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Welcome

Module 1 RAC. Welcome. Jason Roberts. Training Manager. SAFETY. Mobile Phones Fire Alarm Exits Toilets Practical Testing Workshop Awareness. Introduction. Why training in service? Technology Advancements

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Welcome

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Presentation Transcript

  1. Module 1 RAC Welcome

  2. Jason Roberts Training Manager

  3. SAFETY • Mobile Phones • Fire Alarm • Exits • Toilets • Practical Testing • Workshop • Awareness

  4. Introduction • Why training in service? • Technology Advancements • Better understanding of what is actually happening during operation and diagnostic • Product problems are dealt with efficiently by you. • Less incorrect warranty diagnosis • Opportunity for two way feedback • What we are going to cover today? • Support Manual • Equipment • Basic Theory • Control Functions • Checking testing

  5. Support Manual • 2 x Books Residential (RAC) Commercial (PAC) • 25 Codes across all products • Quick access to rectification • A5 Convenience

  6. CERTIFICATE • On line questionnaire • One submission attempt • Certificate if passed

  7. RecommendedTools

  8. Multimeter • “Diode” test function is essential • Sharp or needlepoint probes are recommended.

  9. Clamp Meter – True RMS • To monitor current draw to unit and compressor. • A frequency function is • HIGHLY RECOMMENDED

  10. Inverter Checker • Connect to the inverter in place of a DC Compressor, LED’s flash ON and OFF to indicate switching of Inverter. • A quick visual check of Inverter function • DOES NOT test Inverter under load.

  11. Insulation tester • Commonly known as a “Megger” • Used to test compressor windings for shorts to earth • A multimeter IS NOT an Insulation tester

  12. Thermometer • Who has a Digitemp? • Thermometer with “bead” type thermocouple or touch probe • Can be attached to a pipe with a cable tie. • Can be slipped in with the factory pipe temperature sensor.

  13. Serial signal test lead • A serial signal test lead is used to measure the indoor and outdoor communication signal. • Easily made with a spare multimeter lead and a 1000V diode • We will even give you a diode for free  • Invaluable for working on Fujitsu General units

  14. What is an inverter? • A device that converts normal alternating current to an adaptable voltage & frequency. This in turn allows a motor speed to increase or slow down.

  15. Inverter Benefits • Compressor speed is controlled automatically to reduce energy consumption. • The target temperature can be achieved more rapidly as the compressor can increase its output to meet peak demand. • The control temperature is more accurately controlled improving customer comfort.

  16. Inverter Block Diagram

  17. Power / Filter PCB • Visually check the varistors for signs of physical damage such as splitting or burning. • A varistor will fail or “blow” if an excess voltage is applied, it’s normally a sign of a mains power supply issue. • Check for AC Voltage IN and OUT of the Power PCB

  18. Inverter Block Diagram POWER FACTOR CORRECTION CIRCUIT

  19. Posistor / Power Relay Circuit POSISTOR By passes Power Relay, allowing initial power up as the power relay is not energised by default. It Only allows low current to pass through it. The Posistor goes open circuit if abnormal current flow is detected on power up. POWER RELAY Energised by outdoor control PCB

  20. Posistor / Power relay The Posistor is a safety device used to prevent subsequent damage after a component in the inverter has failed. The initial fault will occur and usually trip the power supply circuit breaker to the system. When the power supply is reset the Posistor detects the over current as the outdoor unit powers up and open circuits preventing power flow into the inverter and any further damage. The Posistor itself does not actually fail, it is similar to a self resetting fuse and will open circuit when excess current flows through it. Once the fault downstream has been corrected the Posistor will reset.

  21. Inverter Block Diagram POWER FACTOR CORRECTION CIRCUIT

  22. Diode Bridge / Bridge Rectifier • The AC Voltage enters the Diode Bridge and is converted into DC Voltage • 240 VAC in = ~240 VDC OUT

  23. Diode bridge checks II • Before starting test, ensure outdoor unit is isolated • Use a digital multimeter set to Diode Check mode • Disconnect wires to component if possible

  24. Heat sink paste Heatsink paste must be used If there was white paste on the component’s you removed then a new coating must be applied to the replacement component’s The old paste must be cleaned off the heat sink, Methylated spirits and some rag or paper towel works well A small artists palette knife is very handy to apply an even coating and keeps you and the machine free from mess

  25. ACTPM / Active Filter Module Check White Black Brown Blue N1 Red Yellow P

  26. ACTPM / Active Filter Module 2 • Before starting test, ensure outdoor unit is isolated • All wires must be disconnected from the Active Filter to do the tests • Multimeter must be set to Resistance.

  27. ACTPM / Choke Coil • Most systems have a separate power factor correction device that may be called the ACTPM or ACTIVE FILTER MODULE. • On small systems where there is only one inverter / controller pcb in the outdoor unit, the power factor correction circuit is part of the main inverter PCB • The power factor correction circuit includes a large coil of copper wire referred to as the Reactor, Inductor or Choke coil.

  28. Inverter Block Diagram POWER FACTOR CORRECTION CIRCUIT

  29. Smoothing Capacitor • Capacitors store energy and are used to smooth out any ripples in the DC Voltage. • Beware they BITE ! • At this stage the DC power has now been boosted, corrected and smoothed and is ready to be used to drive the compressor.

  30. Inverter Block Diagram POWER FACTOR CORRECTION CIRCUIT

  31. + + S1 S3 S5 S1 S3 S5 U U S4 S6 S2 V W S4 S6 S2 V W - - + P S1 S3 S5 U MOTOR S4 S6 S2 V W - N By changing the ON-OFF cycle of the switch, the rotation of the motor can be varied at the desired frequency. If the DC voltage is changed, the input voltage of the motor can be also varied. Practically, the motor is rotated by using 6pcs of transistors instead of a switch, and the transistor is alternately turned ON-OFF. + S1 S3 S5 U S4 S6 S2 V W - Intelligent Power Module (IPM) • The IPM takes the High Voltage DC power and switches it to each phase of the compressor creating artificial three phase power. time S1 S2 S3 S4 S5 S6 ON OFF U – V V – W W – U

  32. Intelligent Power Module Check

  33. Intelligent Power Module Check II • This procedure performs a static test of the component only and will identify a shorted transistor which is one of the causes of an IPM error. • Before starting test, ensure outdoor unit is isolated • Use a digital multimeter set to Diode Check mode • Disconnect wires to component if possible V’ Phase U’ Phase W’ Phase positive Negative

  34. Intelligent Power Module Checks III

  35. Inverter Block Diagram POWER FACTOR CORRECTION CIRCUIT

  36. Inverter Checker The Inverter phase checker may be used to check the switching operation of the Intelligent power Module. It is plugged into the compressor harness connector or at the compressor terminals, depending on model to simulate the compressor The lights will flash on and off in sequence to indicate correct switching of the IPM. If any lights do not light to the same brightness as the others or if any lights stay permanently ON or OFF then the IPM is defective or it is being given incorrect switching signals from the controller PCB.

  37. Inverter Compressor testing Winding resistance between phases vary depending on model, they range from 0.188 Ohm (AOT54LJBYL) to 1.41 ohms (AOT24LMADL) between phases. A Dedicated milliohm meter is the only way to accurately measure compressor winding resistances. Most compressor winding resistances are stated at 20° or 25 °C, the compressor must be at the stated temperature for the reading to be accurate. Insulation resistance MUST be checked using an INSULATION TESTER (“Megger”) at 500V not a normal multimeter.

  38. Inverter Block Diagram POWER FACTOR CORRECTION CIRCUIT

  39. Main- Inverter- Controller PCB The Controller PCB functions: • Low voltage power supply • Microprocessor • Serial communication • Thermistors • Outdoor fan motor, AC or DC • Electronic expansion valve

  40. Break

  41. Practical Session

  42. WARNING Some of the equipment being demonstrated today will be “LIVE” Please make sure all due care and attention is taken, there will be 240 VAC present and up to 400V DC. Please watch others as they are watching you! STAY SAFE!

  43. Serial signal Communication • The serial signal is used for the indoor unit and outdoor unit to communicate • with each other • The serial signal is modulated on an AC sine wave INFORMATION 1 Forward Serial signal Outdoor Unit Indoor Unit INFORMATION 2 Reverse Serial signal Example of Serial Signal of ASY24PBA-W/AOY24PMAL

  44. Communication Signal

  45. Diode Lead Signal Check This test is to check the indoor unit is communicating to the outdoor unit Place the diode lead on to the signal line Place the black lead on to the neutral line If the reading is approx 30 to 60 VDC the indoor unit is communicating to the outdoor unit. If the signal is 0 to 5 VDC start checking the indoor unit for defective components. This test is to check the outdoor unit is communicating to the indoor unit Place the diode lead on to the neutral line Place the black lead on to the signal line If the reading is approx 30 to 60 VDC the outdoor unit is communicating to the indoor unit. If the signal is 0 to 5 VDC start checking the outdoor unit for defective components.

  46. Communication Serial signal testing

  47. DC Fan motors • DC fan motors are self contained inverter driven variable speed motors. • DC Fan motors are becoming more common in Outdoor units and in many Indoor units. • Distinguished by a Multi pin connector with 5 leads • Controlled by a speed signal from Main PCB based on compressor speed and outdoor ambient temp. • The DC motor provides a Feedback signal to Main PCB. • NEVER DISCONNECT OR RE-CONNECT WHILST POWER APPLIED

  48. DC Fan Motor Checks Before disconnecting or reconnecting ANY DC Fan motors the power supply must be isolated and the DC voltage within the unit drained below 40VDC Fan motor feedback signal (BLUE) (Or Brown) Fan motor speed signal (YELLOW) DC Control Power 15VDC (WHITE) DC Ground (BLACK) High Voltage DC 330-380 VDC (RED)

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