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August 2011

Inverter PAC Electrical Circuit Check Point. August 2011. Inverter driven PAC. Contents. 1. Main Circuit. 2. Check Point. 3. Reference. 4. Inverter Checker. 5. Electrical Wiring. 6. Servicing. +. +. -. -. 1. 2. N. 3. F1(250V, 2A). 1. Main circuit.

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August 2011

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  1. Inverter PACElectrical Circuit Check Point August 2011

  2. Inverter driven PAC

  3. Contents 1. Main Circuit 2. Check Point 3. Reference 4. Inverter Checker 5. Electrical Wiring 6. Servicing

  4. + + - - 1 2 N 3 F1(250V, 2A) 1. Main circuit 1-1. FDC100-140VS (4-6HP 3-phase) R1 R2 Inverter PCB U PWB2 Noise filter PCB L PWB3 TB 52C DM TB5 L1 L1i RS L1o ～ +4 C1 U U L2 R3 L2i L2o ～ V CM CT1 L3 V IPM -6 L3o L3i ～ W C2 K G W F(8A) No R4 Ni IPM sensor TB6 T12 CNW2 E CN1 CN2-1 F(４A) CNR CNW1 To Indoor Unit CNW CNIP Control PCB CNW2 PWB1 F2(250V, 4A) CNI1 CNI2 LED1 Yellow CNA1 CNO1 LED1 Green LED2 Red CNA2 CANFAN1 FM1

  5. F (20A) F6(5A) + - L1 N 1. Main circuit 1-2. FDC71VN (3HP Single-Phase) C1 Noise filter PCB PWB3 L1 TB T4 T25 T27 T24 T26 U T1 T5 T28 T21 LED1 Yellow V T2 T22 T6 T29 IPM CM Inverter PCB W CNO1 PWB2 T30 CNO2 1 IPM sensor T8 2 T10 CNI4 CNI2 CNG2 T9 T11 3 T13 F2(4A) To Indoor Unit CNW CNA1 CNA2 CNI1 CNI3 CNG1 CNIP CNW2 SW setting PCB CNQ1 CNQ1 F3 (250V, 2A) Control PCB PWB1 F4 (250V, 2A) SW setting PCB CNQ2 CNQ2 LED1 Green LED2 Red CNFAN FM

  6. + F(30A) - 1 2 N 3 F1(250V, 2A) 1. Main circuit 1-3. FDC100-140VN (4-6HP Single-phase) Noise filter PCB U Inverter PCB PWB3 U TB DM V PWB2 V CM IPM L1 W Ri W ～ + Ro P１ LED1 Yellow CT1 IPM sensor Si So - N1 ～ F(8A) CNI4 CNI2 N2 CNACT1 P2 N2 P 1 E 2 E F(４A) P + ー A/F Module C1 N2 To Indoor Unit L1 L2 L CNI1 CNI3 CNW Control PCB CNW2 PWB1 CNA1 F2(250V, 4A) CNA2 LED1 Green LED2 Red CNIP CNFAN1 FM1

  7. L1 + + L2 - - L3 1 2 N 3 F1(250V, 2A) 1. Main circuit 1-4. FDC200,250VS (8,10HP 3-phase) R1 R2 U Inverter PCB Noise filter PCB PWB2 L PWB3 TB 52C DM U P U L1i RS L1o ～ +4 C1 V CM V R3 L2i L2o ～ W CT1 N W -6 L3o L3i ～ C2 K G IPM sensor IPM No R4 Ni P2 F(10A) P3 LED1 Red LED2 Green N2 E CNR CNI3 Power PCB for Fan Motor CNW1 CNW To Indoor Unit Control PCB CNA1 CNQ1 PWB1 F2(250V, 4A) CNW2 PWB4 CNA2 CNQ2 LED2 Red LED1 Green CNI1 CNIP CNFAN2 CNFAN1 FM1 FM2

  8. F (20A) F6(5A) + - L1 N 2. Check Point Power supply check: Check the power between L1 and N at terminal block TB. (If AC198-264V is detected, it is normal) 2-1. FDC71VN (3HP Single-Phase) Fuse F(20A) check: There must be continuity. (If the fuse F(20A) is blown, replace it) Voltage check: Voltage between T26 and T27 must be DC280-373V at stopping and DC370-400V at operating. C1 Noise filter PCB PWB3 L1 TB T4 LED1 (Yellow) : Indication for anomaly At normal operation ⇒ Keeps flashing At anomaly ⇒ Flashing or lighting See page 12 for detail T25 T27 T24 T26 U T1 T5 T28 T21 LED1 Yellow V T2 T22 T6 T29 IPM CM Inverter PCB W CNO1 PWB2 T30 CNO2 1 IPM sensor T8 2 T10 LED1 (Green) : Indication for operation If it is flashing at each 0.5 sec, it is normal. If it lights off, check the connection of CNI1. CNI4 CNI2 CNG2 T9 T11 Fuse F3 check: There must be continuity. (If the fuse F3 is blown, check if a fan motor is ok by hand) 3 T13 F2(4A) To Indoor Unit Fuse F6 check: There must be continuity. (If the fuse F6 is blown, replace it after checking the wiring to indoor unit) CNW CNA1 CNA2 CNI1 CNI3 CNG1 CNIP CNW2 SW setting PCB CNQ1 CNQ1 F3 (250V, 2A) Control PCB Fuse F2 check: There must be continuity. (If the fuse F2 is blown, replace it after checking crankcase heater, 4-way valve and drain pan heater) PWB1 F4 (250V, 2A) LED1 Green LED2 Red SW setting PCB CNQ2 CNQ2 CNFAN LED2 (Red) : Indication for anomaly At normal operation ⇒ Lights off At anomaly ⇒ Keeps flashing Check error code DC fan motor check: See page 32 and 34 for detail FM

  9. + F(30A) - 1 2 N 3 F1(250V, 2A) Power supply check: Check the power between L1 and N at terminal block TB. (If AC198-264V is detected, it is normal) 2. Check Point 1-2. FDC100-140VN (4-6HP Single-phase) Voltage check: Voltage between P and N2 must be DC280-385V at stopping. Fuse F(30A) check: There must be continuity. (If the fuse F(30A) is blown, replace it) Noise filter PCB U Inverter PCB PWB3 U TB DM V PWB2 V CM IPM L1 W Ri W ～ + Ro P１ LED1 Yellow CT1 IPM sensor Si So - N1 ～ F(8A) LED1 (Yellow) : Indication for anomaly At normal operation ⇒ Keeps flashing At anomaly ⇒ Flashing or lighting See page 12 for detail CNI4 CNI2 N2 CNACT1 P2 N2 P 1 E Fuse F(4A) check: There must be continuity. (If the fuse F(4A) is blown, replace it after checking crankcase heater, 4-way valve and drain pan heater) 2 E F(４A) P + ー A/F Module C1 N2 To Indoor Unit L1 L2 LED1 (Green) : Indication for operation If it is flashing at each 0.5 sec, it is normal. If it lights off, check the connection of CNI1 L CNI1 CNI3 CNW Control PCB CNW2 PWB1 CNA1 F2(250V, 4A) CNA2 LED1 Green LED2 Red Fuse F2 check: There must be continuity. (If the fuse F2 is blown, check if a fan motor is ok by hand) LED2 (Red) : Indication for anomaly At normal operation ⇒ Lights off At anomaly ⇒ Keeps flashing Check error code CNIP CNFAN1 Fuse F(8A) check: There must be continuity. (If the fuse F(8A) is blown, replace it after checking the wiring to indoor unit) FM1 DC fan motor check: See page 32 and 34 for detail

  10. + + - - 1 2 N 3 F1(250V, 2A) 2. Check Point Power supply check: Check the power between L1-L2, L2-L3 and L3-L1 at terminal block TB. (If AC343-415V is detected, it is normal) 1-3. FDC100-140VS (4-6HP 3-phase) Fuse F(8A) check: There must be continuity. (If the fuse F(8A) is blown, replace it after checking the wiring to indoor unit) R1 R2 Inverter PCB U PWB2 Noise filter PCB L PWB3 TB 52C DM Voltage check: Voltage between (+) and (-) must be DC485-588V at stopping. TB5 L1 L1i RS L1o ～ +4 C1 U U L2 R3 L2i L2o ～ V CM CT1 L3 V IPM -6 L3o L3i ～ W C2 K G W F(8A) No R4 Ni IPM sensor TB6 T12 LED1 (Green) : Indication for operation If it is flashing at each 0.5 sec, it is normal. If it lights off, check the connection of CNI1 CNW2 E CN1 CN2-1 F(４A) Characteristics of sensor : See technical manual 08-PAC-T-118 (P306) CNR CNW1 LED2 (Red) : Indication for anomaly At normal operation ⇒ Lights off At anomaly ⇒ Keeps flashing Check error code To Indoor Unit CNW CNIP Control PCB CNW2 PWB1 F2(250V, 4A) CNI1 CNI2 LED1 Yellow CNA1 CNO1 LED1 (Yellow) : Indication for anomaly At normal operation ⇒ Keeps flashing At anomaly ⇒ Flashing or lighting See page 12 for detail LED1 Green LED2 Red CNA2 CANFAN1 Fuse F2 check: There must be continuity. (If the fuse F2 is blown ,check if a fan motor is ok.) DC fan motor check: See page 32 and 34 for detail FM1

  11. L1 + + L2 - - L3 1 2 N 3 F1(250V, 2A) 2. Check Point Power supply check: Check the power between L1-L2, L2-L3 and L3-L1 at terminal block TB. (If AC343-415V is detected, it is normal) 2-4. FDC200,250VS (8,10HP 3-phase) Fuse F(10A) check: There must be continuity. (If the fuse F(10A) is blown, replace it after checking the wiring to indoor unit) R1 R2 U Inverter PCB Noise filter PCB PWB2 L PWB3 TB 52C DM U P U Voltage check: Voltage between (+) and (-) must be DC485-588V at stopping. L1i RS L1o ～ +4 C1 V CM V R3 L2i L2o ～ W CT1 N W -6 L3o L3i ～ C2 K G IPM sensor IPM No R4 Ni P2 F(10A) P3 LED1 Red LED2 Green LED1 (Green) : Indication for operation If it is flashing at each 0.5 sec, it is normal. If it lights off, check the connection of CNI1 N2 E CNR CNI1 voltage check: See page 13 for detail CNI3 Power PCB for Fan Motor CNW1 CNW LED1 (Red) : If it lights off, normal If it is flashing or lighting, check it See page 13 for detail. To Indoor Unit Control PCB CNA1 CNQ1 PWB1 F2(250V, 4A) CNW2 PWB4 CNA2 CNQ2 LED2 Red LED1 Green CNI1 Fuse F2 check: There must be continuity. (If the fuse F2 is blown, check if a fan motor is ok by hand) LED2 (Green) : If it keeps flashing, micro-computer works well. If it lights off, anomaly. Check the connection of CNI3 CNIP CNFAN2 CNFAN1 LED2 (Red) : Indication for anomaly At normal operation ⇒ Lights off At anomaly ⇒ Keeps flashing Check error code FM1 FM2 DC fan motor check: See page 32 and 34 for detail

  12. 3. Reference (for FDC71VN-140VN/S) 3-1 Cause of anomaly at flashing LED 1 (Yellow) on Inverter PCB 1 time flash : Current cut (Over current of power transistor ・Short-circuit of wiring for compressor ・Inverter PCB failure ・Power transistor failure 2 time flash : Overheat of power transistor ・Loose fixing of radiation fin for power transistor (Loose fixing with screws, Insufficient application of silicon grease and etc.) ・Power transistor sensor failure 3 time flash : Compressor rotor position detection failure ・Compressor failure ・Inverter PCB failure 4 time flash : Start-up failure of compressor ・Compressor failure ・Inverter PCB failure ・Power transistor failure 5 time flash : Current cut error ・Inverter PCB failure Keeps lighting : Communication error between inverter PCB and outdoor control PCB ・Disconnection of CNI1, 2, 3, 4 connector or of wire between CNI1, 2, 3, 4 ・Outdoor control PCB failure ・Inverter PCB failure Keeps flashing : Normal

  13. - - - + + + Connector Voltage 1 12V Swing between 8V and 12V (Measured with analog tester) 2 CNI1 3 Swing between 4V and 5V (Measured with analog tester) 4 3. Reference (for FDC200, 250VS) 3-2 Cause of anomaly at flashing LED 1 (Red) on Inverter PCB 1 time flash : Current cut (Over current of power transistor ・Short-circuit of wiring for compressor ・Inverter PCB failure ・Power transistor failure 2 time flash : Overheat of power transistor ・Loose fixing of radiation fin for power transistor (Loose fixing with screws, Insufficient application of silicon grease and etc.) ・Power transistor sensor failure 3 time flash : Compressor rotor lock ・Compressor failure ・Inverter PCB failure 4 time flash : Start-up failure of compressor ・Compressor failure ・Inverter PCB failure ・Power transistor failure 5 time flash : Prevention for demagnetization ・Short-circuit of wiring for compressor ・Inverter PCB failure ・Power transistor failure 　 ・Disconnection of compressor motor neutral line 6 time flash : Inverter PCB failure Keeps lighting : Communication error between inverter PCB and outdoor control PCB ・Disconnection of CNI1, 3 connector or of wire between CNI1 and 3. ・Outdoor control PCB failure ・Inverter PCB failure 3-3 Voltage check for CNI1 connector

  14. 4. Inverter checker 【Previous】 In case of previous inverter PAC with vector inverter PCB, inverter checker cannot be use. [Only the 120deg. energizing control type models (8,10HP) are available to use] ⇒It cannot judge which one is damaged, inverter or compressor. 【Improved】 In case of new inverter PAC (3-6HP), “ Test mode” function is added in order to use inverter checker. （Turn SW10-4 on the inverter PCB ON and power ON ） It becomes available for all inverter models LED1 LED1 LED1 LED1 LED1 LED1 LED2 LED2 LED2 LED2 LED2 LED2 LED ON/OFF pattern LED3 LED3 LED3 LED3 LED3 LED3 LED4 LED4 LED4 LED4 LED4 LED4 LED5 LED5 LED5 LED5 LED5 LED5 LED6 LED6 LED6 LED6 LED6 LED6 Repeating ON OFF

  15. 4. Inverter checker ＜Principle of operation＞ According to switch the mode (6 patterns) of power transistor, LED of inverter checker will light ON in order. ⇒If inverter has anomaly, LED will be flashing. P U LED 1 LED1 10 k Ω / 2 W LED2 LED 2 LED3 ~ U V LED4 LED 3 10 k Ω / 2 W LED5 LED 4 LED6 Light on ~ V W LED 5 10 k Ω / 2 W LED on inverter checker LED 6 ~ W Inverter checker N Inverter

  16. 4. Inverter checker ＜Connecting inverter checker to actual unit ＞ Inverter checker

  17. 5. Electrical wiring 5-1. Power cable Single-phase model 3-phase model Power cable Max. over Cable Grounding Indoor-outdoor Outdoor unit Power thickness current length wire thickness wire thickness model source (mm2) (A) (m) (mm) (mm) 3.5 17 21 FDC71VN 1-phase FDC100VN 220-240V 50Hz 24 5.5 5.5 25 FDC125VN 220V 60Hz FDC140VN 1.6mm FDC100VS Φ 1.6 x 3wires Φ 3-phase 15 FDC125VS 27 3.5 380-415V 50Hz FDC140VS 380V 60Hz 19 21 FDC200VS 5.5 22 31 FDC250VS

  18. 5. Electrical wiring 5-2. Interconnecting cable between indoor and outdoor unit Be sure to use 3-core cable for interconnecting wire and do not use sealed cable. In case that 4-core or multi-core cable is used, if proper grounding work is not done, communication anomaly may happen by the electrical noise through grounding wire.

  19. 5. Electrical wiring 5-3. Necessity of Grounding In Japan all of electric equipment are obliged to be grounded with proper grounding resistance (less than 100 ohm) When the dielectric breakdown occurs in the transformer of supplying power or in the air conditioner, in case of high grounding resistance, there might have some risk of electrical shock, communication anomaly and/or earth leakage breaker malfunction. Transformer Transformer Earth leakage breaker Earth leakage breaker 6600 V 200 V 6600 V 200 V Breaker Breaker Grounding wire Grounding wire Ground Ground Grounding resistance: high Grounding resistance: lowl Grounding resistance: High Grounding resistance: Low

  20. 5. Electrical wiring 5-4. Grounding for Inverter Models By releasing the electrical noise through grounding, electric noise level of the inverter unit is kept within the control range Inverter compressor tends to generate electrical noise Electrical noise Leak current Grounding is regulated by the electric equipment safety norm in Japan Our products specifications is premised on the proper grounding requirement

  21. 5. Electrical wiring 5-5. In case of improper grounding work If grounding is not done properly, there might have not only The risk of electrical shock but also Communication anomaly, Earth leakage breaker malfunction Electrical noise generated by other equipment could penetrate into the air conditioner through grounding wire in case of improper grounding work. Inverter unit releases electrical noise through grounding. If the grounding work is not done properly, inverter unit is affected by the noise generated by other equipment through grounding. The cause of this problem is improper grounding work, not other equipment Transformer Earth leakage breaker 6600 V 200 V Breaker Other Equipment Interconnecting wire between indoor and outdoor unit Ground Grounding resistance: high

  22. 5. Electrical wiring 5-6. Case 1 (Earth leakage breaker malfunction) Investigation result Phenomenon When the fan motor with thyristor control of refrigeration unit (installed near to inverter unit) starts running, the current on the grounding wire of inverter unit becomes increasing Earth leakage breaker is activated a while after compressor starts. Cause Electrical noise generated by the refrigeration unit penetrates into the inverter unit through grounding wire and earth leakage breaker is activated. Measure Grounded independently

  23. 5. Electrical wiring 5-6. Case 2 (Communication anomaly) signal wave (before measure) Phenomenon Immediately after power ON, Red LED on outdoor PCB is flashing 2 times (Communication error between outdoor andindoor unit) Investigation result Due to solid soil and stones, ground bar cannot be inserted more than 30cm signal wave (after measure) Cause Due to high grounding resistance, electrical noise from other unit affects to the communication line of inverter unit. Measure Grounded properly

  24. ～ ～ ～ ～ ～ ～ 5. Electrical wiring 5-6. Case 2 (Communication anomaly) Switchboard Switchboard Switchboard Grounding Grounding Grounding Power supply Power supply Power supply Power supply Power supply Power supply Outdoor Unit Other Equipment Outdoor Unit Outdoor Unit Other Equipment Other Equipment Indoor Unit Indoor Unit Indoor Unit In case that the unit and other equipment is on the same metal base, proper grounding is required as well. Be sure to use earth leakage breaker with surge current protection.

  25. 6. Servicing Resistance(100kΩ) Break results no power supply 6-1. Diagnosis of Inverter PCB Fuse Blown out results no power supply Connector of communication line Loose insertion of connector results communication error PTC (27Ω） If damaged, no power supplying after power on again results staying off of LED Connector of communication line Loose insertion of connector results communication error Power line from control PCB(15V, 18V) Loose insertion of connector results staying off of LED LED Yellow LED Red 100～140VN models 200-250VS models

  26. 6. Servicing 6-2. Diagnosis of Control PCB Fuse (F1) Blown out results no power supply Fuse (F2) Blown out results no power supply to fan motor CT for current safe Current control by detection of L3-phase Pump down switch for relocation of unit Pump down operation will stop automatically by detecting low pressure Connector of communication line with inverter PCB Loose insertion of connector results communication error LED Normal : Green LED keeps flashing Anomaly : Red LED is flashing 100～140VS models

  27. 6. Servicing 6-3. Check point when PCB anomaly happens Be sure to confirm whether the Diode Module is burnt or not, when following anomaly happens. ＜Anomaly＞ ① Breaker is activated ② Inverter PCB anomaly ③ Power transistor anomaly ④ Fuse is burnt （＊checking method is shown in next page） Because Diode Module is not mounted on the PCB of models (FDC100-250), in case that the diode module is burnt even if PCB is replaced, breaker could be activated again and/or power could not be supplied.

  28. ② ～ + ④ ＋④ ①～ ③ ～ ① ～ ②～ ③～ － ⑤ －⑤ ① AC1 ② AC2 ③ AC3 ④R5 ＋4 K ①AC1 G ②AC2 ③AC3 ＋4 R5 ④ －6 ⑤ -6 ⑤ 6. Servicing 6-4. Diode Module In case of FDC100-140VN (4-6HP) Inner circuit of diode module Outlook of diode module In case of FDC100-250VS (4-10HP) Outlook of diode module Inner circuit of diode module

  29. 6. Servicing 6-5. How to check Diode Module Measure the resistance the point (No. 1-12)shown in following table by circuit tester.  ①-⑤ are the terminal No. shown in the drawing in previous page. <Judgement> i) If the resistance is 0-several k ohm, diode module could be burnt. ii)If the resistance is infinitive (∞), diode module could be burnt either. ※In case that the judgement is i) or ii), diode module should be replaced.

  30. 6. Servicing 6-6. Replacement of power transistor Application of silicon grease Necessity of application of silicon grease 　　・Application of silicon grease have a positive effect on heat radiation by filling small gap between semiconductor device (like as power transistor and diode module) and radiation fin. 　　・High thermally-conductive type (oil compound type) of silicon is recommendable. Application procedure ・Be sure no dust and no dirty on the heat radiation surface of power transistor or diode module in order to have good radiation performance. 　　・Be sure to apply silicon grease uniformly 　　・Thin film of silicon applied on radiation fin side either makes good fitting Good Sample Bad Sample

  31. 6. Servicing 6-7. DC fan motor anomaly ① Don’t disconnect and connect the power connector of DC fan motor of outdoor unit during supplying main power. [Caution] Cutting off and on the power of DC fan motor during supplying main power may cause the damage of DC fan motor. [Caution] in case that the fan is rotated by wind, don’t cut off the power too. ＊Because the induction voltage generated by rotating fan motor may cause the damage of DC fan motor. ② If the DC fan motor is broken, there is some cases that control PCB cannot work. [Caution] Because the power line of DC fan motor and control PCB is common. So in case of some models no power can be supplied to inverter PCB. [Reference] If the power line of DC fan motor is short circuited, DC fan motor can not be turned smoothly, because the turning torque becomes bigger. Accordingly turning fan by hand is useful way to judge the DC fan motor failure.

  32. 6. Servicing 6-8. How to judge fan motor anomaly Ordinary way to judge the irregularity is whether the turning torque is bigger or not, but in some case it is not. Judgement can be done by measuring resistance between 1(Vm) and 4(GND)of CNFAN 1 or 2 connector with digital circuit tester If the resistance is less than 1k-ohm, fan motor is damaged. 1 (Vm) Red : Supplying power line of motor (about DC280V) 4 (GND) Black: Ground (common with the power for motor and controller) 5 (Vcc) White : Supplying power line of controller (about DC15V) 6 (Vsp) Yellow: Fan motor speed command (about DC0-5V) 7 (FG) Blue : Pulse input of motor frequency 8 (DM) Pink : Input of rotation direction (about DC2-4V) 9 (LA) Gray : Output voltage for angle adjustment (about DC2-4V) In case of the unit with 2 fan motors (200 and 250 model), even if the other fan motor is still normal, replacement of both fan motors is recommendable.

  33. 6. Servicing 6-9. Error caused by fan motor failure Following error codes can be detected by a fan motor failure. If 15VDC’s signal is dropped due to fan motor anomaly. E41 : Power transistor overheat E45 : Inverter communication error E51 : Inverter and fan motor anomaly E59 : Compressor startup failure Error output (15VDC)

  34. 6. Servicing 6-10. Other components ① Be sure to insert the fasten connector to compressor terminal block deeply. [Caution] If the insertion is not enough, it may cause the failure of compressor start up and/or current cut during operation. [Caution] If the unit is kept operation without any correction, compressor may have damage. ② Don’t replace the inverter PCB immediately, if the communication error (E45) between inverter PCB and control PCB happens. [Caution] Check LED on inverter PCB and diagnose according to the troubleshooting procedure.

  35. Thank you for your attention!

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