Repair Guideline For TCL DC Inverter Air Conditioner

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Repair Guideline for TCL DC Inverter Air Conditioner

ContentsI. Electrical Control of Inverter Air Conditioner ······················21. Main compositions of the electrical control of inverter air conditioner ······22. Wiring of Inverter AC Unit ·····················33. Current Flow ··················44. Computer Control Function Flow Chart for Inverter AC Unit ···················55. Protection and Fault II. Troubleshooting ················81. According to the fault code ·····················8(1) Display E1 or E2: ·········8(2) Display ·····················9(3) Display E3, E7, E8 ·······10(4) Display ·····················11(5) Display EC ···················13(6) Display ·····················14(7) Display ····················16(8) Display ····················17(9) Display E9 (Firstly display P0 or P9, then change to �·18(10) Display �·············20(11) Display EE ·················22(12) Display P0 ··················23(13) Display P1 ··················24(14) Display P2 ··················24(15) Display P4 ··················25(16) Display P5 ··················25(17) Display P6 ··················26(18) Display P7 ··················27(19) Display P8 ··················27(20) Display P9 ··················282. Other faults ····················291) The indoor unit works normally but the outdoor unit does not work. ········292) The outdoor unit is stopped when the air conditioner has run for a period of time ·············293) The air conditioner is tripped when it is ···················304) The complete unit does not work ············30Appendix 1 ···31Appendix 2 ···34Appendix 3 ···36Cautions on Replacement of PCB ··········371

I. Electrical Control of Inverter Air Conditioner1. Main compositions of the electrical control of inverter air conditionerThe electrical control of inverter air conditioner is divided into indoor control system and outdoorcontrol system.Relative to the fixed-speed air conditioner, the indoor control system is added with onecommunication circuit, but removed of the control circuits for compressor, 4-way valve andoutdoor fan. The other circuits are basically the same.The outdoor circuit is generally divided into three parts, i.e. outdoor power source board, PowerFactor Correction (PFC) board and Intelligent Power Module (IPM). The details are as follows:IPM boardPFC boardOutdoor power source boardTCL Inverter Air Conditioner Model 1 – 1.5P has been developed for four generations.The 1st generation (V1) applies 120 square wave control plan and the all PFC plan is used forpower treatment.The 2nd generation (V2) remains to apply 120 square wave control plan, but the partial PFC planis used for power treatment. This product is never put into batch production.The 3rd generation (V3) applies 180 sine wave plan and partial PFC plan. This model is also few.The 4th generation (V4) remains to apply 180 sine wave plan (including 2P unit), where onlysignificant adjustment is made to the function architecture. That is, the indoor control plan appliedfor the 1st and 2nd generation is changed to outdoor control (For details on the function distribution,please refer to the Control Function Chart below.The 5th generation(V5), the function is same as V4, but the Power source board, PFC board andIPM boardhave already integrated onto one board (All-In-One) for easily installation and2

repairing.The products 2P and higher are mainly developed for two generations.The 1st generation (VP1) applies NEC 180 sine wave plan and indoor control.The 2nd generation (VP2) applies TI DSP 180 sine wave plan and outdoor control. (Exclusive of2P unit).There are derivative models, e.g. full DC inverter unit, inverter floor-standing unit and LC plan.See Appendix 1 for details.2. Wiring of Inverter AC UnitOrWhBLBLTransformerBrBrOrMain controlboardY/GY/GBLDisplay circuitboardBL4-way ValveMotorprotectorRelayY/GBRBLBLOptionalHeat exchangerRoom temperaturesensorGuide louvermotorCoil ReBLReCompressorRe Wh BLBLReElectricHeaterFan MotorReBrOutdoor power source boardY/GModule boardCompressor top protection switch(Optional)BLExhaust temperature sensorReBLOutdoor temperature sensorOutdoor coil temperature sensorNote: There is no LOW FAN for single-speed motor P9-2Indoor unit Outdoor unitPort: P9 pair port for dual-speed motor3. Current LiveMaincontrolboardLivePFC boardNeutralCommunication wireGroundOutdoorpowersourceCompressorIPM boardIndoorunit3

4. Computer Control Function Flow Chart for Inverter AC Unit1) Outdoor control planOutdoor control systemIndoor control systemIndoor control boardLiveCommunication with outdoor unitIndoor fan controlLouver motor controlHealth assembly controlTemperature detectionFan speed feedbackElectric heater controlSelection of cool-heat and cool-onlymodelSelection of data sheetSelection of Fahrenheit andCentigrade temperatureSelection of LED OR without LEDdisplayNeutralIPM moduleOutdoor power source boardSignalwireStorage of working parametersFrequency generationOutdoor temperature detectionCommunication with indoor unitCommunicationwireOutdoor fan controlCommunication4-way valve controlOutdoor power treatmentFault and compressor statePFC controlindicationSwitch signal on top of theEmergencyl Switch signal inputRemote signal inputDC powerOutdoor PFC boardAC rectifierElectronic expansion valve controlDisplay boardCompressor driveIPM fault outputCommunication with IPMChassis heating controlTemperature or fault code displaysource boardPower ON/OFFcompressorSignal inputCommunication with powerPressure switch signal processingVoltage samplingPower factor adjustmentProtection current sampling2) Indoor control planIndoor controlOutdoor controlOutdoor power sourceboardIPM moduleST72141Communication with power sourceboard、PFC control、IPM drive、Currentsampling and processing 、 Voltagesampling and signal processing 、Detection of compressor feedback signalPS21865Compressor inverter driveIPM fault signal outputSignalwireTMP86F807NTemperature detectionCommunication with indoorunitOutdoor fan controlSignal wire 4-way valve controlCommunication with moduleCommunicboardation wirePower source indicationRepair key signal processingCompressor top temperaturePFC controlprotectionGround wireL wireN wireCommunication wireIndoor main PCBTMP86PH46NGWorking frequency controlIndoor fan controlSwing motor controlTemperature detectionStorageofmodelparametersOperating signal processingOutdoor power outdoor unitOther optional functionsOutdoor PFC boardAC rectifierPower factor adjustmentBoosting of DC voltageProtection current samplingBMC processingAC voltage samplingDC harmonicsSupply DC powerHarmonic inhibition4Indoor display panelRemote signal acceptancePreset temperature displayProtection and fault displayKey operation

5. Protection and Fault CodesFault CodeFunction Indicator (flash)Digital LED displayIndoor/outdoor communication faultRUN & TIMER: BlinkE0outdoor communication faultRUN & TIMER: BlinkECRoom temperature sensor (IRT)RUN-1/8 sec.E1Indoor pipe (coil) temperature sensor(IPT)RUN-2/8 sec.E2Outdoor pipe (coil) temperature sensor(OPT)RUN-3/8 sec.E3System abnormalRUN-4/8 sec.E4Model configuration wrongRUN-5/8 sec.E5Indoor fan motor faultRUN-6/8 sec.E6Outdoor temperature sensorRUN-7/8 sec.E7Exhaust temperature sensorRUN-8/8 sec.E8Intelligent power module of drive andmodule faultRUN-9/8 sec.E9Outdoor fan motor fault (DC Motor)RUN-10/8 sec.EFCurrent sensor faultRUN-11/8 sec.EAEEPROM faultRUN-12/8 sec.EETemperature switch fault (on top of thecompressor)RUN-13/8 sec.EPVoltage sensor faultRUN-14/8 sec.EUIntake temperature sensorRUN-15/8 sec.EHFault TypeProtection CodeFunction Indicator (flash)Digital LED displayOvervoltage /undervoltage protectionRUN: Blink; TIMER: 1 blink /8 secP1Overcurrent protectionRUN: Blink; TIMER: 2 blink /8 secP2Exhaust overtemperature protectionRUN: Blink; TIMER: 4 blink /8 secP4Subcooling protectionunder cooling modeRUN: Bright; TIMER: 5 blink /8secP5Overheating protectionunder cooling modeRUN: Bright; TIMER: 6 blink /8secP6Overheating protectionunder heating modeRUN: Bright; TIMER: 7 blink /8secP7Outdoor overtemperature/ undertemperature protectionRUN: Bright; TIMER: 8 blink /8secP8Drive protection (software control )RUN: Blink; TIMER: 9 blink /8 secP9Modulecontrol)RUN: Blink; TIMER: 10 blink /8secP0Protection Typeprotection(hardware5

Display on outdoor power source board: The indicator alerts the fault in a cycle as such that it isbright for 0.5 seconds, dark for 0.5 seconds, blinks “n” times and then dark for 3 seconds.Blinktimes(n)Fault MessageBlinktimes(n)Fault Message1IPM protection18Short-circuit / open-circuit fault ofintake temperature sensor2Overvoltage / undervoltage19Outdoor EEPROM fault3Overcurrent20Outdoor fan motor protection4Exhaust overtemperature protection21Indoor fan motor protection5Outdoorprotection6Drive fault and protection (V1,VP1)23System in shortage of Freon7Communication fault with indoorunit24Model configuration wrong8Compressoroverheat(compressor top switch)25Indoor sensor fault9Short-circuit / open-circuit fault ofoutdoor temperature sensor26Indoor coil sensor fault10Short circuit / open-circuit fault ofoutdoor heat exchanger temperaturesensor27Indoor EEPROM fault11Short-circuit / open-circuit fault ofexhaust temperature sensor28Indoor fan motor fault12Voltage sensor fault30drive nt sensor fault31Outdoor environmentalovertemperature /undertemperature protection14IPM fault32Indoor coil deforst prevention15communication fault between powersource board and intelligent powermodule33Indoor coil overheating protection16No feedback frommotor(outdoor unit)17Defrost stateDCfan6

Display on V5 All-in-one boardBlinkBlinkFault MessageCountsFault MessageCountsShort-circuit/open-circuitfault1IPM fault23Outdoor coil sensor fault4Absorption temperature sensor fault5Exhaust temperature sensor fault6Current sensor fault7Compressor drive fault8Compressor drive protection9Outdoor overheat protection10IPM protection11AC overcurrent protection12Exhaust Temperature Protection13Compressor top temperature protection14Exhaust Overtemperature Protection15Voltage protection16Exhaust underpressure protection17Exhaust Overpressure Protection18Indoor antifreeze protection19Indoor overheat protection20Indoor / outdoor communication fault21Outdoor EEPROM fault2223Outdoor DC fan fault24Outdoor coil overheat protection25Model configuration wrong26Indoor fan fault27Reserved28Reserved29Reserved30ReservedV5 All-in-one board7ofoutdoor temperature sensorOutdoorambientovertemperatureprotection

II. Troubleshooting1. According to the fault code(1) Display E1 or E2:SymptomDisplay E1 or E2Room temperature sensor (IRT) and IndoorCauseS/Npipe (coil) temperature sensor (IPT) faultInspections1How to SolveRemarksInsert again if loose.Photo 1Measure the resistance on the twoReplace the temperature sensorPhoto 2ends of indoor temperature sensor:if the resistance is incurred to(25 / 5KΩ). For other resistance,drift, open or short circuiting.Contactbetweenindoortemperature sensor CN6 (RT, IPT)and slot2please refer to the Temperature –Resistance Sheet (Appendix 1).3If the above testing is normalReplace the indoor control boardPosition and marking of temperature sensorsCN6 (RT, IPT) on indoor control boardMeasure the resistance ofindo or temperature sensor1033 Unit and 1240 Unitindicate the dimensions of indoor unit.8

(2) Display E6SymptomDisplay E6CauseIndoor fan motor faultS/N1InspectionsHow to SolveIf the fan does not run, readjustCheck the indoor cross-flow fanthe fan position until it can runbladesmoothly.If the motor insert (CN3, CN4) on2Insert again if loose.indoor main PCB is in good contactwith the slot3Startup capacitance value4The above inspections are normalRemarkspartCapacitance incorrect. ReplaceYellow-linewith a new capacitor.partReplace the indoor main PCB9Red-line

(3) Display E3, E7, E8SymptomDisplay E3, E7, E8Outdoor pipe (coil) temperature sensor ure sensor faultS/NInspectionsIf1thetemperatureHow to SolvesensoronRemarksInsert again if loose.Photo 3Measure the resistance on the two ends ofReplace the temperature sensorPhoto 4outdoor temperature sensor:if the resistance is incurred toResistance of CN1 terminal sensor –drift, open or short circuiting.outdoor power source board is ingood contact with the slot (CN1,CN2)(25 / 5KΩ). For other resistance, please2refer to the Temperature – ResistanceSheet. Resistance of CN2 terminal sensor– (25 / 20KΩ). For other resistance,please refer to the Exhaust TemperatureSensor Resistance Sheet.3If the above testing is normalOutdoor power source boardPosition and marking oftemperature sensors (CN1, CN2) onoutdoor power source boardCN1 terminal sensorCN2 terminal sensor10

(4) Display E4SymptomDisplay E4System abnormal: Let the compressor run for 5minutes. If the indoor coil temperature cannotCausebe 2 lower than that before the compressor isstarted (2 higher for heating mode), it can bejudged that the system is abnormal.S/N12InspectionsChecktheHow to Solvehigh-pressureandIf not open, open again to ensurelow-pressure valves.the system circulation is smooth.Check the system refrigerant (StartThe system is in shortage ofand run under cooling mode. Whenrefrigerant. Test with pressurethe compressor is started, check thegauge, check the leakage pointoutlet temperature for its change. Ifand recharge the refrigerant.RemarksPhoto 5Photo 6the change is not obvious after 5minutes)Check3coilReplace the temperature sensortemperature sensor (25 /5KΩ).if the resistance is incurred toFor other resistance, please refer todrift, open or short circuiting.thetheevaporatorTemperature–Photo 7ResistanceSheet.1. The flow might be uneven forPhoto 8indoor system. Short circuit JP4jumper of the indoor controlboard to shield this protectionfunction (V1 – Indoor MainPCB).2. The flow might be uneven for4indoor system. Dial the JP4The above inspections are normalswitch of the outdoor powersource board to position “1” toshield this protection function(V4 – Power Source Board).Replace the indoor main PCBif the problem cannot be solvedby using the above methods.11Photo 9

12

(5) Display ECSymptomDisplay ECOutdoor communication fault between power sourceboard and intelligent power moduleHow to SolveRemarksCauseS/N12InspectionsCheck the contact of communication wire(CN5) between power source board andintelligent power moduleAfterthecomplete unitis energized,checktheindicators onoutdoorpower sourceboardandintelligentpower moduleYellow-linepartInsert again if loose.The indicator on powersource board blinksnormal (bright for 1second and dark for 1second),buttheindicator on intelligentpower module does notwork normallyReplacetheintelligentpower moduleIf the fault remainsunsolved, replacethe power sourceboard again.Red-line partTheindicatoronintelligentpowermodule blinks normal(bright for 1 second anddark for 1 second), butthe indicator on powersource board does notwork normallyReplacethepowersourceboardIf the fault remainsunsolved, artVP1Replace powersource boardIf the fault remainsunsolved, replacetheintelligentpowermoduleagain.CN5 positionand marking13

(6) Display EPSymptomDisplay EPTemperature switch fault ( on top of theCauseS/N1compressor)InspectionsCheck the insert position CN3 of thecompressor top temperature switchwires on outdoor power sourceboard23Insert again if loose.RemarksPhoto 10Jumper short-circuiting (Thisfunction not provided for 1 –1.5P unit)No switch on compressor topCompressortemperature.Thetemperatureis very high,accompaniedwithbadsmell.How to SolveCheck the U, V andW wires of thecompressor.The correct sequence of U. Vand W wiring shall be “red,white and blue”. Connect againif incorrect.Photo 11Check the systempressure.The pressure is low. Addrefrigerant to ensure the systempressure is normal.Photo 12Check theventilationthereisobstructionaffects theradiating ofconditioner.Install to the position as requiredin the Instruction Manual andensure the air inlet and outlet ofthe outdoor unit is smooth.outdoorand ifanythatnormalthe airCompressortemperature:Thetemperature is not high. Shortcircuit CN3.14If the fault is solved after shortcircuiting, replace the shelltemperature switch.If the fault remains easereplace the outdoor powersource board.

1 – 1.5P CN3 jumper. The jumper maybe used as alternative if there is nocompressor top switch.The correct sequence of U. V and W wiring shall be“red, white and blue”15

(7) Display EAS/NSymptomDisplay EA

3 repairing. The products 2P and higher are mainly developed for two generations. The 1st generation (VP1) applies NEC 180 sine wave plan and indoor control. The 2nd generation (VP2) applies TI DSP 180 sine wave plan and outdoor control. (Exclusive of 2P unit). There are derivative models, e.g. full DC inverter unit, inverter floor-standing unit and LC plan.

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