TROUBLESHOOTING. KSIO MINI Split DC Inverter Air Conditioner. Model Numbers:

Transcription

1 KSIO MINI Split DC Inverter Air Conditioner TROUBLESHOOTING Model Numbers: KSIO009-H24-I KSIO02-H23-I KSIO08-H22-I KSIO024-H29-I KWIO09-H2 KWIO2-H2 WARNING Installation MUST conform with local building codes or, in the absence of local codes, with the National Electrical Code NFPA70/ANSI C-993, or current edition and Canadian Electrical Code Part CSA C.22.. The information contained in this manual is intended for use by a qualified service technician familiar with safety procedures and equipped with the proper tools and test instruments. Installation or repairs made by unqualified persons can result in hazards to you and others. Failure to carefully read and follow all instructions in this manual can result in equipment malfunction, property damage, personal injury and/or death. This service manual is to be used only by a certified service technician.

2 9. Troubleshooting Safety Electric charge is still kept in capacitors even when the power supply is shut off. Do not forget to discharge the electric charge in capacitor. Electrolytic Capacitors (HIGH VOLTAGE! - CAUTION!) For other models, please connect discharge resistance (approx. 00Ω 40W) or soldering iron (plug) between, - terminals of the electrolytic capacitor on the contrary side of the outdoor PCB. te: The picture above is only for reference. The plug of your side may be different. 38

3 9. Indoor Unit Error Display Operation lamp Timer lamp Display LED STATUS time X E0 Indoor unit EEPROM parameter error 2 times X E Indoor / outdoor units communication error 3 times X E2 Zero-crossing signal detection error 4 times X E3 Indoor fan speed has been out of control 5 times X E4 6 times X E5 Indoor room temperature sensor T open circuit or short circuit Evaporator coil temperature sensor T2 open circuit or short circuit 7 times X EC Refrigerant leakage detection 2 times O F 3 times O F2 4 times O F3 Outdoor ambient temperature sensor T4 open circuit or short circuit Condenser coil temperature sensor T3 open circuit or short circuit Compressor discharge temperature sensor T5 open circuit or short circuit 5 times O F4 Outdoor unit EEPROM parameter error 6 times O F5 Outdoor fan speed has been out of control times P0 IPM malfunction or IGBT over-strong current protection 2 times P Over voltage or over low voltage protection 3 times P2 High temperature protection of compressor top diagnosis and solution(only for 9k,2k models) 5 times P4 Inverter compressor drive error Olight Xoff flash 39

4 9.2 Outdoor unit error display For KSIO009-H24-I, KSIO02-H23-I: 40

5 . Problems LED 2 (Green) LED (Red) IU display Standby for normal O X 2 Operation normally X O 3 IPM malfunction or IGBT over-strong current protection X P0 4 Over voltage or too low voltage protection O O P 5 Over voltage or too low voltage protection O P 6 Inverter compressor drive error X P4 7 Inverter compressor drive error O P4 8 Inverter compressor drive error P4 4

6 KSIO08-H22-O T3.5AL/250VAC CN3 E2 FUSE2 T20AL/250VAC PTC PTC2 HEAT-N RY4 CN4 HEAT-L RY2 RY3 BLUE 4-WAY-N CN33 4-WAY-N L-OUT ZR2 R55 RY CN3 C64 E5 FUSE E3 CN32 E4 CN8 CN9 CN7 CN6 C3 L-IN CN2 ZR3 CN37 CN4 CompTop PMV CN2 C5 D7 CN30 R38 BROWN C2 R95 HuiQi L R8 T C N-IN CN R83 R9 CN3 CN20 C8 R47 DAS CN38 R82 D9 E25 R37 Q R40 E4 R30 R3 R43 IC8 R9 R2 R45 ZR Q2 IC0 R56 C22 IC C24 D4 E23 PaiQi D R4 CN S DZ R20 R60 R44 IC203 CN6 R208 C26 R207 IC202 R23 IC9 C23 C208 E7 E204 R48 R22 R46 TEMP IC7 R204 R42 R5 R209 R2 D206 C23 C53 R54 R203 Q3 R39 R62 CN5 C6 C C24 C205 C206 C202 C204 R6 R27 IC20 R205 R20 E8 R50 R49 C9 E24 D2 D203 D202 E202 R202 IC3 C52 E20 C29 C38 T20 C49 R59 C36 C4 E 6 7 R70 R53 C3 R7 R20 C20 C209 R69 IC5 D204 R79 R76 R67 D205 D0 C68 R206 D20 R26 C203 R68 R80 C72 CN34 C2 R74 C62 YELLOW D209 E203 C45 X C42 C4 IC8 C7 CN36 D207 E207 E3 IC4 R94 C63 D208 R25 R24 LED3 C73 R92 R93 C20 C4 C47 IC6 LED4 C69 R64 R90 R89 E28 R65 R77 C56 LED2 LED E206 R27 IC3 R28 CN22 R29 C60 C6 TestPort CN2 PCPort CN24 IC9 C20 C30 CE-KFR26W/BP3N(PMV)-20.D.3.WP2-24LC04 IC7 OSC R63 R66 R73 R75 R78 R R2 24LC256 C37 C40 C39 RED CN25 IC5 C50 E6 R57 C5 R36 E8 C58 R52 DZ2 IC6 C2 R35 R34 IC2 C8 E5 C25 C28 C59 CN26 R33 C7 E27 BR2 R32 C65 C27 C66 R04 E26 D6 D7 D5 R0 R87 C54 R84 C55 R02 R0 R09 R07 R08 R06 R58 R72 C44 C43 C48 C70 R86 CN7 U CN8 E2 V E20 CN9 W R03 R05 R9 C57 R D R8 E22 C67 C33 C46 E9 C35 RED CN28 BLUE BROWN CN29 C34 R88 R85 C32 CN27 YELLOW IPM U V W N BR CN35 VB VB2 VB3 P U V W U- V- W- FAULT ISO 7V VSS LED2 LED2 on and LED off (standby) LED2 off and LED on (running) LED other status (error) LED4 LED3 power light when power is on, LED4 aways on Flashing once per second(low speed flashing) (standby) Flashing once per half second (high speed flashing) (error) aways on (running). Problems LED2 (Green) LED (Red) IU display standby for normal O X 2 Operation normally X O 3 IPM malfunction or IGBT over-strong current protection X P0 4 Over voltage or too low voltage protection O O P 5 Over voltage or too low voltage protection O P 6 Inverter compressor drive error X P4 7 Inverter compressor drive error O P4 8 Inverter compressor drive error P4 Olight Xoff 2.5Hz flash 42

7 43 KSIO024-H29-O P E Q L-OUT CE-KFR80W/BP3T4N(DC MOTOR)-30.D.03.WP- DC MOTOR 7V N- N- S P RUN LED (standby) Flashing once per second(low speed flashing) (error) Flashing once per half second (high speed flashing) (running) aways on P P2 FUSE T5A 250VAC D34 D33 D32 D3 CN28 Q5 CN5 N Q CN39 C83 C82 C8 C80 CN37 R8 R7 R6 R5 R4 R3 R2 R R98 L30 IC32 IC30 IC8 E33 E3 E28 E27 DZ D30 CN38 SW CN5 T2B CN27 PFC-CONTROL CN26 TestPort R0 R09 R08 R07 R06 R05 R04 R03 R97 R57 R56 R55 IC9 D28 D27 C79 C78 R77 DSP R46 E7 E8 E C77 C76 C75 C74 C73 C72 D C7 IC R87 IC5 D2 ZR3 ZR2 ZR RY4 RY3 RY2 RY R02 R0 R00 R99 R96 R95 R94 R93 R92 R9 R90 R89 R88 R86 R85 R84 R83 R82 R8 R80 R79 R78 R76 R75 R74 R73 R72 R7 R70 R69 R68 R67 R66 R65 R64 R63 R62 R6 R60 R59 R58 R54 R53 R52 R5 R50 R49 R48 R47 R45 R44 R42 R4 R40 R39 R38 R37 R36 R35 R34 R33 R32 R3 R30 R29 R28 R27 R26 R25 R24 R23 R22 R2 R20 R9 R8 R7 R6 R5 R4 R3 R R0 R9 R8 R7 R6 R5 R4 R3 R2 R Q4 Q3 Q2 PTC P- GND IC6 IC4 IC3 IC2 IC IC0 IC8 IC7 IC5 IC4 IC3 IC2 FUSE2 T30A 250VAC E3 E2 E0 E9 E6 E4 E2 E D9 D8 D7 D6 D4 D3 D2 D D0 D9 D8 D7 D6 D5 D4 D3 CT CONdebug CN25 S-A CN24 D CN23 S-B CN22 C CN2 TO-DRIVE CN20 S-C CN9 B CN8 A CN7 T3/T4 CN6 S-D CN4 LOW/HIGH CN2 CompTop CN7 PAI QI C59 C58 C57 C56 C55 C54 C53 C5 C49 C47 C46 C45 C44 C43 C42 C4 C40 C39 C38 C37 C36 C35 C34 C33 C32 C3 C30 C29 C28 C27 C26 C25 C24 C23 C22 C2 C20 C9 C8 C7 C6 C5 C4 C3 C2 C0 C9 C AS D20 D5 C60 C6 C62 C63 C64 C65 C66 C67 C68 C69 C70 E4 E5 IC6 X IC7 C8 C7 C6 L L2 CN2 N CN8 N CN 4-WAY CN6 HEAT CN9 HEAT2 CN3 L-IN CN4 N-IN CN29 N-OUT CN0 R20 LED C52 C48 C5 C3 C4 C2 C84 C C85 P-2 GND

8 9.3 Diagnosis and Solution 9.3. EEPROM parameter error diagnosis and solution (E0/F4) Error Code E0/F4 Malfunction decision conditions Indoor or outdoor PCB main chip does not receive feedback from EEPROM chip. Supposed causes Installation mistake Trouble shooting: Shut off the power supply and turn it on 5 seconds later. Is it still displaying the error code? PCB faulty If the EEPROM chip is welded on main PCB, replace the main PCB directly. Otherwise, check whether the EEPROM chip plugged in main PCB well? Correct the connection. Replace the main PCB. EEPROM: a read-only memory whose contents can be erased and reprogrammed using a pulsed voltage. For the location of EEPROM chip, please refer to the below photos. Indoor PCB Outdoor PCB (8k model) te: The two photos above are for reference only; it may be not the same with the ones on your side. 44

9 9.3.2 Indoor / outdoor unit s communication diagnosis and solution (E) Error Code E Malfunction decision conditions Supposed causes Wiring mistake Trouble shooting: Indoor unit does not receive the feedback from outdoor unit during 0 seconds and this condition happens four times continuously. Power off, then turn on the unit 5 seconds later(reconnect the power wire ).Is the error still displaying after several minutes? Indoor or outdoor PCB faulty Measure Vs, is it moving alternately with positive value? (Vs is the voltage between L2 and S of outdoor unit. Connect the red pin of multimeter with L2 port, black pin with S port) Check all the wiring with outdoor units. Is the wiring to the outdoor main PCB connect ed correctly? Is the reactor connected well? Measure the resistance of the reactor(the one without capacitor ). If it is zero,follow the below step. If not, replace a new reactor. Check all the wiring with indoor units. Is the wiring to the indoor main PCB connected correctly? Replace the outdoor main PCB. Replace the indoor main PCB. Power on. Is the error extinguished? Power on. Is the error extinguished? Replace the indoor main PCB. Replace the outdoor main PCB. 45

10 Remark: Use a multi-meter to test the DC voltage between L2 port and S port of outdoor unit. The red pin of multi-meter connects with L2 port while the black pin is for S port. When AC is running normal, the voltage will move alternately between -50V to 50V. If the outdoor unit is malfunctioning, the voltage will move alternately with positive value. If the indoor unit has malfunction, the voltage will be a certain value. Remark: Use a multi-meter to test the resistance of the reactor which does not connect with capacitor. The normal value should be around zero ohm. Otherwise, the reactor must have malfunction and need to be replaced. 46

11 9.3.3 Zero crossing detection error diagnosis and solution (E2) Error Code E2 Malfunction decision conditions When PCB does not receive zero crossing signal feedback for 4 minutes or the zero crossing signal time interval is abnormal. Probable causes Connection mistake Trouble shooting: PCB faulty Check if the connections and power supply is normal? Correct the connections. Turn on the unit when the power supply is good. Indoor main PCB is defective. Replace indoor main PCB. 47

12 9.3.4 Fan speed has been out of control diagnosis and solution (E3) Error Code E3 Malfunction decision conditions When indoor fan speed keeps too low (300RPM) for certain time, the unit will stop and the LED will display the failure. Probable causes Wiring mistake Trouble shooting: Fan assembly faulty Fan motor faulty PCB faulty Shut off the power supply and turn it on 5 seconds later. Is it still displaying the error code? The unit operates normally. Shut off the power supply, rotate the fan by hand. Does it rotate properly? Find out the cause and have it solved. For example, check whether the fan is blocked or the bearing is broken? Check the wires of fan motor. Are all the connections good? Correct the connections. Check whether the fan motor is normal through index? Replace the fan motor If the malfunction is still existing, replace the main PCB Check whether the main PCB is normal through index 2? Replace the main PCB. The malfunction is solved? 48

13 Index :. Indoor or Outdoor DC Fan Motor (control chip is in fan motor) Measure the resistance value of each winding by using the tester. If any resistance value is zero, the fan motor must have problems and need to be replaced. Index2: : Indoor or Outdoor DC Fan Motor (control chip is in fan motor) Power on and when the unit is in standby, measure the voltage of pin-pin3, pin4-pin3 in fan motor connector. If the value of the voltage is not in the range showing in below table, the PCB must have problems and need to be replaced. DC motor voltage input and output NO. Color Signal Voltage Red Vs/Vm 280V~380V Black GND 0V 4 White Vcc 4-7.5V 5 Yellow Vsp 0~5.6V 6 Blue FG 4-7.5V 49

14 2. Outdoor DC Fan Motor (control chip is in outdoor PCB) NO Color Orange Grey White Pink Black Signal Hu Hv Hw Vcc GND Color Red Blue Yellow Signal W V U ) Release the UVW connector. Measure the resistance of U-V, U-W, and V-W. If the resistance is not equal to each other, the fan motor must have problems and need to be replaced. Otherwise, go to step 2. 2) Power on and when the unit is in standby, measure the voltage of pin4-5 in feedback signal connector. If the value is not 5V, change the PCB. Otherwise, go to step 3. 3) Rotate the fan by hand, measure the voltage of pin-5, pin 2-5 and pin 3-5 in feedback signal connector. If any voltage is not positive voltage fluctuation, the fan motor must has problems and need to be replaced. 50

15 9.3.5 Open circuit or short circuit of temperature sensor diagnosis and solution (E5) Error Code E5 Malfunction decision conditions If the sampling voltage is lower than 0.06V or higher than 4.94V, the LED will display the failure. Probable cause Wiring mistake Sensor faulty PCB faulty Trouble shooting: Check the connections between temperature sensor and main PCB. Are the connections good? Correct the connections. Check the resistance value of the sensor via table(p64)and table 2(p65), is it normal? Replace indoor or outdoor main PCB. Replace the sensor and check if the problem happen again? 5

16 9.3.6 Refrigerant Leakage Detection diagnosis and solution (EC) Error Code EC Malfunction decision conditions Define the evaporator coil temp.t2 of the compressor just starts running as Tcool. During the first 5 minutes after the compressor starts up, if T2 Tcool3.6 F does not keep continuous for 4 seconds and this situation happens 3 times, the display area will show EC and the AC will turn off. Probable cause T2 sensor faulty Indoor PCB faulty System problems, such as leakage or blocking. Trouble shooting: Shut off the power supply and turn it on 5 seconds later. Is it still displaying the error code? Is there cool air blowing out from indoor air outlet? Check if T2 sensor is well fixed. Correct the installation or replace T2 sensor. Does the problem remain again? Replace indoor PCB. Is there any leakage? Especially the connection parts, such as the gas valve and the liquid valve. Repair the leakage and recharge the refrigerant. Is there any blocking? (Such as the capillary or the welded points of the pipes.) Clear the blocking. 52

17 9.3.7 IPM malfunction or IGBT over-strong current protection diagnosis and solution (P0) Error Code P0 Malfunction decision conditions When the voltage signal that IPM send to compressor drive chip is abnormal, the display LED will show P0 and AC will turn off. Probable cause Wiring mistake Trouble shooting: IPM malfunction Outdoor fan assembly faulty Compressor malfunction Outdoor PCB faulty Check if the wiring between main PCB and compressor connected by error and if the wires and connectors are broken? Correct the connection or replace the wires and connectors. IPM continuity check. Check if the IPM terminal resistance values are uniform. Refer to page 64. Replace the IPM board or replace the main PCB if the IPM board and main PCB are integrated together. Check if the outdoor fan runs properly or the outdoor unit ventilation is good. please refer to the solution of fan speed is out of control. Check if the compressor resistance values are uniform.refer to page 63. Replace the compressor. Replace the outdoor main PCB if the main PCB and IPM are separate. 53

18 Take the 9k model as example: P-U P-V 54

19 P-W N-U 55

20 N-V N-W 56

21 9.3.8 Over voltage or too low voltage protection diagnosis and solution (P) Error Code P Malfunction decision conditions An abnormal voltage rise or drop is detected by checking the specified voltage detection circuit. Probable cause Power supply problems. Trouble shooting: System leakage or block PCB faulty Check if the power supply is normal. Disconnect the unit with power supply and try to restart the unit when power supply gets normal. Check if all the connections and wires are good? Correct the connections or replace the wires. Power on and when the unit is in standby, check if the voltage between P and N is around DC 30V or 340V or 380V? For different kinds of units, the voltage differs. Consult with technical engineer to get definite value. Then start up the unit, measure the voltage between P and N. Is it in 220V~400V? Replace the IPM board if it is separate with main PCB. Replace outdoor main PCB. Remark: Measure the DC voltage between P and N port. The normal value should be around 30V. P N 57

22 9.3.9 High temperature protection of compressor top diagnosis and solution (P2) Error Code P2 Malfunction decision If the sampling voltage is not 5V, the LED will display the failure. conditions Probable cause Power supply problems. Trouble shooting: System leakage or block PCB faulty Check if the air flow system of indoor and outdoor units are obstructed? Clear up the air inlet and outlet or the heat exchanger of indoor and outdoor units. Turn off the power supply and turn it on 0 minutes later. Check if the unit can start normally. Check if all the connection, especially the connection of OLP (Over Load Protector) sensor is good. Correct the connection. Check if the refrigerant charge volume is normal? Measure the resistance between the two ports of the OLP. Is it zero? Replace the OLP. Replace the outdoor control PCB. Recharge the correct refrigerant volume. Refrigerant system is blocked, such as capillary or welded point of pipes. 58

23 9.3.0 Inverter compressor drive error diagnosis and solution (P4) Error Code P4 Malfunction decision conditions An abnormal inverter compressor drive is detected by a special detection circuit, including communication signal detection, voltage detection, and compressor rotation speed signal detection and so on. Probable cause Wiring mistake Trouble shooting: IPM malfunction Outdoor fan assembly faulty Compressor malfunction Outdoor PCB faulty Check if the wiring between main PCB and compressor connected by error and if the wires and connectors are broken? Correct the connection or replace the wires and connectors. IPM continuity check. Check if the IPM terminal resistance values are uniform. Refer to page 64. Replace the IPM board or replace the main PCB if the IPM board and main PCB are integrated together. Check if the outdoor fan runs properly or the outdoor unit ventilation is good. please refer to the solution of fan speed is out of control. Check if the compressor resistance values are uniform.refer to page 63. Replace the compressor. Replace the outdoor main PCB if the main PCB and IPM are separate. 59

24 Main parts check. Temperature sensor checking Disconnect the temperature sensor from PCB, measure the resistance value with a tester. Temperature sensors Room temperature sensor (T) Indoor coil temperature sensor (T2) Outdoor coil temperature sensor (T3) Outdoor ambient temperature sensor (T4) Compressor discharge temperature sensor (T5) Measure the resistance value of each winding by using the multi-meter. 60

25 Appendix Temperature Sensor Resistance Value Table for T, T2, T3, T4 ( C--K) C F K Ohm C F K Ohm C F K Ohm C F K Ohm

26 Appendix 2 Temperature Sensor Resistance Value Table for T5 ( C --K) C F K Ohm C F K Ohm C F K Ohm C F K Ohm

27 Appendix 3: T() = 9 T() 5 C F C F C F C F C F

28 2. Compressor checking Measure the resistance value of each winding by using the tester. Position Resistance Value DA0SC-30FZ DA30MC-3FZ DA250S2C-30MT Blue - Red 0.8Ω.77Ω 0.55Ω Blue - Black Red - Blue 68 F 68 F 68 F 64

29 3. IPM continuity check Turn off the power, let the large capacity electrolytic capacitors discharge completely, and dismount the IPM. Use a digital tester to measure the resistance between P and UVWN; UVW and N. Digital tester rmal resistance value Digital tester rmal resistance value ()Red (-)Black ()Red (-)Black P N U U V V (Several MΩ) W W ()Red N (Several MΩ) 4: Indoor AC Fan Motor Measure the resistance value of each winding by using the tester. Position Black - Red White - Black Resistance Value RPG3B 00.5Ω±8% 00Ω±8% 68 F 68 F (Brand: Weiling) (Brand: Dayang) 64.5Ω±8% 68.5Ω±8% 68 F 68 F (Brand: Weiling) (Brand: Dayang) 65

30 5: Pressure on Service Port Cooling chart: F ODT IDT BAR 70/ BAR 75/ BAR 80/ F ODT IDT PSI 70/ PSI 75/ PSI 80/ F ODT IDT MPA 70/ MPA 75/ MPA 80/ ,0 0,0 8,0 6,0 4,0 70/59 75/63 80/67 2,0 0,

31 Heating Chart: F ODT IDT 57/53 47/43 37/33 27/23 7/3 BAR BAR BAR F ODT IDT 57/53 47/43 37/33 27/23 7/3 PSI PSI PSI F ODT IDT 57/53 47/43 37/33 27/23 7/3 MPA MPA MPA ,0 35,0 30,0 25,0 20,0 5,0 0, ,0 0,0 57/53 (3.89/.67) 47/43 (8.33/6.) 37/33 (2.78/0.56) 27/23 (-2.78/-5) 7/3 (-8.33/-0.56) 67

32 The Klimaire logo is a registered Trademark of Klimaire Products inc. Copyright 206 Klimaire Products Inc. 290 NW 89 Place, Doral, FL USA Tel: (305) Fax (305) sales@klimaire.com The design and specifications are subject to change without prior notice for product improvement. Consult with the sales agency or manufacturer for details.