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Product Marketing Sales Training. Course Contents Fundamentals of Inverter Air-Conditioner System OYL Inverter Product Range Service / Troubleshooting.

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Presentation on theme: "Product Marketing Sales Training. Course Contents Fundamentals of Inverter Air-Conditioner System OYL Inverter Product Range Service / Troubleshooting."— Presentation transcript:

1 Product Marketing Sales Training

2 Course Contents Fundamentals of Inverter Air-Conditioner System OYL Inverter Product Range Service / Troubleshooting

3 Fundamentals of Inverter A/C System Power supply (input) frequency is either 50 Hz or 60 Hz. Inverters change the frequency (15 – 100 Hz) to the compressor according to load requirements. Inverter Compressor operates at different speeds.

4 Fundamentals of Inverter AC = +/- voltage changes U (V) V avg = 0 U (V) t(s) DC = no voltage changes V avg  0 t(s)

5 Fundamentals of Inverter U (V) t(s) U (V) t(s) f = 50 Hz f = 70 Hz Compressor Speed can be varied by changing the Compressor Input Frequency

6 Fundamentals of Inverter IN: 240 VAC f = 50 Hz OUT: variable f = variable Rectifier (AC-DC) Inverter (DC-AC) PWM waveform MCU System control Brushless Motor Power supply 220~240/1Ph/50Hz O/D temp sensor Current sensor

7 Difference between AC & DC Inverter Motor efficiency Motor control method

8 Motor Efficiency DC Efficiency AC Efficiency AC total loss Running loss Exciting loss 1.00.5[kW] [%] Motor Output 90 80 70 60 50 Efficiency DC total loss

9 Motor control method VDC Ascent Comp. Load N1N2N3 REVOLUTION TORQUE VAC Ascent DC motor revolution Depend on ( Vdc ) AC motor revolution Depend on freq. (FV curve) DC motor control method ・ PAM : Vdc change ・ PWM : Vdc fix but duty change ( AVG VDC change )

10 Advantages of Inverter System Room Temperature comfort Fast cooling / heating Less compressor ON / OFF cycle Low starting current (Soft start) Improvement in Low Temperature characteristic during Heating mode. Low energy consumption

11 Room Temperature Comfort Precise Room Temperature control Less temperature fluctuation  0.5 deg Celsius from Set Temperature

12 Fast Cooling / Heating Quick ramp-up of compressor speed. Enables A/C to reach set temperature faster.

13 Less ON / OFF cycle Time Compressor capacity Full capacity Conventional compressor ON OFF ON OFF ON OFF Once Set Temperature is reached, Inverter compressor still runs BUT at lower frequency. Conventional compressor will STOP. Therefore, ON/OFF strain for inverter compressor is less, making it lasts longer.

14 Low Starting Current Inverter compressor start-up at lower frequency, then quickly ramps up. Starting current is lower. Running current Hours of operation Conventional air conditioner: High starting current Frequent on/off cycle Inverter air conditioner: Low starting current Smooth operation

15 Improvement in Low Temperature Characteristics i) During low ambient temperature the inverter unit will run at max frequency which the capacity will improve compare with normal fix compressor unit ii) During defrost, the inverter unit will run at max frequency thus the defrost time will be less.

16 Low Energy Consumption Most Frequently Used Area Inverter

17 OYL Inverter Product Range Available for R22 (AC) and R410A (DC) Single – split & Multi-Split Wall-mounted, Ceiling Cassette, Ceiling Convertible, Ceiling Concealed.

18 OYL Inverter Product Range Indoor Wall – Mounted (5)WMX10/15/20/25G(R)

19 OYL Inverter Product Range Indoor Ceiling Cassette (5)CKX10/15/20C(R) (5)CKX20/25A(R)

20 OYL Inverter Product Range Indoor Ceiling Convertible (5)CMX15/20/25E(R)

21 OYL Inverter Product Range Indoor Ceiling Concealed (5)CCX10/15/20/25C(R)

22 Inverter Product Range Outdoor Condensing C – Series (Single-split) 5SLX10/15/20/25C(R)

23 Inverter Product Range Outdoor Condensing A – Series R410A (Multi-split DC Inverter) 5MSX20/25/30A(R)

24 Inverter Product Range Outdoor Condensing A – Series R22 (Multi-split AC Inverter) MSV25/35A

25 Inverter Product Range Specifications (Single – Split) R410A DC Inverter

26 Inverter Product Range Specifications (Single – Split) R410A DC Inverter

27 Inverter Product Range Specifications (Multi – Split) R410A DC Inverter

28 Inverter Product Range Specifications (Multi – Split) R22 AC Inverter

29 Inverter Product Range

30 Installation Wiring Installation i) Additional signal wire (Low voltage LIVE) ii) Power supply : 3 wires iii) Indoor to outdoor : 4 wires (including E) vi) Earth wires must be connected for indoor and outdoor unit.

31 Installation Wiring connection INDOOR OUTDOOR 1 – Comp 2 – Neutral 3 – Signal Power Supply L N Signal Earth N L MCB / ELCB

32 Protection Algorithms A) Current Control I1 I2 Compressor stops Frequency 1 step down Frequency 1 step up Total Current Maintain Frequency I3

33 Protection Algorithms b) Compressor discharge temperature Compressor Discharge Temperature 115°C Compressor stops Frequency 1 step down Frequency 1 step up Maintain Frequency 108°C 95°C

34 Protection Algorithms c) Starting control Freq C Freq 6 4 min 1 min 0 When target frequency > Freq 6, – Freq 6 for one min. When target frequency > Freq C Freq 6 for one min and at Freq C for 1 min

35 Protection Algorithms c) Starting control

36 Protection Algorithms c) Starting control

37 Trouble-shooting AIR – CONDITIONAL PROBLEMS Insufficient Cooling/Heating Refrigerant circuit problem Starting or running failure Electrical circuit problem

38 Diagnoses by use of pressure gauge Pressure measurement Refrigerant charging Vacuuming To troubleshoot the refrigerant circuit pressure gauge is one of the important tooling Both of the LP and HP must closed for pressure measurement Trouble-shooting

39 Insufficient cooling Insufficient Cooling Unit Starts High cooling load Refrigerant circuit Leakage Restriction e.g at strainer, capillary, filter dryer, etc Compressor Less or no compression (Low running current) Excessive heat source e.g. electric kettle Room overcrowded with people Windows/ doors wide open Check air circulation Indoor/Outdoor coil dirty (clogged) Air filters dirty Fan malfunction Obstruction at air inlet/outlet of indoor/outdoor unit Satisfactory operation with temperature difference of air intake & discharge of indoor unit 10 º C - 15ºC Insufficient Cooling Unit Starts High cooling load Refrigerant circuit Leakage Restriction e.g.. at strainer, capillary, filter dryer, etc Compressor Less or no compression (Low running current) Excessive heat source e.g. electric kettle Room overcrowded with people Windows/ doors wide open Check air circulation Indoor/Outdoor coil dirty (clogged) Air filters dirty Fan malfunction Obstruction at air inlet/outlet of indoor/outdoor unit Satisfactory operation with temperature difference of air intake & discharge of indoor unit 10 º C - 15ºC

40 Insufficient Heating Insufficient Cooling Unit Starts High cooling load Refrigerant circuit Leakage Restriction e.g at strainer, capillary, filter dryer, etc Compressor Less or no compression (Low running current) Windows/ doors wide open Check air circulation Indoor/Outdoor coil dirty (clogged) Air filters dirty Fan malfunction Obstruction at air inlet/outlet of indoor/outdoor unit Satisfactory operation with temperature difference of air intake & discharge of indoor unit 10 º C - 15ºC Insufficient Heating Unit Starts High Heating load Refrigerant circuit Leakage Restriction e.g.. at strainer, capillary, filter dryer, etc Compressor Less or no compression (Low running current) Windows/ doors wide open Check air circulation Indoor/Outdoor coil dirty (clogged) Air filters dirty Fan malfunction Obstruction at air inlet/outlet of indoor/outdoor unit Satisfactory operation with temperature difference of air intake & discharge of indoor unit 16 º C - 25ºC

41 Pressure conditions

42 Pressure table definition Note: Outdoor air 35ºC DB Indoor air 27ºC DB/ 19.5ºC WB

43 Excessive refrigerant Causes For systems with EXV Improper expansion valve adjustment. Poor installation of feeler bulb. Overcharged refrigerant. For systems with capillary tube Overcharged refrigerant

44 Insufficient refrigerant 2 types – amount of refrigerant in the system is not enough. – amount of refrigerant passing through expansion device is not enough Possible causes – undercharge refrigerant – refrigerant leak – choked filter, drier – faulty expansion device

45 Excessive condensing pressure Possible causes – air flow short circuit – insufficient air flow – partially blocked condenser – presence of air or non-condensable gases in the system. – operation beyond upper ambient temperature limits

46 Electrical circuit trouble-shooting Electrical circuit problem – Key components functioning checking – Controller for different models – Troubleshooting steps for the inverter controller

47 Required Tools Clamp meter AC CURRENT DC CURRENT FREQ RESISTANCE VDC VAC LIGHT

48 Required Tools Multi-meter AC CURRENT DC CURRENT RESISTANT VDC VAC CONTINUITY

49 Key Components - Capacitor  Functions To smoothen the DC bus for the inverter board  Testing Use multi-meter to check the conductivity of the terminal Terminal  Problems I)Caused by over voltage II)Electrolyte dried up causing it malfunction III)High ambient working condition

50 Key Components – Bridge Diode + ~ ~ -  Function To rectifier the AC source to DC source  Testing Use multi-meter to check the conductivity of the terminal. Normally, 0.4V – 0.6V or KΩ  Problems I)Caused by over voltage II)Working ambient to high

51 Key Components - Reactor  Function Introduce at the inverter circuit to compensate for reactive power and improve power factor  Testing I)Resistance should be around 0.4Ohm II)If the conductivity is open loop mean the reactor failure III)Coil/steel plate and external bracket resistance should infinite IV)No obvious burn marks

52 Key Components - PTC  Function Due to high capacitor charge current during start up, the PTC electronic starter and relay combination acts to cushion the excessive charge current  Testing Resistance of the PTC on sheet metal at ambient temp is 40±20% Ohm

53 Key Components - Sensors Sensor I) Sensor as an ADC input value for the controller II) The Longertech sensor value (yellow socket) is different with the OYL inverter sensor III) Sensor value for the sensor can be measured using multi-meter in 2 form. Resistance value (no PCB running) or Vdc value IV) For Vdc value checking, the value get from multi- meter need to minus by 5Vdc before refer to the table V) For resistance value checking, the value can refer directly

54 Sensor values 25 ºC kOhm2.3533Vdc 25 ºC KOhm1.2830Vdc  Longertech sensor value 25 ºC 10.00kOhm1.45Vdc  OYL sensor value Example: Measured from multi-meter is 3.27KOhm. 5.00KOhm KOhm = 1.728KOhm From the table, 1.728KOhm convert back to 35 ºC Discharge Sensor Room/ coil Sensor All the value same for discharge, room and coil

55 Control board – 5SLX10/15C BRIDGE DIOD E - CAPACITOR REACTOR TERMINAL BLOCK IPM POWER BOARD MCU

56 Control board – 5SLX20/25C IPMCU REACTOR POWER BOARD E - CAPACITOR TERMINAL BLOCK BRIDGE DIOD

57 POWER BOARD TERMINAL BLOCK BRIDGE DIOD E - CAPACITOR FAN CAPACITOR IPM PFC CAPACITOR Control board – MSV25A

58 POWER BOARD E - CAPACITOR IPM BRIDGE DIOD FAN CAPACITOR TERMINAL BLOCK PTC CONTACTOR FUSE PFC CAPACITOR Control board – MSV35A

59 TERMINAL BLOCK POWER BOARD CAPACITOR FAN CAPACITOR REACTOR PFC IPM Control board – 5MSX20/25/30A

60 Indoor Error Codes - I/D LED Blinking Outdoor Error Codes - Compressor Running LED Blinking - Compressor Stopped LED Blinking Error Codes

61 LED Fault IndicationsTroubleshooting Methods 1234 ● Defrost Operation (Red)Ignore ● I/D Sensor Error (Yellow)Check I/D Sensor wire and value (~5kΩ) ● Coil Temp. Sensor ErrorCheck Coil Sensor wire and value (~5kΩ) ● O/D Temp. Sensor ErrorRefer O/D Unit ●● Compressor OverloadRefer O/D Unit ●● IPM ErrorRefer O/D Unit ●● O/D Current TripRefer O/D Unit ●● Compressor Overheat / Gas LeakRefer O/D Unit ●● I/D Fan Feedback ErrorCheck I/D Fan Wire ●● Communication ErrorCheck Wiring Error Codes – (5)WMX-G

62 BlinksBlinking Indication 1Normal Running, with no limitation 2Voltage Limit 3Cooling unit : Outdoor Coil Temperature Limit Heating unit : Indoor Coil Temperature Limit 4Total Current Limit 5Discharge Temperature Limit 6Cooling unit : Indoor Coil Temperature Limit 7Indoor Fan Control 8Outdoor Frequency Adjustment Error Codes – Outdoor Compressor Running LED Blinking

63 Compressor Stopped LED Blinking BlinkFault IndicationsTroubleshooting Methods 1O/D Ambient Sensor ErrorCheck O/D Ambient Sensor Wire & Connection 2O/D Coil Sensor ErrorCheck O/D Coil Sensor Wire & Connection 3O/D Disc. Sensor Error / Comp. Overheat Check O/D Disc Sensor Wire & Connection; Check Pressure & Compressor 4DC Comp. Feedback ErrorCheck Comp. Wire & Feedback Wire (Not applicable for A/C Inverter) 5Communication ErrorCheck Communication Wire & Connection for both I/D & O/D 6Over Current ErrorCheck Total Current; Check Pressure & Compressor 7No LoadNot Applicable 8Over / Under VoltageCheck Power Supply 9DC Comp. Start FailureCheck Comp. Wire & Feedback Wire; Check Compressor Error Codes – Outdoor

64 Compressor Stopped LED Blinking BlinkFault IndicationsTroubleshooting Methods 10Cooling OverloadCheck Pressure 11DefrostIgnore 12IPM ProtectionCheck Power Supply; Check Main Board / Filter Board; Check Bridge Diode; Check IPM Board; Check Compressor 13Read EEPROM ErrorCheck EEPROM Chip Connection 14Write EEPROM ErrorCheck EEPROM Chip Connection 15DC Fan Motor Feedback ErrorIgnore 16AC Peak Current ErrorIgnore 17O/D Suction Sensor ErrorCheck O/D Suction Sensor Wire & Connection (Applicable only for Heat Pump Unit) Error Codes – Outdoor

65 Compressor Stopped LED Blinking BlinkFault IndicationsTroubleshooting Methods 18NoneIgnore 19DC Comp. Speed Control ErrorCheck IPM Board; Check Compressor; 20NoneIgnore 21O/D Suction Pipe A Sensor ErrorCheck Suction Pipe A Sensor Wire & Connection 22O/D Suction Pipe B Sensor ErrorCheck Suction Pipe B Sensor Wire & Connection 23O/D Suction Pipe C Sensor ErrorCheck Suction Pipe C Sensor Wire & Connection 24O/D Suction Pipe D Sensor ErrorCheck Suction Pipe D Sensor Wire & Connection 31Communication Error with I/D ACheck Communication Wire & Connection with I/D A 32Communication Error with I/D BCheck Communication Wire & Connection with I/D B 33Communication Error with I/D CCheck Communication Wire & Connection with I/D C 34Communication Error with I/D DCheck Communication Wire & Connection with I/D D Error Codes – Outdoor

66 L N E Multi split inverter Single split inverter  Use multi-meter to check the power supply to the controller  Single split refer 1 & 2 and multi split refer L & N  Supply around 220 ~ 240VAC Power supply checking

67  Use multi-meter to check the continuity of the fuse  Fuse with sound ‘BEEP’ is ok  Fuse with OL for the resistance and no ‘BEEP’ is nok Fuse checking

68  Use multi meter to check the communication line between indoor and outdoor  Signal (3) line references to neutral (2). Check VDC for signal and neutral  The VDC will fluctuate to show the communication transmit between indoor and outdoor Communication wires checking

69 Bridge Diode AC Voltage Checking  Use multi-meter to check the AC voltage across the bridge diode  Supply around 220 ~ 240VAC

70 Electrolytic Capacitor Checking  Use multi-meter to check the DC voltage across the E-CAP  In normal case the value should around Vdc

71 Bridge Diode Continuity Checking + ~ ~ - (Diode ~ 0.4 – 0.6V)  Use multi-meter to check the continuity of the bridge diode  The value must around 0.4 – 0.6V or kΩ  The bridge diode with ‘BEEP’ sound is nok 5SLX 10/15CR & MSV 25/35A (LONGERTECH)

72 Bridge Diode Continuity Checking + Result show in kΩ + Multi-meter will show value in one direction and OL in another direction when we change the multi-meter direction. If both direction show value means the bridge diode already short OK

73 ++ ++ NG If both direction show value means the bridge diode already short Bridge Diode Continuity Checking

74 + + Result show in Vdc Same with the result show in kΩ, multi-meter will show value in one direction and OL in another direction when we change the multi-meter direction. If both direction show value means the bridge diode already short Bridge Diode Vdc value checking

75 NG + + Same with the result show in kΩ, multi-meter will show value in one direction and OL in another direction when we change the multi-meter direction. If both direction show value means the bridge diode already short Bridge Diode Vdc value checking

76 5SLX 10CR/15CR (OYL) 5SLX 20/25CR & 5MSX 20/25/30AR  Use multi-meter to check the connectivity of the bridge diode  The bridge diode with ‘BEEP’ sound is nok Value Ω is OK Value KΩ is OK Bridge Diode Vdc value checking

77 PFC BOARD FOR 5SLX 20/25CR & 5MSX 20/25/30AR IGBT DIODE Please check the IGBT and DIODE with multimeter

78 Using multimeter with continuity function. 1)Multimeter show OL means ok 2)If Multimeter show value around 0Ohm ~ to few Ohm and with the “BEEP” sound means diode short already and the PFC need to be change

79 1)Multimeter show OL means ok 2)If Multimeter show value around 0Ohm ~ to few Ohm and with the “BEEP” sound means IGBT short already and the PFC need to be change Using multimeter with continuity function.

80 IPM DC Voltage Across Checking  Use multi-meter to check the DC voltage across the IPM  The value should around 270 – 330VDC depends on the PFC it used

81 + - U V W  + & - from the DC bus  U, V, W to compressor Intelligent Power Module (IPM)

82 +- -+ OK NOK If both direction show value means the bridge diode already short

83 Compressor connectivity checking between the terminal  Use multi-meter to check the connectivity between the terminal  The multi - meter should have “BEEP” sound to show the winding short  If the multi-meter show OL means the winding of compressor burn or short Compressor connectivity checking between the terminal

84 Compressor connectivity checking  Use multi-meter to check the connectivity between the body and terminal  The multi-meter should show OL  If the ‘BEEP’ sound shown means the compressor short

85 Diagnostic Tool Interceptor – For Inverters Including AC and DC Inverters Single-Splits & Multi-Splits

86 Interceptor Capability – Intercepts or captures communication signals within the inverter electronics nervous system.

87 Hardware Installation Schematic Single-split Multi-split

88 Features Displays Operating Parameters – Temperature Readings for ALL sensors Outdoor Air Temperature Outdoor Coil Temperature Indoor Air Temperature Indoor Coil Temperature Indoor Set Temperature Compressor Discharge Temperature

89 Display Operating Parameters

90 Features Compressor – Running Frequency EXV – Number of Pulses – Status Operating Mode for both Indoor and Outdoor Indoor Fan Speed

91 Features Data Logging Data Storage & Transmission Graphical Representation

92 Data Logging “Set-and-Forget” – Once program is started properly, data is collected automatically. – There is no need for constant human monitoring. – Monitoring period is limited only by free hard disk space. – BUT ensure constant power supply during the entire monitoring period. – Power-Saving Features must be Disabled.

93 Data Storage & Transmission Data Storage – Data is stored as.ice files in the computer. – Useful for future reference. Data Transmission –.ice files can be transmitted by back to OYL for further analysis. – All parameters can be converted and manipulated using 4 different formats. Text XML HTML table Excel

94 Graphical representation All parameters can be shown in graph form (time-based) for easier understanding. Graph can be customized e.g. Titles, Colours, Types of Axis, etc. Ability to export to – Metafile – Bitmap – JPG – GIF – PCX One-Click to Send by Useful to generate Service Reports

95 Graphical representation

96

97 Interceptor sales package CD-ROM containing – Interceptor Installation Program – Hardware Installation Manual – Software Manual – Extras (required for full functionality) Adobe Acrobat Reader 6.0 Internet Explorer 6.0 SP1 Microsoft DotNet Framework

98 Interceptor sales package Interceptor Module RS232 Serial Connection Cable

99 Computer requiremets Notebook or Desktop Computer with built- in RS232 Serial Port Microsoft Windows XP Professional Minimum 128 MB RAM Minimum 50MB of Hard Disk Space

100 Thank you


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