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Johnson Controls DHY09CSB21S, Installation And Maintenance Manual

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Johnson Controls DHY09CSB21S Installation And Maintenance Manual Download Page 32

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Installation and Maintenance

(2) IPM protection, desynchronizing malfunction, phase current of compressor is overcurrent (AP1 below is control
board of outdoor unit)

Main detection point:

If control board AP1 and compressor 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 diagnosis process:

Summary of Contents for DHY09CSB21S

Page 1: ...PLEASE READ AND UNDERSTAND THIS MANUAL BEFORE USING THIS INVERTER DRIVEN AIR CONDITIONING UNIT KEEP THIS MANUAL FOR FUTURE REFERENCE INDOOR UNITS DHY09NWB21S DHY12NWB21S DHY18NWB21S DHY24NWB21S DHY09CSB21S DHY12CSB21S DHY18CSB21S DHY24CSB21S Type Model Model Type 03257 17 OUTDOOR UNITS ...

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: ...and Maintenance 2 2 4 Installation Checking Parts 4 3 Troubleshooting 9 3 1 Precautions before Performing Inspection or Repair 9 3 2 Confirmation 10 3 3 Flashing LED of Indoor Outdoor Unit and Primary Judgment 10 3 4 How to Check Simply the Main Part 19 3 4 Troubleshooting for Normal Malfunction 32 Appendix 34 Appendix 1 Reference Sheet of Celsius and Fahrenheit 34 Appendix 2 Configuration of Conn...

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: ...nch At least 5 8 9 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 2 3 inch At least 11 4 5 inch At least 19 2 3 inch At least 11 4 5 inch At least 78 3 5 inch A t l e a s t 1 1 8 i n c h ...

Page 10: ...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 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 outdoor unit mount select it according to the actua...

Page 12: ...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 in f...

Page 13: ...iping hole Space to the wall 5 8 9inch above Space to the wall 5 8 9inch above Outlet pipe Condensate hose Condensate hose Tape Outlet pipe Torque wrench Open end wrench Indoor pipe Pipe Union nut Union nut Pipe joint Pipe Fig 7 Insulating pipe Refer to the following table for torque tightening Drain hose Insulating pipe 1 Add insulating pipe in the indoor condensate hose in order to prevent conde...

Page 14: ...nd up Pipe 1 Bind up the connection pipe power cord and condensate hose with the band As shown in Fig 14 2 Reserve a certain length of drain 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 ...

Page 15: ...n joint of sleeve and baffle remove the wire clip connect the power connection wire and power cord to the wiring terminal fix them with screws As shown in Fig 23 6 Arrange the Pipes 1 The pipes should be placed along the wall bent reasonably and hidden The semidiameter of bending the pipe is 4 in 2 If the outdoor unit is higher than the wall hole a U shaped curve in the pipe is a must before pipe ...

Page 16: ... can t be placed 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 manifold gauge completely and operate for 10 15min to check if the pressure of manifold gauge ...

Page 17: ...hock and casualty or even death due to drop from high attitude Static maintenance is is performed while the unit is d energized For static maintenance make sure that the unit is de energized and the plug is disconnected dynamic maintenance is the maintenance during energization of the unit Before dynamic maintenance check that the unit is properly grounded using a voltage tester Check the copper p...

Page 18: ...wer Supply Confirm that the power breaker operates ON normally 2 Confirmation of Power Voltage Confirm that power voltage is AC 208 230 10 If power voltage is not in this range the unit may not operate normally 3 3 Flashing LED of Indoor Outdoor Unit and Primary Judgment ...

Page 19: ... sensor has open or short circuit F5 Blinks for 5 times Blinks for 7 times 14 Communication malfunction of indoor and outdoor units E6 Blinks for 6 times 15 Malfunction of circuit for detecting phase current of compressor U1 Blinks for 12 times 16 Demagnetization protection of compressor HE Blinks for 14 times 17 Malfunction of voltage drop of DC bus bar U3 Blinks for 20 times 18 Module temperatur...

Page 20: ...s for 5 times Blinks for 4 times 52 Overlow voltage protection for DC bus bar PL Blinks for 21 times Blinks for 12 times 53 Overhigh voltage protection for DC bus bar PH Blinks for 11 times Blinks for 13 times 54 PFC protection HC Blinks for 6 times Blinks for 14 times 55 Overhigh power protection not for outdoor L9 Blinks for 20 times Blinks for 9 times 56 Abnormal reversing of 4 way valve U7 Bli...

Page 21: ...or unit Yellow indicator blinks for twice Yellow indicator blinks for 4 times Yellow indicator blinks for 5 times Yellow indicator blinks for 6 times Yellow indicator blinks for 7 times Yellow indicator blinks for 8 times Red indicator blinks for once Red indicator blinks for twice Red indicator blinksfor 3 times Red indicator blinks for 4 times Red indicator blinks for 5 times Red indicator for 6...

Page 22: ...ch refrigrant blockage of capillary an dincrease of suction temp improper running of compressor burning in or stuck of bearing damage of discharge valve malfunction of protector Processing method adjust refrige rant amount replace the capillary replace the compressor use univers al meter to check if the 6 System malfunction Overload protection When tube temperature Check the temperature of outdoor...

Page 23: ...or fan motor operates During heating operation the complete unit stops Refer to the corresponding malfunction analysis 6 High temperature resistant protection E8 OFF 3S and blink 8 times Ƶ ƶ Ƶ Ƶ During cooling operation compressor will stop while indoor fan will operate During heating operation the complete unit stops Refer to the malfunction analysis overload high temperature resistant 7 Internal...

Page 24: ... will sop after operating for about 3 mins while indoor fan will operate During heating operation the complete unit will stop after operating for about 3 mins 1 Outdoor temperature sensor hasnt been connected well or is damaged Please check it by referring to the resistance table for temperature sensor 2 The head of temperature sensor hasnt been inserted into the copper tube 15 Limit decrease freq...

Page 25: ...p while indoor fan will operate During heating operation the complete unit will stop operation Refer to the malfunction analysis IPM protection loss of synchronism protection and overcurrent protection of phase current for compressor 25 PFC protection HC OFF 3S and blink 6 times ƶ Ƶ ƿ ƿ During cooling and drying operation compressor will stop while indoor fan will operate During heating operation ...

Page 26: ...ping for DC bus bar U3 OFF 3S and blink 20 times ƶ Ƶ Ƶ Ƶ During cooling and drying operation compressor will stop while indoor fan will operate During heating operation the complete unit will stop Supply voltage is unstable 35 Voltage of DC bus bar is too low PL OFF 3S and blink 21 times ƶ Ƶ Ƶ ƶ During cooling and drying operation compressor will stop while indoor fan will operate During heating o...

Page 27: ... Malfunction is eliminated Replace the controller with one ofthe same model End no no no no yes yes Malfunction is removed no yes yes no Is the wiring terminal between temperature sensor and the controller loosened or poor ly contacted Is there short circuit due to tri pover of the pa rts Is the temperature sensor normal according to the Resistance Table Replace it with a temperature sensor of the...

Page 28: ...otor can operate smoothly Is malfunction eliminated Reinsert the wiring terminal of indoor fan It s the malfunction of main board Replace the main board with the same model It s the malfunction of main board Replace the main board with the same model It s the malfunction of main board Replace the main board with the same model Start Whether the blade can operate smoothly Energize and restart upthe...

Page 29: ... controller Install a matching jumper cap No Is the jumper cap inserted incorrectly or improperly Re insert the jumper cap The mainboard is defined abnormal replace it Yes No Yes End Is the malfunction eliminated Yes No No Yes Replace the jumper cap No Yes Is the malfunction eliminated Is the malfunction eliminated ...

Page 30: ... done a Check if protective tube FUSE 1 has open circuit If so replace it with a protective tube of the same model b Energize the unit and check buzzer sounds If not the mainboard of indoor unit can t be used c Energize the unit with display and check if all icons are displayed after energization and if the display is normal If not the main board can t be used 2 The mainboard for replacement shall...

Page 31: ... 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 mi nutes or use DC voltmeter to measure the v...

Page 32: ...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 33: ...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 connecti...

Page 34: ...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 20min 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 p...

Page 35: ... 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 3min N If the stop time is not enough and the high and low pressure of system is not balance please start it after 3min Improve the connection situation of control board AP1 and compressor COMP connect it with wiring diagra...

Page 36: ...s normally 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 ...

Page 37: ...gram 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 ead foot an d th e fifth lead foot is similar less than 100 After the unit de energized for 20min Remove malfunction Y N N N If the overload protector SAT is well connected N Under ambient temperature test the resistance of overloa...

Page 38: ...Capacity is short circuit and replace it Y Re energize the unit and start it Cut the terminal of reactor test the resistance between two terminals of reactor with ohmic meter Replace the reactor Re energize the unit and start it Check the connection wire of reactor L of outdoor unit and PFC capacity If there is damaged short circuit Replace connection wire with circuit diagram Replace control boar...

Page 39: ...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 malfunctio...

Page 40: ...details Malfunction of compressor Compressor can t operate Refer to point 5 of maintenance method for details 3 5 Troubleshooting for Normal Malfunction 1 Air Conditioner can t Be Started Up 2 Poor Cooling heating for Air Conditioner 3 Horizontal louver can t Swing Possible Causes Discriminating Method Air conditioner Status Troubleshooting No power supply or poor connection for power plug After e...

Page 41: ...Replace drain pipe Wrapping is not tight Water leaking from the pipe connection place of indoor unit Wrap it again and bundle it tightly 5 Compressor can 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...

Page 42: ...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 43: ...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 44: ...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 45: ...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 46: ... 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 47: ...39 ...

Page 48: ... Johnson Controls Inc USA LIT 12012177 Product improvement specifications and appearance in this manual are subject to change without prior notice ...

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