons at the same time for 5s to go to the programming menu Press Mode button to adjust the setting items and press or button to set the actual value 8 9 1 Setting ambient temperature sensor dual ambient temperature sensors function In the programming area press Mode button to adjust to 00 i...

Page 35: ...cooling mode after outdoor unit stops when reaching temperature setpoint in heating mode duct type unit and floor ceiling unit will blow residual heat for 60s and then stop indoor unit fan Cassette units always operate in low fan speed and will blow residual heat for 60s Mode 2 After outdoor unit stops when reaching temperature setpoint The indoor fan motor stops operation with a 10s delay regardl...

Page 36: ...tions 1 Without occupancy function LCD displays 00 2 With occupancy function LCD displays 00 8 9 9 Selecting building management system or central controller In the programming area press Mode button until 10 is displayed at the controller Press or button to scroll through selections 1 Central controller LCD displays 00 2 Building management sys tem LCD displays 01 8 9 10 Selecting fan mode of ind...

Page 37: ...03 5 Compensate 4 39 LCD displays 04 6 Compensate 5 41 LCD displays 05 7 Compensate 6 43 LCD displays 06 8 Compensate 7 45 LCD displays 07 9 Compensate 8 46 LCD displays 08 10 Compensate 9 48 LCD displays 09 11 Compensate 10 50 LCD displays 10 12 Compensate 11 52 LCD displays 11 13 Compensate 12 54 LCD displays 12 14 Compensate 13 55 LCD displays 13 15 Compensate 14 57 LCD displays 14 16 Compensat...

Page 38: ...e of a displayed error E1 high pressure protection Figure 2 6 1 9 CENTRAL CONTROLLER 9 1 Smart Zone Controller 9 1 1 Function The smart zone controller can directly control up to 16 sets of indoor units in a control network and is available to check the running status of any unit through the LCD including running mode timer fan speed centralized control etc PE Temperature excursion protection PL L...

Page 39: ...he running temperature of the indoor unit with max 86 30 C and min 61 16 C Under the timer setting status It is used to set the timer period with max 24 hours Under the clock setting status It is used to set the hour and minute 5 6 Mon 1 9 It is used for the switchover between unit 1 and unit 9 Under the timer or clock setting status it indicates Monday 7 Tue 2 10 It is used for the switchover bet...

Page 40: ...between unit 7 and unit 15 Under the timer or clock setting status it indicates Sunday 13 8 16 It is used for the switchover between unit 8 and unit 16 14 Timer Time It is used to set the timer or on off time of the selected indoor unit as well as to set the clock of the system 15 Central It is used for the switchover between single and centralized control modes 16 Shield It is used to deactivate ...

Page 41: ...ays the set temperature indoor unit code 01 16 and symbols of Celsius and Fahrenheit scale 7 Control mode It displays CENTER under the centralized control mode and no display under the single control mode 8 Ambient temperature Serial port It displays the ambient temperature serial port as well as symbols of Celsius and Fahrenheit scale 9 Indoor unit code On off status Numbers indicate the indoor u...

Page 42: ...one 3 Working principle When a room card or similar object is inserted the interface allows the indoor unit to be operated normally When the card is removed the indoor unit returns to the off state and cannot be turned on Connect the door control detection port of indoor main board with the interface of door control board CN1 in the following Figure connect the door control signal to the door cont...

Page 43: ...rd is not inserted the unit will go to standby state If the unit has a wired zone controller icon will be displayed on the wired zone controller If the unit has no wired zone controller there will be no display The unit will control the ON OFF of unit according to the detected information 3 Setting method Under off state of the unit press Function and Timer buttons at the same time for 5s to go to...

Page 44: ... module is connected the unit will control the ON OFF of unit according to the signal detected by occupancy module When there is nobody in the room and the unit has a wired zone controller icon will be displayed on the wired zone controller if the unit has no wired zone controller there will be no display The unit will control the ON OFF of unit according to detected information 3 Setting method W...

Page 45: ...ress mode is defaulted to be connecting to a central controller mode and the defaulted address is 1 When the central controller is connected centralized control of the unit can be realized to control unit ON OFF operation mode set fan speed temperature and weekly timer Service Manual Figure 2 7 8 human sensitive occupancy Note When the door control function and occupancy function have been set at ...

Page 46: ...tained after a power failure The detailed setting is as shown in the Figure below Figure 2 7 12 2 Address setting of each unit When the address mode is set to be central controller address mode The address setting value range is 01 16 The setting method is Under off state of the unit press Function and Mode buttons at the same time for 5s to enter setting interface of wired zone controller address...

Page 47: ...Service Manual 38 Figure 2 7 13 ...

Page 48: ...on and Timer buttons at the same time for 5s to go to the programming menu Press Mode button until 10 is displayed at the controller Press or button scroll through selections Central controller address mode LCD displays 00 Building management control address mode LCD displays 01 Choose the first selection and then press Enter Cancel button to save and exit setting Now the address of wired controll...

Page 49: ...indoor mainboard Then connect the required units to realize central control of these units Notes When central controller is to be connected set the address mode into central controller address mode through wired zone controller Building management system control address mode can not be set The unit addresses in the same network must be different otherwise communication malfunction will occur and t...

Page 50: ...tically Refrigerant lacking protection If the unit reports system refrigerant lacking within 10min after turning on the unit the unit will stop operation If the fault occurs successively 3 times the unit cannot be recovered automatically Refrigerant recycling mode If enter refrigerant recycling mode through special operation E3 will be displayed After exiting refrigerant recycling mode the code wi...

Page 51: ... displayed and the indoor unit can work normally 11 F3 Malfunction of outdoor ambient temperature sensor Outdoor ambient temperature sensor If the outdoor ambient temperature sensor is detected of open circuit or short circuit for 5s successively outdoor ambient temperature sensor malfunction will be reported The unit can automatically resume operation after the malfunction disappears If outdoor a...

Page 52: ...malfunction of 4 way valve 4 way valve After the compressor starts operation in heating mode if the outdoor unit detects the difference between evaporator temperature and indoor ambient temperature is lower than the protective value for 10min successively direction changing malfunction of 4 way valve will be reported and the outdoor unit will stop operation The unit can automatically resume operat...

Page 53: ...ture sensor error P7 P7 Compressor current protection P5 P5 DC busbar under voltage protection PL PL Compressor startup failure Lc Lc Drive module reset P0 P0 Compressor motor desynchronizing H7 H7 Phase loss Ld Ld Drive to main control communication error P6 P6 IPM protection H5 H5 Compressor overload protection H3 H3 AC current protection input side PA PA Charging circuit error PU PU PFC protect...

Page 54: ...45 11 FLOW CHART FOR TROUBLESHOOTING 11 1 Troubleshooting Flow Chart of Main Control Malfunction E1 High Pressure Protection Service Manual ...

Page 55: ...ally to ensure smooth air return and air outlet E3 stands for three statuses 1 Low pressure protection 2 Refrigerant lacking protection 3 Refrigerant recycling mode 1 If enter refrigerant recycling mode through special operation the displayed E3 is not an error code It will be eliminated when exiting refrigerant recycling mode 2 If you do not want to have refrigerant lacking protection you can ent...

Page 56: ...door unit and outdoor unit is connected well Check if there is open circuit in the communication wire between indoor unit and outdoor unit Reconnect the communication wire Replace the communication wire Check if the outdoor unit is energized Energize the outdoor unit Replace the mainboard Yes Yes No No No Yes Service Manual ...

Page 57: ... or make sure the float of full water switch works normally Yes F0 Malfunction of Indoor Ambient Temperature Sensor Malfunction of indoor ambient temperature sensor Check if the indoor ambient temperature sensor on mainboard is inserted on the needle stand correctly Disconnect the temperature sensor and measure if its resistance is normal Correctly insert the temperature sensor on the needle stand...

Page 58: ...r on the needle stand Replace the temperature sensor Replace the indoor mainboard Yes No No Yes F2 Malfunction of Condenser Temperature Sensor Malfunction of condenser temperature sensor Check if the condenser temperature sensor on mainboard is inserted on the needle stand correctly Disconnect the temperature sensor and measure if its resistance is normal Correctly insert the temperature sensor on...

Page 59: ...e sensor on the needle stand Replace the temperature sensor Replace the outdoor mainboard Yes No No Yes F4 Malfunction of Discharge Temperature Sensor Malfunction of discharge temperature sensor Check if the discharge temperature sensor on mainboard is inserted on the needle stand correctly Disconnect the temperature sensor and measure if its resistance is normal Correctly insert the temperature s...

Page 60: ...51 F5 Malfunction of Wired Controller Temperature Sensor Malfunction of wired controller temperature sensor Replace the wired controller H6 Malfunction of Outdoor Fan Motor Service Manual ...

Page 61: ...inboard Operate the unit with the new motor Replace the indoor mainboard Yes No No Yes 11 2 Troubleshooting Flow Chart of Drive Malfunction Note For Outdoor Unit Drive Inverter by Single phase Motor P0 Drive module reset P7 IPM or PFC temperature sensor error PA AC current protection input side PC Current sensor circuit error HC PFC protection 48k only P0ǃP7 ˆPA ˆHC or PC is displayed on wired zon...

Page 62: ... controller P8 is displayed in the mainboard 88 Indicating light Is the IPM or PFC module of mainboard tightened No Works normally Replace the mainboard Yes Tighten the IPM or PFC module PH DC busbar over voltage protection PL DC busbar under voltage protection Service Manual ...

Page 63: ...urrent protection H7 Compressor motor desynchronizing H5 IPM protection Ld Phase loss P5 H7 H5 or Ld is displayed in the mainboard 88 indicating light Is the compressor phase sequence right Yes Replace the mainboard Does it work normally No Replace the compressor Work normally Yes adjust the compressor phase sequence Is the compressor wire terminals tightened Tighten the compressor wire terminals ...

Page 64: ...g light Is the PFC wire tightened or is the sequence right Tighten the PFC wire or adjust the sequence Replace the mainboard Yes No Works normally ee driving board chip error Yes Yes ee is displayed on the wired controller Is the jumper loose Works Normally Tighten the jumper Replace the mainboard No Service Manual ...

Page 65: ...56 H6 DC fan error Service Manual ...

Page 66: ...upply of fan motor 3 pin Fan GND 4 pin 15V 5 pin Signal control 6 pin NC Interface of DC fan motor 1 pin DC bus voltage 2 pin Suspended 3 pin DC bus GND 4 pin 15V 5 pin Control signal input 6 pin Not connected 5 DC_MOTOR1 DC fan motor1 1 pin Power supply of fan motor 3 pin Fan GND 4 pin 15V 5 pin Signal control 6 pin Signal Feedback Interface of DC fan motor 1 pin DC bus voltage 2 pin Suspended 3 ...

Page 67: ...rotection obligate Interface of high pressure protection 12 LPP Low pressure switch for system protection obligate Interface of low pressure protection 13 OVC COMP Compressor overload protection Interface of compressor overload protection 14 T SENSOR2 1 2 pin Tube sensor 3 4 pin Ambient temperature 5 6 pin Air discharge 1 2 pin Case temperature sensor 3 4 pin Ambient temperature sensor 5 6 pin Dis...

Page 68: ...nduction wire brown 3 N Neutral wire input white 4 AC L Live wire input red 5 COMM COMM1 Communication interface 6 JTAG1 Reserved 7 PWR Control power input 8 DC BUS1 Bus electric discharging interface for testing 9 L2 1 PFC induction wire yellow 10 L1 2 PFC induction wire white 11 P OUT Reserved 12 G OUT Reserved 13 W Compressor Phase W 14 V Compressor Phase V 15 U Compressor Phase U Service Manua...

Page 69: ...terface No Printing Interface 1 N OUT1 Neutral wire output 1 white only for 18k 2 N OUT Neutral wire output white 3 L OUT Live wire output red 4 E1 Grounding wire 5 E2 Reserved 6 AC L Live wire input red 7 AC N Neutral wire input white Service Manual ...

Page 70: ...nput white 4 L2 2 PFC induction wire blue 5 L2 1 PFC induction wire yellow 6 L1 2 PFC induction wire white 7 PWR Control power input 8 JTAG1 Reserved 9 COMM Communication interface 10 DC BUS1 DC bus electric discharging needle stand for testing 11 DC BUS DC bus interface connect to filtering board 12 U Compressor Phase U 13 V Compressor Phase V 14 W Compressor Phase W Service Manual ...

Page 71: ...face No Printing Interface 1 N OUT Neutral wire output white 2 L OUT Live wire output red 3 DC BUS DC bus interface connect to drive board 4 AC L Live wire input red 5 N Neutral wire input white 6 E1 Reserved 7 E Grounding wire screw hole Service Manual ...

Page 72: ... If any measured valve is 0 it indicates the IPM is damaged 11 4 2 Method of Testing PFC Module Short Circuit only for DHR48CSB21S 1 Preparation before test prepare a universal meter and turn to its diode option and then remove the wires L1 2 L2 1 after it is powered off for one minute 2 Testing Steps Step 1 Put the black probe on the place P and the red one on the wiring terminal L1 2 L2 1respect...

Page 73: ...64 DHR48CSB21S Service Manual Service Manual ...

Page 74: ... Handling Instruction 1 Remove external casing 1 Remove the top cover and handle 2 Remove the grille outer case and right side plate 2 Remove motor 1 Remove the blade nut and then remove the blade 2 Remove the motor from motor support 3 Remove compressor 1 Reclaim the refrigerant from the entire system 2 Unsolder the 4 way valve piping assy from compressor 3 Remove the compressor mounting bolts 4 ...

Page 75: ...ng Instruction 1 Remove external casing 1 Remove the top cover and handle 2 Remove the grille outer case front side plate and right side plate 2 Remove motor 1 Remove the blade nut and then remove the blade 2 Remove the motor from motor support 3 Remove compressor 1 Reclaim the refrigerant from the entire system 2 Unsolder the 4 way valve piping assy from compressor 3 Remove the compressor mountin...

Page 76: ...tep Illustration Handling Instruction 1 Remove external casing 1 Remove the top cover and handle 2 Remove the grille outer case and right side plate 2 Remove motor 1 Remove the blade nut and then remove the blade 2 Remove the motor from motor support 3 Remove gas liquid separator 1 Reclaimthe refrigerant from the entire system 2 Unsolder the 4 way valve piping assy from gas liquid separator 3 Remo...

Page 77: ...everse order of disassembly 42k 48k Important Before disassembly and assembly make sure that the power to the system has been disconnected and verified as voltage free Step Illustration Handling Instruction 1 Remove external casing 1 Remove the top cover and handle 2 Remove the grille outer case and right side plate 2 Remove motor 1 Remove the blade nuts and then remove the blades 2 Remove the mot...

Page 78: ...assis 5 Assemble unit Assemble the unit in the reverse order of disassembly 12 2 Indoor Unit 12 2 1 Duct type Removal and Assembly of Fan Motor Step Illustration Handling Instruction 1 Unplug the motor cables Use screwdriver to remove the electric box cover and unplug the motor cables in electric box 2 Remove the filter sub assembly and air inlet cover board Remove the filter sub assembly from the...

Page 79: ...lace with new motor If the new motor comes with a mounting bracket attach the bracket to the housing after sliding on the fan cages Be sure to tighten the cages onto the motor shafts 7 Reassembly of the unit Reassemble the unit in the reverse order of disassembly and test operation Disassembly of filter screen for return air Important Make sure that the power supply to the system is turned off bef...

Page 80: ... removed 2 Disassembly of electric parts box By removing the screws inside the box the electrical box can be completely removed This should not be necessary unless the box is damaged Removal of condensate pan Important Make sure that the power supply is turned off before disassembling and protect all the parts during disassembly Step Illustration Handling Instruction 1 Disassembly of cover plate T...

Page 81: ... Make sure that the power supply is off and protect the copper tube and aluminum fin Use caution when removing coil to prevent damage Step Illustration Handling Instruction 1 Removal of evaporator screws Remove the cover plate and the screws on each end of the coil 2 Seal plate removal Remove the screws holding the seal plate for the tubing assemblies At this point the flare connections may be dis...

Page 82: ...ws holding condensate pan Use screwdriver to loosen the screws holding the drain pan in place 2 Remove the condensate pan Carefully remove the condensate pan 3 Loosen the bolts holding the fan blades in place Use a wrench or socket to carefully remove the fan blade bolts 4 Remove the fan blade The fan blade can now be removed ...

Page 83: ...r to carefully tighten the screws holding the motor 8 Mount the fan blade and tighten the bolts Mount the fan blade and use a wrench or socket to carefully tighten the bolts holding the fan blade in place Do not overtighten as damage may occur 9 Reinstall the condensate pan and tighten the screws Use a screwdriver to carefully tighten the screws holding the condensate pan in place Take care to not...

Page 84: ...osen the screws holding the condensate pan in place 2 Remove the condensate pan Remove the condensate pump and replace it 3 Pull out the water outlet pipe and loosen the screws holding the condensate pump Pull out the water outlet pipe and use screwdriver to loosen the screws holding the condensate pump 4 Take out the pump and replace it Take out the pump and replace it ...

Page 85: ...6NCB21S DHR42NCB21S Removal of main outer cover Important Make sure that the power supply is turned off before disassembling Use care when disassembling and do not put the cover or filters near a high temperature heat source Step Illustration Handling Instruction Disassembly of sub assy of front grille 1 Unscrew the 2 clasps of the upper grille and the 2 screws of the clasps 2 Open the grille disa...

Page 86: ...e to moisture and impact damage Step Illustration Handling Instruction Removal of electrical box cover Remove the three screws as shown in the picture then remove the cover Disassembly of air deflecting louvers Important Make sure the power supply is cut off before disassembling and protect all the parts during disassembly especially the linkages of the air deflecting louvers Step Illustration Han...

Page 87: ...rge air guide Remove the display board mounting support and mounting plate of the motor in this order Disassembly of fan and motor components Important Make sure that the power supply is turned off before disassembling and protect all the parts during disassembly especially the fastening screws for the fans Step Illustration Handling Instruction 1 Disassembly of front and back fan cage housings Pr...

Page 88: ...4NCB21S DHR48NCB21S Removal of the main grille cover PSRUWDQW 0DNH VXUH WKDW WKH SRZHU VXSSO LV WXUQHG RII EHIRUH GLVDVVHPEOLQJ DQG SURWHFW DOO WKH SDUWV GXULQJ GLVDVVHPEO R QRW SXW ILOWHU DVVHPEOLHV QHDU D KLJK WHPSHUDWXUH KHDW VRXUFH Step Illustration Handling Instruction Removal of grille sections 1 Unscrew the 2 clasps of the upper grille and the two screws of the clasps 2 Open the grille disa...

Page 89: ... Remove three screws as shown by the arrows in the drawing on the left and remove the electrical box cover Removal of the discharge air louvers Important Make sure the power supply is turned off before disassembling and protect all the parts during disassembly especially linkages and connections of the louvers Step Illustration Handling Instruction Removal of the discharge air louvers Remove the d...

Page 90: ... motor components Important Make sure that the power supply is turned off before disassembling and protect all the parts during disassembly especially the fastening screws for fans Step Illustration Handling Instruction Disassembly of front and back fan cage housings Press the buckle at the joints of front and back of the fan cage housings by hand and pull upward to remove the front housing Then r...

Page 91: ...ng clamp and motor attaching clamp subassembly to remove the motor Removal of right and left mounting plates Important Make sure that the power supply is turned off before disassembling and protect all the parts during disassembly Step Illustration Handling Instruction Removal of right and left mounting plates Disassemble the bolts on right and left mounting plates with tools As is shown by the ar...

Page 92: ...83 ...

Page 93: ...Product improvement specifications and appearance in this manual are subject to change without prior notice Johnson Controls Inc USA LIT 12012189 ...

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