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Johnson Controls DHW18CMB21S, Service Manual

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Johnson Controls DHW18CMB21S Service Manual Download Page 29

21

Desynchronizing happens
during operation

Outdoor unit is working?

Unit radiation is good?

yes

yes

yes

yes

yes

no

no

no

no

no

End

Replace the compressor

Eliminate the malfunction

Replace the outdoor

 mainboard

Replace the outdoor unit

Replace the fan capacitor

Refrigerant amount is too much?

Input voltage is normal?

connected well

Check if fan 

terminal is

Improve radiation

 situation of the unit

(such as cleaning

the heat exchanger,

 improve ventilation

Turn on the unit

after the power 
supply voltage

 resumes normal

Charge refrigerant 

according to the 

service manual

Summary of Contents for DHW18CMB21S

Page 1: ...K INVERTER DRIVEN AIR CONDITIONING UNITS PLEASE READ AND UNDERSTAND THIS MANUAL BEFORE USING THIS INVERTER DRIVEN AIR CONDITIONING UNIT KEEP THIS MANUAL FOR FUTURE REFERENCE OUTDOOR UNITS DHW18CMB21S DHW24CMB21S Type 03257 17 Model ...

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: ...d Control 12 7 Troubleshooting 15 7 1 Flashing LED of Indoor Outdoor Unit and Primary Judgment 15 7 2 Malfunction Checking and Elimination 16 7 3 Maintenance Method for Normal Malfunction 29 8 Removal Procedures 31 Appendix 44 Appendix 1 Reference Sheet of Celsius and Fahrenheit 44 SSHQGL RQ JXUDWLRQ RI RQQHFWLRQ 3LSH 44 Appendix 3 Pipe Expanding Method 45 Appendix 4 List of Resistance for Ambient...

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: ...1 Technical Information Service Manual 1 Summary 1 Features and Summary Outdoor Unit DHW18CMB21S DHW24CMB21S ...

Page 10: ...sor Trademark Compressor Model Compressor Refrigerant Oil Type Compressor Type L R A Compressor Rated Load Amp RLA Compressor Power Input Compressor Thermal Protector Metering Method Cooling Operation Ambient Temperature Range Heating Operation Ambient Temperature Range Condenser Material Condenser Pipe Diameter Rows Fin Gap mm Coil length l X height H X coil width L Fan Motor Speed rpm H M L Outp...

Page 11: ... of Liquid Pipe2 inch 1 4 Metric Outer Diameter of Gas Pipe1 inch 3 8 Metric Outer Diameter of Gas Pipe2 Metric inch 3 8 Connection Pipe Max Height Distance indoor and indoor ft 32 8 Connection Pipe Max Height Distance indoor and outdoor and indoor up ft 32 8 Connection Pipe Max Height Distance indoor and outdoor and outdoor up ft 32 8 Max equivalent connection pipe length outdoor to last indoor f...

Page 12: ... Compressor Model Compressor Refrigerant Oil Type Compressor Type L R A Compressor Rated Load Amp RLA Compressor Power Input Compressor Thermal Protector Metering Method Cooling Operation Ambient Temperature Range Heating Operation Ambient Temperature Range Condenser Material Condenser Pipe Diameter Rows Fin Gap mm Coil length l X height H X coil width L Fan Motor Speed rpm H M L Output of Fan Mot...

Page 13: ...r of Liquid Pipe2 inch 1 4 Metric Outer Diameter of Gas Pipe1 inch 3 8 Metric Outer Diameter of Gas Pipe2 inch 3 8 Metric Outer Diameter of Gas Pipe2 Metric inch 3 8 Connection Pipe Max Height Distance indoor and indoor ft 32 8 Connection Pipe Max Height Distance indoor and outdoor and indoor up ft 32 8 Connection Pipe Max Height Distance indoor and outdoor and outdoor up ft 32 8 Max equivalent co...

Page 14: ...6 Technical Information Service Manual 3 Outline Dimension Diagram 35 1 8 38 27 5 9 15 3 5 13 3 7 22 14 1 2 Unit inch Unit inch DHW18CMB21S DHW24CMB21S 38 4 7 35 1 8 13 3 7 17 1 3 31 1 9 22 14 1 2 ...

Page 15: ...Not available for 14K 18K model C2 C3 D3 D2 B3 B2 A2 A3 A1 A unit electronic expansion valve B1 B unit electronic expansion valve C1 C unit electronic expansion valve D1 D unit electronic expansion valve A2 A unit gas pipe temperature sensor B2 B unit gas pipe temperature sensor C2 C unit gas pipe temperature sensor D2 D unit gas pipe temperature sensor A3 A unit liquid pipe temperature sensor B3 ...

Page 16: ... OG Orange Ɣ QGRRU 8QLW ƔDescription DHW18CMB21S 5 5 27720 7 21 7 5 1 225 81 7 2 7 50 1 2 7 50 1 7521 3 16 21 9 9 9 9 3 16 21 7521 1 225 81 7 57 57 57 28778 7 03 6 1625 2875220 7 03 6 1625 867 7 03 6 1625 9 203 0 1 02725 9 1 2 1 2035 6625 1 7 5 5 5 7 1 9 5 78 57 57 5 78 57 57 20 11 5 8 1 8 8 1 8 1 8 1 1 3 3 1 1 3 0DLQ RDUG 8 9 5 8 8 5 9 8 7 6 1625 32 5 7 7 7 203 7 50 1 2 29 203 6 7 2 7 50 1 7 50 1...

Page 17: ...8 1 1 8 1 8 1 8 7 50 1 7 50 1 2 9 9 9 7521 3 16 21 9 9 1 225 81 7 1 1 225 81 7 1 1 1 3 0 1 2 5 1 3 1 7 1 7 7 4 4 4 57 57 1 225 81 7 1 5 725 2 2 2 7 50 1 2 7 50 1 9 9 3 16 21 7521 7521 3 16 21 9 9 78 78 57 57 57 57 78 20 11 5 1 57 57 9 8 9 29 203 8 203 3 36 33 57 7 6 1625 1 7 7 5 1 7 5 2035 6625 9 9 9 8 211 725 97 97 1 1 6 3 3 7 03 3 3 48 48 3 3 7 03 3 3 6 7 03 6 1625 6 1625 6 1625 6 1625 7 03 6 3 ...

Page 18: ...of outdoor unit 5 High pressure protection terminal 6 Low pressure protection terminal 7 Terminal of outdoor unit 8 Electric heating belt terminal of chassis 9 Terminal of 4 way valve 10 Electric heating belt terminal of compressor 11 Terminal of temperature sensor wire for liquid valve and gas valve 12 Terminal of electronic expansion valve 13 Terminal of communication wire for indoor unit and ou...

Page 19: ... 8 Terminal of outdoor unit 9 Terminal of 4 way valve 10 Temperature sensor for liquid valve and gas valve for unit A 11 Temperature sensor for liquid valve and gas valve for unit B 12 Temperature sensor for liquid valve and gas valve for unit C 13 Temperature sensor for liquid valve and gas valve for unit D 14 Electronic expansion vale for unit A 15 Electronic expansion vale for unit C 16 Electro...

Page 20: ...n at every speed for at least 80s When the quantity of running indoor units is changed the unit will enter the control described in 1 3 5 1 and 1 3 5 2 When the compressor stops the outdoor fan runs at present speed and stops after 1min 1 2 Dry Mode also called dehumidification mode 1 2 1 The dry conditions and process are the same as those in cooling mode 1 2 2 The status of 4 way valve De energi...

Page 21: ...de then compare the mode of the other indoor units to see if there is a conflict Cooling mode dry mode is in conflict with heating mode b Fan mode is in conflict with heating mode and the heating mode is the basic mode No matter which indoor unit operates first the unit will run in heating mode 2 2 Overload protection function When the discharge tube temperature is a little low the compressor rais...

Page 22: ... after resetting of the main power 2 8 Compressor Phase Lock out Protection When the compressor starts if one of the three phases is detected open the compressor will enter phase lock out protection The error code will be cleared after 1min the unit will restart and then detect if there is still phase lock out protection If the phase lacking protection is detected for 6 times continuously the comp...

Page 23: ...t a c r e p m u j f o n o i t c e t o r p n o i t c n u f l a M 6 H n o i t c n u f l a m e r a w d r a H r for indoor unit o t o m U D I t u o h t i w f o k c a b d e e F Indoor ambient temperature sensor is open short circuited Hardware malfunction F1 Indoor evaporator temperature sensor is open short circuited Hardware malfunction F2 Liquid valve temperature sensor is open short circuited Hardw...

Page 24: ...ote controller within 200s Lc 4 E r o s s e r p m o c f o n o i t c e t o r p e r u t a r e p m e t e g r a h c s i d h g i H Overload protection E8 5 E n o i t c e t o r p t n e r r u c r e v o t i n u e l o h W 5 P n o i t c e t o r p t n e r r u c e s a h p r o s s e r p m o C Compressor desynchronizing H7 d L n o i t c e t o r p e s r e v n i e s a h p g n i k c a l e s a h p r o s s e r p m o...

Page 25: ...correct wiring method If the resistance is normal If the resistance is above 500M Replace the compressor Replace the outdoor mainboard Please check 1 if the indoor and outdoor heat exchanges are dirty if there is obstacle to affect the radiation 2 if the indoor and outdoor fans are running normally 3 if the pressure of the system is too high 4 if the refrigerant is too much which causes the high l...

Page 26: ...oints If the mainboard is broken If the wiring of the induction is connected well and if the induction is broken Flow chart Start Check if power supply is normal Power supply is abnormal yes no Turn on the unit after power supply resumes normal Replace the outdoor mainboard End ...

Page 27: ...l yes yes yes no no no Check if the outdoor induction is broken n o i t c u d n i e h t e c a l p e R n e k o r b s i n o i t c u d n i e h T Replace the outdoor mainboard Malfunction is eliminated End Turn on the unit after the power supply resumes to normal situation ...

Page 28: ...alfunction Eliminate the malfunction Eliminate the malfunction Replace the compressor End no no no no no no yes yes yes yes yes yes The unit appears desynchronizing as soon as energizing and starting The stop duration of the compressor is longer than 3min The wiring of the compressor is connected properly Reconnect the wire properly The eletric expansion valve is broken Replace the eletric expansi...

Page 29: ...place the outdoor mainboard Replace the outdoor unit Replace the fan capacitor Refrigerant amount is too much Input voltage is normal connected well Check if fan terminal is Improve radiation situation of the unit such as cleaning the heat exchanger improve ventilation Turn on the unit after the power supply voltage resumes normal Charge refrigerant according to the service manual ...

Page 30: ...e wiring of the eletric expansion valve is coonected well Replace the overload protector Check the coil of the eletric expansion valve replace it if it is broken Eliminate the malfunction Reconnect according to the wiring diagram Check the refrigerant status if there is refrigerant leakage recharge it according to the service manual Note the detection method of the coil of the eletric expansion va...

Page 31: ... no no no no yes yes yes yes yes yes If the connection wire of the compressor is connected well and correctly Eliminate the malfunction Reconnecttheconnectionwire ofthecompressoraccording to the wiring diagram If the refrigerant charging amount is too much Charge the refrigerant according to the service manual Eliminate the malfunction Eliminate the malfunction Replace the compressor End Replace t...

Page 32: ...heck whether the temperature senspr is normal according to resistance table Replace the temperature sensor with the same model Replace the controller with the same model End Eliminate the malfunction6 6 Temperature sensor malfunction Main checking points If the terminal of the temperature sensor is loosended or not connected If the temperature sensor is damaged or broken If the mainboard is broken...

Page 33: ... fan is connected reliably If it is loose Flow chart Start yes yes no no End Replace the outdoor mainboard If the connection wire of DC fan is loose Check if the outdoor fan is blocked by foreign objects Turn on the unit after removing the foreign objects Turn on the unit after the connection wire is properly connected ...

Page 34: ...tion of some indoor units De energize check if the connection wire of indoor and outdoor unit and the wire of the eletric box is connected correctly no no no Connected correctly Reconnect according to the wiring diagram yes yes yes De energize change the communication wire of the well communicated indoor unit and malfunction indoor unit then energize the unit and wait for 3min The malfunction indo...

Page 35: ...ectly Connected correctly Reconnect according to the wiring diagram Connected correctly Reconnect according to the wiring diagram De energize check if the connection wire between the outdoor mainboard and the filter board according to the wiring diagram The connection wire is broken Replace the connection wire Check if there is power input bewtweenthenetrualwireandlive wire of the outdoor mainboar...

Page 36: ... Start If the outdoor ambient temperature is above 127 F 53 C yes yes yes no no no It is a normal protection please operate the unit after the outdoor ambient temperature has changed If the indoor and outdoor radiation is insufficient Improve the radiation environment of the unit Iftheoutdoorfanisworkingnormally Check if the terminal of the fan is connected well if the fan is broken Replace fan ca...

Page 37: ...n of compressor RPSUHVVRU FDQ W RSHUDWH Refer to point 5 of maintenance method for details 7 3 Maintenance Method for Normal Malfunction 1 Air Conditioning Unit Doesn t Start 2 Poor Cooling Heating for Air Conditioning Unit 3 Horizontal Louver Doesn t Swing Possible Causes Discriminating Method Air Conditioner Status Troubleshooting No power supply or poor connection for power plug After energizat...

Page 38: ...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 make sure all wiring terminals a...

Page 39: ...e refrigerant completely before removal Steps Procedure 5HPRYH WKH VFUHZV LQJ ELJ KDQGOH DQG ULJKW VLGH plate to remove the big handle 1 Remove big handle and wire connection cover Before disassembly 5HPRYH WKH VFUHZV LQJ ZLUH FRQQHFWLRQ FRYHU and right side plate to remove the wire connection cover big handle wire connection cover DHW18CMB21S ...

Page 40: ...O DQG OHIW and right side plate to remove top cover 5HPRYH WKH VFUHZV LQJ JULOOH DQG SDQHO WR UHPRYH the grille on the panel 5HPRYH WKH VFUHZV LQJ SDQHO FKDVVLV DQG PRWRU support to remove the panel 2 Remove top cover 3 Remove grille 4 Remove panel top cover grille panel ...

Page 41: ... remove the right side plate 5HPRYH WKH VFUHZV LQJ JULOOH gaurd DQG OHIW VLGH plate to remove grille guard 5HPRYH WKH VFUHZV LQJ FKDVVLV DQG FRQGHQVHU support to remove the left side plate 5 Remove right side plate 6 Remove guard grille 7 Remove left side plate right side plate grille guard left side plate ...

Page 42: ...o remove the fan blade 5HPRYH WKH WDSSLQJ VFUHZV LQJ PRWRU SXOO RXW WKH pin of leading wire for motor and remove the screws LQJ PRWRU VXSSRUW DQG FKDVVLV WR UHPRYH WKH PRWRU and motor support sub assy 9 Remove axial fan blade 10 Remove motor and motor support sub assy 8 Remove condenser support condenser support axial fan blade motor motor support sub assy ...

Page 43: ...sheet to remove the PFC electrical inductance Welding cut the welding point jointing the four way valve with blow torch to remove the four way valve sub assy Note Please make sure there s no refrigerant in the unit before removing any tube or compressor 12 Remove PFC electrical inductance 13 Remove four way valve sub assy 11 Remove electric box sub assy electric box sub assy PFC electrical inducta...

Page 44: ...sub assy 5HPRYH WKH VFUHZV LQJ LVRODWLRQ VKHHW DQG OLTXLG receiver and lift to remove the liquid receiver Remove the screws fixing isolation sheet and condenser side plate to remove the isolation sheet assy 15 Remove liquid receiver 16 Remove the isolation sheet assy 14 Remove suction pipe sub assy suction pipe sub assy liquid receiver isolation sheet assy ...

Page 45: ...SRUW DVV DQG chassis sub assy to remove the valve support assy Welding cut the welding point jointing EXV sub assy and refrigerant collection pipe to remove the EXV assy Note Fully pack the big valve with wet cloth when welding cutting to avoid high temperature damage of valve 18 Remove valve support assy 19 Remove EXV assy 17 Remove compressor compressor valve support assy EXV assy ...

Page 46: ... connecting the top panel with the front panel and the right side plate and then remove the top panel 2 Remove grille front side plate and panel Remove Remove the 1 screw connecting the front side plate and the panel and then remove the front side plate the 2 screws connecting the grille and the panel and then remove the grille 2 Steps Procedure grille front side plate top panel ...

Page 47: ...emove right side plate and left side plate Remove the screws connecting the right side plate with the chassis the valve support and the electric box and then remove the right side plate assy panel right side plate Remove the screws connecting the left side plate and the chassis and then left side plate remove the left side plate assy ...

Page 48: ...erminals and then pull the electric box upwards to remove it Remove the 4 tapping screws fixing the motor disconnect the leading wire insert of the motor and then remove the motor Remove the 2 tapping screws fixing the motor support and then pull the motor support upwards to remove it electric box fan motor axial flow blade Remove the nuts fixing the blade and then remove the axial flow blade 1 2 ...

Page 49: ... 7 Remove isolation sheet Remove the 3 screws fixing the isolation sheet and then remove the isolation sheet Isolation sheet Discharge the refrigerant completely unsolder the pipelines connecting the compressor and the condenser assy and then remove the 4 way valve assy 4 way valve assy 4 way valve assy Connection Pipe insulation ...

Page 50: ...g the valve subassemblies Unsolder the welding joint connecting the gas valve and the return air pipe Remove the gas valve Note When unsoldering the soldering joint wrap the gas valve with wet cloth completely to avoid damage to the valve caused by high temperature Unsolder the welding joint connecting the liquid valve and the connecting pipe Remove the liquid valve Remove screws fixing valve supp...

Page 51: ...43 Service Manual 11 Remove condenser sub assy Remove the chassis sub assy and condenser sub assy chassis sub assy condenser sub assy ...

Page 52: ...Celsius ć 32 33 32 0 55 56 55 4 13 79 80 78 8 26 34 35 33 8 1 57 58 57 2 14 81 80 6 27 36 35 6 2 59 60 59 15 82 83 82 4 28 37 38 37 4 3 61 62 60 8 16 84 85 84 2 29 39 40 39 2 4 63 62 6 17 86 87 86 30 41 42 41 5 64 65 64 4 18 88 89 87 8 31 43 44 42 8 6 66 67 66 2 19 90 89 6 32 45 44 6 7 68 69 68 20 91 92 91 4 33 46 47 46 4 8 70 71 69 8 21 93 94 93 2 34 48 49 48 2 9 72 71 6 22 95 96 95 35 50 51 50 1...

Page 53: ...the pipe Ɣ RQ UP WKH SLSH OHQJWK DFFRUGLQJ WR WKH GLVWDQFH RI LQGRRU XQLW DQG RXWGRRU XQLW Ɣ XW WKH UHTXLUHG SLSH ZLWK SLSH FXWWHU B Remove the burrs Ɣ 5HPRYH WKH EXUUV ZLWK VKDSHU DQG SUHYHQW WKH EXUUV IURP JHWWLQJ LQWR WKH SLSH C Put on suitable insulating pipe D Put on the flare nut Ɣ 5HPRYH WKH XQLRQ QXW RQ WKH LQGRRU FRQQHFWLRQ SLSH DQG RXWGRRU YDOYH LQVWDOO the flare nut on the pipe E Flare ...

Page 54: ... 72 2 439 111 0 737 5 63 46 34 10 2 73 2 358 112 0 717 4 60 23 35 9 779 74 2 28 113 0 697 3 57 18 36 9 382 75 2 206 114 0 678 2 54 31 37 9 003 76 2 133 115 0 66 1 51 59 38 8 642 77 2 064 116 0 642 0 49 02 39 8 297 78 1 997 117 0 625 1 46 6 40 7 967 79 1 933 118 0 608 2 44 31 41 7 653 80 1 871 119 0 592 3 42 14 42 7 352 81 1 811 120 0 577 4 40 09 43 7 065 82 1 754 121 0 561 5 38 15 44 6 791 83 1 69...

Page 55: ... 34 13 59 73 3 144 112 0 956 4 80 31 35 13 04 74 3 04 113 0 93 3 76 24 36 12 51 75 2 94 114 0 904 2 72 41 37 12 76 2 844 115 0 88 1 68 79 38 11 52 77 2 752 116 0 856 0 65 37 39 11 06 78 2 663 117 0 833 1 62 13 40 10 62 79 2 577 118 0 811 2 59 08 41 10 2 80 2 495 119 0 77 3 56 19 42 9 803 81 2 415 120 0 769 4 53 46 43 9 42 82 2 339 121 0 746 5 50 87 44 9 054 83 2 265 122 0 729 6 48 42 45 8 705 84 2...

Page 56: ...1 3 22 15 362 9 24 51 41 63 10 93 102 3 13 14 342 8 25 49 19 64 10 54 103 3 04 13 323 9 26 47 08 65 10 18 104 2 96 12 306 2 27 45 07 66 9 83 105 2 87 11 289 6 28 43 16 67 9 49 106 2 79 10 274 29 41 34 68 9 17 107 2 72 9 259 3 30 39 61 69 8 85 108 2 64 8 245 6 31 37 96 70 8 56 109 2 57 7 232 6 32 36 38 71 8 27 110 2 50 6 220 5 33 34 88 72 7 99 111 2 43 5 209 34 33 45 73 7 73 112 2 37 4 198 3 35 32 ...

Page 57: ...49 ...

Page 58: ...Product improvement specifications and appearance in this manual are subject to change without prior notice Johnson Controls Inc USA LIT 12012186 ...

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