Johnson Controls Z Series Installation And Maintenance Manual Download Page 10 | Manualshive

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Installation and Maintenance

2.2

Main Tools for Installation and Maintenance

1. Level meter, measuring 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

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Summary of Contents for Z Series

Page 1: ...ONING UNITS PLEASE READ AND UNDERSTAND THIS MANUAL BEFORE USING THIS INVERTER DRIVEN AIR CONDITIONING UNIT KEEP THIS MANUAL FOR FUTURE REFERENCE 1DOOR UNIT6 DHZ09NWB21S DHZ12NWB21S DHZ18NWB21S 287 225 81 76 DHZ09CSB21S DHZ12CSB21S DHZ18CSB21S Type Model Model Type 03257 17 ...

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: ... Leak Detection 8 2 10 Post Installation Testing 8 3 Maintenance 9 3 2 Error Code List 10 3 3 Procedures of Troubleshooting 17 3 4 Troubleshooting for Normal Malfunction 41 Appendix 43 Appendix 1 Reference Sheet of Celsius and Fahrenheit 43 Appendix 2 Configuration of Connection Pipe 43 Appendix 3 Pipe Expanding Method 44 Appendix 4 List of Resistance for Temperature Sensor 45 2 2 MainTools forIns...

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: ...to the wall At least 5 7 8 inch At least 98 7 16 inch At least 5 7 8 inch At least 5 7 8 inch At least 118 inch 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 Atleast1113 16inch At least 19 11 16 inch At least 11 13 16 inch At least 78 5 8 inch ...

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...

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Page 13: ...SLSH RI LQGRRU XQLW V VKRZn LQ LJ LQG WKH MRLQW ZLWK WDSH V VKRZn LQ LJ 4 Outlet Pipe 7KH SLSH FDQ EH OHG RXW LQ WKH GLUHFWLRQ RI ULJKW UHDU ULJKW OHIW RU UHDU OHIW V VKRZn LQ LJ KHQ VHOHFWLQJ OHDGLQJ RXW WKH SLSH IURP OHIW RU ULJKW SOHDVH FXW RII WKH FRUUHVSRQGLQJ KROH RQ WKH ERWWRP FDVH V VKRZn LQ LJ 2SHQ D SLSLQJ KROH ZLWK WKH GLDPHWHU RI RU LQFK RQ WKH VHOHFWHG RXWOHW SLSH SRVLWLRQ Q RUGHU WR ...

Page 14: ...HQJWK RI condensate KRVH DQG SRZHU FRUG IRU LQVWDOODWLRQ ZKHQ ELQGLQJ WKHP KHQ ELQGLQJ WR D FHUWDLQ GHJUHH VHSDUDWH WKH LQGRRU SRZHU DQG WKHQ VHSDUDWH WKH condensate KRVH V VKRZn LQ LJ LQG WKHP HYHQO 7KH OLTXLG SLSH DQG JDV SLSH VKRXOG EH ERXQG VHSDUDWHO DW WKH HQG 9 Hang the Indoor Unit 3XW WKH ERXQG SLSHV LQ WKH ZDOO SLSH DQG WKHQ PDNH WKHP SDVV WKURXJK WKH ZDOO KROH DQJ WKH LQGRRU XQLW RQ WKH Z...

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Page 16: ...tect any leak Apply soap water to the suspected leak position and observe for 3 minutes if bubbles appear then there is a leak 2 9 Vacuum Pump Leak Detection NO WHPV WR EH FKHFNHG 3RVVLEOH PDOIXQFWLRQ 1 DV WKH XQLW EHHQ LQVWDOOHG UPO 7KH XQLW PD GURS VKDNH RU emit noise 2 DYH RX GRQH WKH UHIULJHUDQW OHDNDJH WHVW W PD FDXVH LQVXI FLHQW FRROLQJ KHDWLQJ FDSDFLW 3 V KHDW LQVXODWLRQ RI SLSHOLQH VXI FLH...

Page 17: ...tenance is needed follow the steps below to discharge electricity of electrolytic capacitor after power off 1 Open the top cover of outdoor unit and then remove the cover of the electric box 3 After finishing discharging electricity measure the voltage between points A and B with universal meter to make sure if electricity discharging is completed in order to prevent electric shock If the voltage ...

Page 18: ...unction analysis discharge protection overload 5 Overcurrent protection E5 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 Always During cooling operation co...

Page 19: ...maged 14 Outdoor ambient temperature sensor is open short circuited F3 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 hasn t been connected well or is damaged Please check it by referring to the resistance table for temperature sensor 15 Outdoor condens...

Page 20: ...e unit will stop operation 1 Measure the voltage of position L and N on wiring 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 ...

Page 21: ...alysis of capacitor 29 Malfunction of module temperature sensor circuit P7 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 During cooling operation compressor will stop while indoor fan will operate During heating operation the compl...

Page 22: ... contact of DC motor control end 3 Fan motor is stalling 4 Motor malfunction 5 Malfunction of mainboard rev detecting circuit 38 Desynchro nizing of compressor H7 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 ove...

Page 23: ... voltage is unstable 46 Malfunction of complete units current detection U5 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 If this malfunction o...

Page 24: ...OFF 0 5s Operation Indicator Cool Indicator Heating Indicator Yellow Indicator Red Indicator Green Indicator 53 Normal communica tion 54 55 Defrosting U8 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 The complete unit stops operation Its the normal sta...

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Page 26: ...inated 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 is 1...

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Page 29: ... 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 Replace communication cord Replace ODU s main board Malfunction eliminated Malfunction eliminated Malfunction eliminated Yes Yes Yes Yes No no No Yes Y...

Page 30: ...tdoor mainboard AP1 Replace outdoor mainboard Measure the voltage input with AC voltmeter see fig 30 Voltage within 180VAC 260VAC Shut down the power and wait 20 minutes or use DC voltmeter to measure the voltage on the two ends of electrolytic capacitor until the voltage is lower than 20V Check the connection of reactor and connection wire If the wiring of reactor L is normal Replace outdoor main...

Page 31: ...LV KHDY I UDGLDWLQJ RI XQLW LV JRRG 0DOIXQFWLRQ GLDJQRVLV SURFHVV N H5 H7 or P5 is displayed after turning on the unit Measure if the voltage input is within 180 265V with AC voltmeter see fig 30 The compressor is well connected with mainboard AP1 Heat exchanger is blocked with dirt Clean the heat exchanger to improve its performance Restart the unit Restart the unit Restart the unit Restart the u...

Page 32: ...re is higher than 53 Normal protection please use it after improving the outdoor ambient temperature Unit restarts normally Unit restarts normally If the radiating of indoor and outdoor unit is good Improve the radiating environment of unit clean the heat exchanger and remove surrounding obstacles If the indoor and outdoor fan are running normally Connect normally Adjust the connection Replace out...

Page 33: ...w pressure of system is not balanced please start the unit after 3min If the compressor wire COMP UVW is well connected and connection sequence is correct Check the connection situation of outdoor mainboard AP1 and compressor COMP and the connect it according to wiring diagram If the refrigerant charging amount is too much Does the unit start up normally Charge the refrigerant according to service...

Page 34: ...DJHG ƽ I WKH UHIULJHUDQW LV OHDNHG ƽ 7KH FRPSUHVVRU RYHUORDG SURWHFWLRQ WHUPLQDO LV QRW FRQQHFWHG ZHOO ZLWK WKH PDLQERDUG ƽ I WKH RYHUORDG SURWHFWRU LV GDPDJHG ƽ HDW H FKDQJH RI XQLW LV QRW JRRG KHDW H FKDQJHU LV GLUW DQG XQLW UDGLDWLQJ HQYLURQPHQW LV EDG ƽ 7RR PXFK ORDG RI WKH V VWHP FDXVHV KLJK WHPSHUDWXUH RI FRPSUHVVRU DIWHU ZRUNLQJ IRU D ORQJ WLPH ƽ 0DOIXQFWLRQ RI GLVFKDUJH WHPSHUDWXUH VHQVRU ...

Page 35: ...ompressor overload protection terminal is not connected well with the mainboard reconnect them correctly Heat exchange of unit is not good heat exchanger is dirty and unit radiating environment is bad improve the radiating environment and clean the heat exchanger Too much load of the system causes high temperature of compressor after working for a long time decrease the load for operation Is the m...

Page 36: ...nnect the plug correctly Check the connection wire between reactor mainboard and situation of connection If there is short circuit or the connection wire is loose Reconnect the wire or replace the connection wire according to the wiring diagram Check the surface of reactor coil If it is damaged Replace the reactor Power on and restart the unit Power on and restart the unit Replace outdoor mainboar...

Page 37: ...malfunction Check built in wiring of indoor and outdoor unit If the wiring is damaged Replace the wire Check the malfunction type with communication malfunction detector Malfunction of outdoor communication circuit Replace outdoor mainboard AP1 Replace indoor mainboard AP2 Is the malfunction eliminated Is the malfunction eliminated End Check the connection wire according to the wiring diagram Reco...

Page 38: ...ectrolytic capacitor of power DC 180V 380V Test 5 Two ends of diode D15 30 PRGXODU 9 SRZHU VXSSO DC 14 5V 15 6V Test 6 Two ends of electrolytic capacitor C715 9 SRZHU VXSSO DC 12V 13V Test 7 Two ends of electrolytic capacitor C710 9 SRZHU VXSSO DC 5V Test 8 Two ends of electrolytic capacitor C226 9 SRZHU VXSSO DC 3 3V Test 9 7ZR HQGV RI FKLS FDSDFLWRU C912 9 SRZHU VXSSO DC 15V 18V Test 10 Between ...

Page 39: ...cuit 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 voltage on the two en...

Page 40: ...SUHVVRU 203 LV ZHOO FRQQHFWHG I WKH DUH ORRVHQHG I WKH FRQQHFWLRQ VHTXHQFH LV FRUUHFW Ɣ V YROWDJH LQSXW LQ WKH QRUPDO UDQJH 7HVW WKH YROWDJH EHWZHHQ 1 RI ZLULQJ ERDUG 7 E YROWDJH PHWHU Ɣ I FRLO UHVLVWDQFH RI FRPSUHVVRU LV QRUPDO V FRPSUHVVRU FRLO LQVXODWLQJ WR FRSSHU SLSH ZHOO Ɣ I WKH ZRUN ORDG RI XQLW LV KHDY I UDGLDWLQJ RI XQLW LV ZHOO Ɣ I WKH UHIULJHUDQW FKDUJLQJ LV DSSURSULDWH 0DOIXQFWLRQ GLDJ...

Page 41: ...2 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 connection order is wrong Connect the contr...

Page 42: ... 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 protec...

Page 43: ...s 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 No 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 diagram No ...

Page 44: ...f 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 Yes No No No Yes Yes No Replace control board AP...

Page 45: ...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 Yes No No No If the overload protector SAT is well connected No Under ambient temperature test the resistance of overlo...

Page 46: ...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 board AP1 Yes Yes No N...

Page 47: ...tion 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 malfunction Yes N Y No If...

Page 48: ...ing Outdoor unit malfunction Test voltage value with Test 13 position in diagram with voltage meter Number jumping Test voltage value with Test 11 position in diagram with voltage meter Number jumping Test voltage value with Test 12 position in diagram with voltage meter Yes Yes Yes Yes Number jumping The circuit of outdoor unit communication is normal Yes No No No N End No ...

Page 49: ...tails 0DOIXQFWLRQ RI FRPSUHVVRU RPSUHVVRU FDQ W RSHUDWH 5HIHU WR SRLQW RI PDLQWHQDQFH PHWKRG IRU details 3 4 Troubleshooting for Normal Malfunction 1 Air Conditioner Doesn t Start 2 Poor Cooling Heating for Air Conditioner 3 Horizontal Louver Doesn t Swing 3RVVLEOH DXVHV LVFULPLQDWLQJ 0HWKRG LU CRQGLWLRQHU 6WDWXV 7URXEOHVKRRWLQJ 1R SRZHU VXSSO RU SRRU FRQQHFWLRQ IRU SRZHU SOXJ IWHU HQHUJL DWLRQ RS...

Page 50: ...densate SLSH Replace drain pipe UDSSLQJ LV QRW WLJKW DWHU OHDNLQJ IURP WKH SLSH FRQQHFWLRQ SODFH RI LQGRRU XQLW UDS LW DJDLQ DQG EXQGOH LW WLJKWO 5 Compressor Doesn t Operate 3RVVLEOH FDXVHV LVFULPLQDWLQJ MHWKRG ALU CRQGLWLRQHU StDWXV 7URXEOHVKRRWLQJ URQJ ZLUH FRQQHFWLRQ RU SRRU connection KHFN WKH ZLULQJ VWDWXV DFFRUGLQJ WR FLUFXLW diagram Connect wires according to wiring diagram to PDNH VXUH DO...

Page 51: ...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 10 73 74 73 4 23 97 98 96 8 36 ...

Page 52: ...teps 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 pipe E E...

Page 53: ... 10 63 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 8...

Page 54: ... 61 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 8...

Page 55: ...74 62 11 32 101 3 22 15 362 9 24 51 41 63 10 93 102 3 129 14 342 8 25 49 19 64 10 54 103 3 04 13 323 9 26 47 08 65 10 18 104 2 955 12 306 2 27 45 07 66 9 827 105 2 872 11 289 6 28 43 16 67 9 489 106 2 792 10 274 29 41 34 68 9 165 107 2 715 9 259 3 30 39 61 69 8 854 108 2 64 8 245 6 31 37 96 70 8 555 109 2 568 7 232 6 32 36 38 71 8 268 110 2 498 6 220 5 33 34 88 72 7 991 111 2 431 5 209 34 33 45 73...

Page 56: ...48 ...

Page 57: ... Johnson Controls Inc USA LIT 12012158 Product improvement specifications and appearance in this manual are subject to change without prior notice ...

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