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

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.

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

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

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

Difference between AC & DC Inverter Motor efficiency Motor control method

Motor Efficiency Efficiency Motor Output ＤＣ Efficiency ＡＣ Efficiency AC total loss Running loss Exciting loss １．０ ０．５ ［ｋＷ］ ［％］ Motor Output ９０ ８０ ７０ ６０ ５０ Efficiency DC total loss

Motor control method DC motor revolution Depend on（Vdc） VDC Ascent Comp. Load N1 N2 N3 REVOLUTION TORQUE VAC Ascent AC motor revolution Depend on freq. (FV curve) DC motor control method 　　・PAM：Vdc change 　　・PWM：Vdc fix but duty change 　　　　　　　（AVG VDC change）　　　　　　　　　　　　

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

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

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

Less ON / OFF cycle 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. Compressor capacity Full capacity Conventional compressor ON OFF ON OFF ON OFF Time

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

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.

Low Energy Consumption Most Frequently Used Area Inverter

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

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

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

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

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

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

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

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

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

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

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

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

Inverter Product Range

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.

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

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

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

Protection Algorithms c) Starting control Freq C Freq 6 4 min 1 min 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

Protection Algorithms c) Starting control

Protection Algorithms c) Starting control

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

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

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 10ºC - 15ºC Restriction e.g.. at strainer, capillary, filter dryer, etc

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 10ºC - 15ºC Insufficient Heating High Heating load Restriction e.g.. at strainer, capillary, filter dryer, etc Satisfactory operation with temperature difference of air intake & discharge of indoor unit 16ºC - 25ºC

Pressure conditions

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

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

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

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

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

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

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

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

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 240-250KΩ Problems Caused by over voltage Working ambient to high + ~ -

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

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

Key Components - Sensors 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

All the value same for discharge, room and coil Sensor values Longertech sensor value 25ºC 5.2860kOhm 2.3533Vdc Room/ coil Sensor 25ºC 57.9400KOhm 1.2830Vdc Discharge Sensor OYL sensor value 25ºC 10.00kOhm 1.45Vdc All the value same for discharge, room and coil Example: Measured from multi-meter is 3.27KOhm. 5.00KOhm - 3.27KOhm = 1.728KOhm From the table, 1.728KOhm convert back to 35ºC

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

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

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

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

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

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

Troubleshooting Methods Error Codes – (5)WMX-G LED Fault Indications Troubleshooting Methods 1 2 3 4 ● Defrost Operation (Red) Ignore I/D Sensor Error (Yellow) Check I/D Sensor wire and value (~5kΩ) Coil Temp. Sensor Error Check Coil Sensor wire and value (~5kΩ) O/D Temp. Sensor Error Refer O/D Unit Compressor Overload IPM Error O/D Current Trip Compressor Overheat / Gas Leak I/D Fan Feedback Error Check I/D Fan Wire Communication Error Check Wiring

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

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

Troubleshooting Methods Error Codes – Outdoor Compressor Stopped LED Blinking Blink Fault Indications Troubleshooting Methods 10 Cooling Overload Check Pressure 11 Defrost Ignore 12 IPM Protection Check Power Supply; Check Main Board / Filter Board; Check Bridge Diode; Check IPM Board; Check Compressor 13 Read EEPROM Error Check EEPROM Chip Connection 14 Write EEPROM Error 15 DC Fan Motor Feedback Error 16 AC Peak Current Error 17 O/D Suction Sensor Error Check O/D Suction Sensor Wire & Connection (Applicable only for Heat Pump Unit)

Troubleshooting Methods Error Codes – Outdoor Compressor Stopped LED Blinking Blink Fault Indications Troubleshooting Methods 18 None Ignore 19 DC Comp. Speed Control Error Check IPM Board; Check Compressor; 20 21 O/D Suction Pipe A Sensor Error Check Suction Pipe A Sensor Wire & Connection 22 O/D Suction Pipe B Sensor Error Check Suction Pipe B Sensor Wire & Connection 23 O/D Suction Pipe C Sensor Error Check Suction Pipe C Sensor Wire & Connection 24 O/D Suction Pipe D Sensor Error Check Suction Pipe D Sensor Wire & Connection 31 Communication Error with I/D A Check Communication Wire & Connection with I/D A 32 Communication Error with I/D B Check Communication Wire & Connection with I/D B 33 Communication Error with I/D C Check Communication Wire & Connection with I/D C 34 Communication Error with I/D D Check Communication Wire & Connection with I/D D

Power supply checking 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 Multi split inverter

Fuse checking 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

Communication wires checking 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

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

Electrolytic Capacitor Checking Use multi-meter to check the DC voltage across the E-CAP In normal case the value should around 270-330Vdc

5SLX 10/15CR & MSV 25/35A (LONGERTECH) Bridge Diode Continuity Checking 5SLX 10/15CR & MSV 25/35A (LONGERTECH) + ~ - (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 240-250kΩ The bridge diode with ‘BEEP’ sound is nok

Bridge Diode Continuity Checking + Result show in kΩ OK OK 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

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

Bridge Diode Vdc value checking + 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 + + 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 Use multi-meter to check the connectivity of the bridge diode The bridge diode with ‘BEEP’ sound is nok Value 380-400Ω is OK Value 190-220KΩ is OK 5SLX 10CR/15CR (OYL) 5SLX 20/25CR & 5MSX 20/25/30AR

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

Using multimeter with continuity function. Multimeter show OL means ok 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

Using multimeter with continuity function. Multimeter show OL means ok 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

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

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

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

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 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

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

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

Hardware Installation Schematic Single-split Multi-split

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

Display Operating Parameters

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

Features Data Logging Data Storage & Transmission Graphical Representation

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.

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

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 Email Useful to generate Service Reports

Graphical representation

Graphical representation

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

Interceptor sales package Interceptor Module RS232 Serial Connection Cable

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

Thank you