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CAUTION
Before Servicing the unit, read the safety precautions in General SVC manual.
Only for authorized service personnel.
Air Conditioner Service Manual
CONTENTS
Part 1 General Information
1. Safety Precautions........................................................................................................3
2. Nomenclature ...............................................................................................................6
2. Nomenclature......................................................................................................................6
1. Safety Precautions
To prevent injury to the user or other people and property damage, the following instructions must be followed.
■ Incorrect operation due to ignoring instruction will cause harm or damage. The seriousness is classified by the follow-
ing indications.
Dangerous Voltage
Be sure to disconnect the power cable plug from the plug socket before disas-
sembling the equipment for a repair.Internal components and circuit boards are at
main potential when the equipment is connected to the power cables. This volt-
age is extremely dangerous and may cause death or severe injury if come in con-
tact with it.
Do not touch the discharging refrigerant gas during the repair work.
The discharging refrigerant gas.The refrigerant gas can cause frostbite.
When the refrigerant gas leaks during work, execute ventilation. If the refrigerant
gas touches to a fire, poisonous gas generates. A case of leakage of the refriger-
ant and the closed room full with gas is dangerous because a shortage of oxygen
occurs. Be sure to execute ventilation.
When removing the front panel or cabinet, execute short-circuit and discharge
between high voltage capacitor terminals. If discharge is not executed, an electric
shock is caused by high voltage resulted in a death or injury.
Do not use a defective or underrated circuit breaker. Use the correctly rated
breaker and fuse. Otherwise there is a risk of fire or electric shock.
Install the panel and the cover of control box securely. Otherwise there is risk of
fire or electric shock due to dust, water etc.
Indoor/outdoor wiring connections must be secured tightly and the cable should
be routed properly so that there is no force pulling the cable from the connection
terminals. Improper or loose connections can cause heat generation or fire.
Do not touch, operate, or repaire the product with wet hands. Hoding the plug by
hand when taking out. Otherwise there is risk of electric shock or fire.
Do not turn on the breaker under condition that front panel and cabinet are
removed.
Be sure to earth the air conditioner with an earthing conductor connected to the
earthing terminal.
Conduct repair works after checking that the refrigerating cycle section has
cooled down sufficiently. Otherwise, working on the unit, the hot refrigerating
cycle section can cause burns.
Do not tilt the unit when removing panels. Otherwise, the water inside the unit
can spill and wet floor.
Do not use the welder in a well-ventilated place. Using the welder in an enclosed
room can cause oxygen deficiency.
Be sure to turn off power switch before connect or disconnect connector, or parts
damage may be occurred.
Check to see if the power cable plug is not dirty or loose. If the plug is dust or
loose it can cause an electrical shock or fire.
Do not use a joined power cable or extension cable, or share the same power
outlet with other electrical appliances. otherwise, it can cause an electrical shock,
excessive heat generation or fire.
Do not insert hands or other objects through the air inlet or outlet while the prod-
uct is operating. There are sharp and moving parts that could cause personal
injury.
Do not block the inlet or outlet of air flow. It may cause product failure
Check to see if the parts are mounted correctly and wires are connected.
Improper installation and connections can cause an electric shock or an injury.
Check the installation platform or frame has corroded. Corroded installation plat-
form or frame can cause the unit to fall, resulting in injury.
After the work has finished, be sure to do an insulation tset to check the resis-
tance is 2[Mohm] or more between the charge section and the non-charge metal
section (Earth position). If the resistance value is low, a disaster such as a leak or
electric shock is caused at user’s side.
Check the drainage of the indoor unit after the repair. If drainage is faulty the
water to enter the room and wet floor.
2. Nomenclature
1 2 - 3 4 5 6 7 8 9 10
Code Type Code of Model Meaning
Notes: The Exploded View part has the particular Function table for each model.
Notes: The Exploded View part has the particular Function table for each model.
+0.5°C. Thermo ON
Setting
Temp.
-0.5°C. Thermo OFF
INV. Comp.
High Low Comp. OFF High Low
Frequency
• Operating frequency of compressor depends on the load condition, like the difference between the room temp. and
the set temp., frequency restrictions.
• If the compressor operates at some frequency, the operating frequency of compressor cannot be changed within 30
seconds. ( not emergency conditions)
• Compressor turned off when
- intake air temperature is in between ±0.5°C of the setting temp. limit for three minutes continuously.
- intake air temperature reaches below 1.0°C of the temperature of setting temp..
• Compressors two minutes time delay.
- After compressor off, the compressor can restart minimum 2 minutes later.
+2°C. Thermo ON
Setting
Temp.
INV. Comp. High Low Comp. OFF High Low Comp. OFF
Frequency
• Operating frequency of compressor depend on the load condition, The difference between the room temp. and set
temp., frequency restrictions.
• If compressor operates at some frequency, the operating frequency of compressor cannot be changed within 30 sec-
onds.
• Condition of compressor turned off
- When intake air temperature reaches +4°C above the setting temperature.
• Condition of compressor turned on
- When intake air temperature reaches +2°C above the setting temperature.
* Condition of indoor fan turned off
- While in compressor on : indoor pipe temp. < 20°C
- While in compressor off : indoor pipe temp. < 30°C
• While in defrost control, between the indoor and outdoor fans are turned off.
• Compressor 2minutes delay
- After compressor off, the compressor can restart minimum 2 minutes later.
Notes: The Temp. of Thermo ON/OFF are different in heating mode and fuzzy operation for heating.
• When intake air temp. is 1 C above the setting temp., condition of compressor is same as in cooling mode operation.
• When intake air temperature reaches 1 C below the setting temp., compressor operates in step1~step3 and the indoor
fan speed again operates at low speed or comes to a stop.
Cooling Cooling
Mode Heating operation
operation operation
4. Utility Functions
4.1 Forced operation
• To operate the appliance by force in case when the remote control is lost, the forced operation selection switch is on
the main unit of the appliance, and operate the appliance in the standard conditions.
• The operating condition is set according to the outdoor temp. and intake air temperature as follows.
Setting speed of
Indoor temp. Operating Mode Setting temp.
indoor fan
ON
Unit
Operation OFF
ON
Indoor
Fan OFF
Setting step L Low OFF
ON
Comp.
OFF
Time
13~14 minutes 1 minute 2~3 minutes
• Air volume is controlled "SH", "H", "Med", "Low" by the remote con- LL Very low, In heating mode
troller. L Low
• "LL" step is selected automatically in Hot start operation. M Med
H High
SH Super high
Auto Natural wind
4.4 Natural Air Control(Auto Wind)
• When the Auto Step is selected and then operated, the high, medi-
um, or low speed of the airflow mode is operated for 2~15 sec. ran-
domly by the Chaos Simulation.
CLOSED
Mode 8
Mode 7
Mode 6 65°
Mode 5
Mode 4
Mode 3 20°
Mode 2 8°
Mode 1
OPEN
Cooling ON temp.
(Setting temp. +0.5˚C)
4.8 Preheat
• This is operation to preheat the compressor by conducting current through motor coils of the compressor for preventing
phenomena that liquid refrigerants are income due to difference between temperature of the outside pipe and tempera-
ture of the compressor as outdoor temperature becomes low.
• Enter preheat operation of the compressor if meeting , , conditions as below at the same time.
where outdoor temperature is less than 5°C
where discharge temperature of the compressor is more than 15°C
where the compressor turns off
COMP
Discharge Temerature
Preheat Off
25˚C
15˚C
Preheat On
10sec
ON
Tact S/W
OFF
Buzzer sound
ON
Operation LED OFF
Flickering 4 times
0.25sec
(1time)
When selecting additional heat Logic
+2°C. Thermo ON
Setting
Temp.
INV. Comp. High Low Comp. OFF High Low Comp. OFF
Frequency
Indoor pipe
Comp. free temp.
6˚C 7˚C
Comp. Step 4
3˚C
Comp. Step 2
T1
Comp. off
T1: 0 ~ 2°C
Starting step
EEV Setting
Open step
ON ON
4-Way
Setting OFF Setting
Outdoor Speed Speed
FAN
Hi Speed
Setting
Speed
Indoor
Hot Hot
FAN Start
OFF Starting
Pre-Heat ON
OFF OFF
LED
Deice STEP 0 1 2 3 4 5 6
5.7 Inverter
5.7.1 Inverter Control
U 3Ø
V Comp.
+ W
Motor
U V W
T2 °C
T1 °C
T on °C
COMP
Freq. Free Fc-1 Fc-2 Fc-1 Fc-2 OFF Free
T3 °C
T2 °C
T1 °C
-13 °C
COMP Freq. Fh min Free Fc-1 Fc-2 OFF Fc-2 Fc-1 Free
25
Comp Freq.
Cond . temp. Outdoor temp.:-10°C
20
Freq.
15
Temp.(°C)
Outdoor fan
10
On On Outdoor pipe temp. Outdoor fan On/Off control
° outdoor fan On/Off
0°C 5
Off Off control 0
0 50 100 150 200
°…
- 0°C Outdoor temp. -5
Time(Min.)
Check to see whether there is any refrigerant leakage, and check whether the power or transmission
1 cable is connected properly.
Check liquid pipe and gas pipe valves are fully opened.
2
NOTE: Be sure to tighten caps.
Confirm that 500 V megger shows 2.0 MΩ or more between power supply terminal block and
ground. Do not operate in the case of 2.0 MΩ or less.
NOTE: Never carry out mega ohm check over terminal control board.
Otherwise the control board may break.
3
Immediately after mounting the unit or after leaving it turned off for an extended length of
time, the resistance of the insulation between the power supply terminal board and the
ground maydecrease to approx. 2.0 MΩ as a result of refrigerant accumulation in the internal
compressor.
If the insulation resistance is less than 2.0 MΩ, turn on the main power supply.
START
Normal
Discharge
temperature
4. Trouble Shooting
1. 2-Way, 3-Way Valve.........................................................................................................29
4. Evacuation ......................................................................................................................32
7. Self Diagnosis.................................................................................................................35
Valve cap
Hexagonal wrench (4mm) Open position
Flare nut Flare nut Closed position
Open position
Pin
Closed position
To To
piping piping Service Service
connection connection port cap port
To outdoor unit To outdoor unit
2. Pumping Down
Gas side
Closed
3-Way
valve
Lo
CLOSE CLOSE
• Procedure
(6) Operate the air conditioner at the cooling
(1) Confirm that both the 2-way and 3-way valves cycle and stop it when the gauge indicates
are set to the open position. 1kg/cm2g.
– Remove the valve stem caps and confirm that
the valve stems are in the raised position. (7) Immediately set the 3-way valve to the closed
– Be sure to use a hexagonal wrench to operate position.
the valve stems. – Do this quickly so that the gauge ends up indi-
cating 3 to 5kg/cm2g.
(2) Operate the unit for 10 to 15 minutes.
(8) Disconnect the charge set, and mount the 2-
(3) Stop operation and wait for 3 minutes, then way and 3-way valve’s stem nuts and the ser-
connect the charge set to the service port of vice port nut.
the 3-way valve. – Use torque wrench to tighten the service port
– Connect the charge hose with the push pin to nut to a torque of 1.8 kg.m.
the service port. – Be sure to check for gas leakage.
Gas side
3-Way
valve Open
Vacuum pump
Lo Vacuum
Gage
OPEN
OPEN
• Procedure
(1) Connect the vacuum pump to the center hose (3) Close the valve (Lo side) on the charge set,
of charge set center hose turn off the vacuum pump, and confirm that
the gauge needle does not move (approxima-
(2) Evacuation for approximately one hour. tely 5 minutes after turning off the vacuum
– Confirm that the gauge needle has moved pump).
toward 0.8 Torr.
(4) Disconnect the charge hose from the vacuum
pump.
– Vacuum pump oil.
If the vacuum pump oil becomes dirty or
depleted, replenish as needed.
Gas side
Open
3-Way
Check valve valve
Charging
cylinder
Lo Vacuum
Gage
(1) OPEN
CLOSE
• Procedure
(1) Connect the charge hose to the charging This is different from previous procedures.
cylinder. Because you are charging with liquid refrigerant
– Connect the charge hose which you dis-con- from the gas side, absolutely do not attempt to
nected from the vacuum pump to the valve at charge with larger amounts of liquid refrigerant
the bottom of the cylinder. while operating the air conditioner.
– If you are using a gas cylinder, also use a
scale and reverse the cylinder so that the sys-
tem can be charged with liquid. (4) Immediately disconnect the charge hose from
the 3-way valve’s service port.
(2) Purge the air from the charge hose. – Stopping partway will allow the gas to be dis-
– Open the valve at the bottom of the cylinder charged.
and press the check valve on the charge set to – If the system has been charged with liquid
purge the air. (Be careful of the liquid refriger- refrigerant while operating the air conditioner
ant). The procedure is the same if using a gas turn off the air conditioner before disconnecting
cylinder. the hose.
(3) Open the valve (Lo side on the charge set and
charge the system with liquid refrigerant. (5) Mount the valve stem nuts and the service
– If the system can not be charged with the spec- port nut.
ified amount of refrigerant, it can be charged – Use torque wrench to tighten the service port
with a little at a time (approximately 150g each nut to a torque of 1.8 kg.m.
time) while operating the air conditioner in the – Be sure to check for gas leakage.
cooling cycle; however, one time is not suffi-
cient, wait approximately 1 minute and then
repeat the procedure (pumping down-pin).
5. Cycle Part
Trouble analysis
1. Check temperature difference between intake and discharge air, and check for the operating current too.
Case 1 Temp. difference : approx. 0°C All amount of refrigerant leaked out.
Current : less than 80% of rated current Check refrigeration cycle.
Case 2 Temp. difference : approx. 8°C Refrigerant leakage Clog of refrigeration cycle
Current : less than 80% of rated current Defective Compressor.
NOTICE
Temperature difference between intake and discharge air depends on room air humidity. When the room air humidity is
relativery higher, temperature difference is smaller. When the room air humidity is relatively lower temperature difference
is larger.
NOTICE
1. The suction pressure is usually 8.5~9.5kg/cm✒G(Cooling) at normal condition.(R410A)
2. The temperature can be measured by attaching the thermometer to the low pressure tubing and wrap it with putty.
6. Self Diagnosis
Error Display Indoor
Error Indicator Cause of Error
Code Indoor Outdoor Operation
1 time 1time 1time 1time 1time
• Indoor Temp. sensor error
1 - Sensor open or short O ON
3 sec 3 sec 3 sec 3 sec
5times 5times
• Communication error
5 O O OFF
3 sec 3 sec
6times 6times
• DC Peak error O O SHUT
6 3 sec DOWN
7times 7times
SHUT
7 • Over current error (CT2) O O
3 sec DOWN
8times 8times
• Indoor fan lock error
8 (BLDC fan model only) O OFF
3 sec
9times 9times
• Outdoor fan lock error
O O OFF
9 (BLDC fan model only)
3 sec
10 times 10 times
• D-Pipe TH. is short or open. O O ON
10
3 sec
CAUTION
START
Yes
Check the connecting cable No
Connect the cable Properly.
between Indoor and outdoor units.
Yes
Check the number of blinks on the
operation indicator or error code
on the display
(refer to the self-diagnosis
function).
Be sure to disconnect the power cable plug from the plug socket before disassembling the
equipment for a repair. Internal components and circuit boards are at main potential when the
equipment is connected to the power cables. This voltage is extremely dangerous and may
cause death or severe injury if come in contact with it.
Be sure to turn off power switch before connect or disconnect connector, or parts damage may
be occurred.
7. Electronic Parts
7.1 The Product doesn t operate at all
Be sure to disconnect the power cable plug from the plug socket before disassembling the
equipment for a repair. Internal components and circuit boards are at main potential when the
equipment is connected to the power cables. This voltage is extremely dangerous and may
cause death or severe injury if come in contact with it.
Be sure to turn off power switch before connect or disconnect connector, or parts damage may
be occurred.
Yes
Yes
Be sure to disconnect the power cable plug from the plug socket before disassembling the
equipment for a repair. Internal components and circuit boards are at main potential when the
equipment is connected to the power cables. This voltage is extremely dangerous and may
cause death or severe injury if come in contact with it.
Be sure to turn off power switch before connect or disconnect connector, or parts damage may
be occurred.
Yes
* Check Indoor TH.
Indoor TH. is working No
- Measure resistance of TH
properly? (air : about 10 kΩ at 25°C, .
pipe : about 5 kΩ at 25°C)
Yes
- If it is not, replace the thermistor.
Be sure to disconnect the power cable plug from the plug socket before disassembling the
equipment for a repair. Internal components and circuit boards are at main potential when the
equipment is connected to the power cables. This voltage is extremely dangerous and may
cause death or severe injury if come in contact with it.
Be sure to turn off power switch before connect or disconnect connector, or parts damage may
be occurred.
Yes
* Check outdoor TH.
Outdoor TH. is working No
- Measure resistance of TH.
properly? (air : about 10kΩ at 25°C,
pipe : about 5kΩ at 25°C)
Yes
- If it is not, replace the thermistor.
Yes
* If it is broken, replace outdoor unit
PCB
* The outdoor unit PCB still has some
problem.
* Replace outdoor unit PCB.
Be sure to disconnect the power cable plug from the plug socket before disassembling the
equipment for a repair. Internal components and circuit boards are at main potential when the
equipment is connected to the power cables. This voltage is extremely dangerous and may
cause death or severe injury if come in contact with it.
Be sure to turn off power switch before connect or disconnect connector, or parts damage may
be occurred.
Yes
No * Check heat-sink TH.
Heat-sink TH. in INV-IC
(or PCB) is operating properly? - Measure resistance of TH.
(about 10kΩ at 25°C)
Yes - If it is not, replace the thermistor.
Be sure to disconnect the power cable plug from the plug socket before disassembling the
equipment for a repair. Internal components and circuit boards are at main potential when the
equipment is connected to the power cables. This voltage is extremely dangerous and may
cause death or severe injury if come in contact with it.
Be sure to turn off power switch before connect or disconnect connector, or parts damage may
be occurred.
• Wrong wiring or missing wire between indoor and outdoor unit cable
• Defect of communication components in indoor unit PCB assembly
Supposed
• Defect of communication components in outdoor unit PCB assembly
Causes
• Defect of power supply components in outdoor unit PCB assembly
• No ground connection in air conditioner unit. (affected by noise in power source)
Indoor - Outdoor
Wiring connection between No 1(BR) - 1(BR)
Indoor unit and out door unit
2(BL) - 2(BL)
Is right ?
3(GN/YL) - 3(GN/YL)
4(RD) - 4(RD)
Yes
Yes
Is the voltage of GND & DC5V in No Check FUSE, NF01/02J, PTC,
outdoor unit PCB about DC 5V ? Power Module, BD-01S in
outdoor unit PCB assembly
Yes
Yes
Be sure to disconnect the power cable plug from the plug socket before disassembling the
equipment for a repair. Internal components and circuit boards are at main potential when the
equipment is connected to the power cables. This voltage is extremely dangerous and may
cause death or severe injury if come in contact with it.
Be sure to turn off power switch before connect or disconnect connector, or parts damage may
be occurred.
Supplied voltage to No
Outdoor PCB is about Check power source
AC 220/240V ?
Yes
Check CN-U,V,W connector
Is connector (CN-U,V,W) No
connected to compressor and (U : RD, V : BL, W : YL)
inserted to PCB in right position?
Yes
* Check refrigerant pressure and
Refrigerant pressure is within No adjust.
limits?
Supplied voltage to No
Outdoor PCB is about Check power source
AC 220/240V ?
Yes
*Check the indoor /outdoor fan motor
No and air circulation condition.
Does indoor / outdoor fan work
running properly? *Low air circulation may cause this
problem
Yes
Refrigerant pressure is within No
Check refrigerant pressure and adjust.
limits ?
Yes
Check the Current Trans. is damaged in outdoor unit PCB (output wire is
disconnected to pin or not)
Be sure to disconnect the power cable plug from the plug socket before disassembling the
equipment for a repair. Internal components and circuit boards are at main potential when the
equipment is connected to the power cables. This voltage is extremely dangerous and may
cause death or severe injury if come in contact with it.
Be sure to turn off power switch before connect or disconnect connector, or parts damage may
be occurred.
Supplied voltage to No
Indoor PCB is about Check power source
AC 220/240V ?
Yes
- remove obstacles in indoor unit
No fan assembled correctly.
Is indoor fan rotating ? - CN-Motor1 & assembling state of
DC Fan connector.
Yes
Is DC - fan driving circuit working No * Check DC Fan Driving circuit
properly ? (Soldering state & Direction)
- R01F~R09F, C01F~C03F,
Yes IC01F~IC03F, Q01F~Q02F, ZD01F
* Check PCB.
- Operate the fan motor with another normal PCB. If the motor is rotate,
the PCB in the unit has problem. Replace the PCB in indoor unit.
CAUTION
Before working, please wait for some time to allow the capacitor to discharge fully.
Working on the equipment that is connected to a power supply can cause an electrical shock.
Please, connect and disconnect the fan motor wires to the PCB after disconnecting the power plug and then resume operation.
Be sure to disconnect the power cable plug from the plug socket before disassembling the
equipment for a repair. Internal components and circuit boards are at main potential when the
equipment is connected to the power cables. This voltage is extremely dangerous and may
cause death or severe injury if come in contact with it.
Be sure to turn off power switch before connect or disconnect connector, or parts damage may
be occurred.
Supplied voltage to No
Outdoor PCB is about Check power source.
AC 220/240V ?
Yes
* Remove obstacles in outdoor unit
No fan assembled correctly.
Is outdoor fan rotating ? * Check connector is not connected
to outdoor PCB assembly (CN-FAN2)
Yes
Is DC - fan driving circuit working No * Check DC Fan driving circuit
properly ? (Soldering state & Direction)
- R01F~R05F, C01F~C03F,
Yes
Q01F~Q04F, ZD01F
* Check PCB.
- Operate the fan motor with another normal PCB. If the motor rotates,
the PCB in the unit has problem. Replace the PCB in outdoor unit.
CAUTION
Before working, please wait for some time to allow the capacitor to discharge fully.
Working on the equipment that is connected to a power supply can cause an electrical shock.
Please, connect and disconnect the fan motor wires to the PCB after disconnecting the power plug and then resume operation.
Be sure to disconnect the power cable plug from the plug socket before disassembling the
equipment for a repair. Internal components and circuit boards are at main potential when the
equipment is connected to the power cables. This voltage is extremely dangerous and may
cause death or severe injury if come in contact with it.
Be sure to turn off power switch before connect or disconnect connector, or parts damage may
be occurred.
Yes
Check D_PIPE TH.
No
D-PIPE TH. is working - Measure resistance of TH.
properly ?
(about 200kΩ at 25°C.)
Yes
Is Sensing circuit of outdoor No
unit PCB working properly ? - Check soldering state of
R07H, R08H, C04H
Yes
Be sure to disconnect the power cable plug from the plug socket before disassembling the
equipment for a repair. Internal components and circuit boards are at main potential when the
equipment is connected to the power cables. This voltage is extremely dangerous and may
cause death or severe injury if come in contact with it.
Be sure to turn off power switch before connect or disconnect connector, or parts damage may
be occurred.