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Summary of Contents for Johnson Controls DHW18CMB21S
- Page 1 Service Manual "W" SERIES 18K - 24K INVERTER-DRIVEN AIR CONDITIONING UNITS Type Model DHW18CMB21S OUTDOOR UNITS DHW24CMB21S PLEASE READ AND UNDERSTAND THIS MANUAL BEFORE USING THIS INVERTER-DRIVEN AIR CONDITIONING UNIT. KEEP THIS MANUAL FOR FUTURE REFERENCE.
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Page 2: Important Notice
Important Notice ● Johnson Controls, Inc. pursues a policy of continuing improvement in design and performance in its products. As such, Johnson Controls, Inc. reserves the right to make changes at any time without prior notice. ● Johnson Controls, Inc. cannot anticipate every possible circumstance that might involve a potential hazard. -
Page 3: Table Of Contents
Service Manual Table of Contents Safety Summary ........................i 1. Features and Summary ...................1 ........................2 3. Outline Dimension Diagram ................6 4. Refrigerant System Diagram ................7 5. Electrical Parts ........................8 5.1 Wiring Diagram........................8 5.2 PCB Printed Diagram......................10 6. Function and Control ....................12 7. -
Page 4: Important Safety Instructions
Never bypass or jump-out any safety device or switch. ● Johnson Controls, Inc. will not assume any liability for injuries or damage caused by not following steps outlined or described in this manual. Unauthorized modifications to Johnson Controls products are prohibited as they…... - Page 5 Take the following precautions to reduce the risk of property damage. ● Be careful that moisture, dust, or variant refrigerant compounds not enter the refrigerant cycle during installation work. Foreign matter could damage internal components or cause blockages. ● If air filters are required on this unit, do not operate the unit without the air filter set in place. If the air filter is not installed, dust may accumulate and breakdown may result.
- Page 6 Controls uses only refrigerants that have been approved for use in the unit’s intended home country or market. Johnson Controls distributors similarly are only authorized to provide refrigerants that have been approved for use in the countries or markets they serve. The refrigerant used in this unit is identified on the unit’s faceplate and/or in the associated manuals.
- Page 7 under pressure and never open pressurized system parts. ● Before installation is complete, make sure that the refrigerant leak test has been performed. If refrigerant gases escape into the air, turn OFF the main switch, extinguish any open flames and contact your service contractor.
- Page 8 ● Communication cabling shall be a minimum of 18-Gauge, 2-Conductor, Stranded Copper. Shielded cable must be considered for applications and routing in areas of high EMI and other sources of potentially excessive electrical noise to reduce the potential for communication errors. When shielded cabling is applied, proper bonding and termination of the cable shield is required as per Johnson Controls guidelines.
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Page 9: Features And Summary
Service Manual 1. Features and Summary 1. Summary Outdoor Unit DHW18CMB21S DHW24CMB21S Technical Information... - Page 10 Service Manual DHW18CMB21S Model Rated Voltage 208/230 Power Rated Frequency supply Phases Cooling capacity(max~min) 5280(2051~6155) Heating capacity(max~min) 5570(2500~6624) Cooling Power Input(max~min) 1650 Heating Power Input(max~min) 1640 Cooling Current Input 10.67/10.56 Heating Current Input 6.78/6.10 Rated Power Input 2800 Rated Current 12.48...
- Page 11 Service Manual Cross-sectional Area of Power Cable Conductor sq in 0.0032 Recommended Power Cable(Core) Connection Pipe Connection Method Flare Connection Not Additional Gas Connection Pipe Length 16.4 Connection Pipe Gas Additional Charge oz/ft. Outer Diameter of Liquid Pipe1 inch (Metric) Outer Diameter of Liquid Pipe2 inch (Metric)
- Page 12 Service Manual DHW24CMB21S Model Rated Voltage 208/230 Power Rated Frequency supply Phases Cooling capacity(max~min) 7620(2198~9672) Heating capacity(max~min) 8500(2198~7500) Cooling Power Input(max~min) 2400 Heating Power Input(max~min) 2350 Cooling Current Input 10.65 Heating Current Input 10.43 Rated Power Input 4550 Rated Current 20.19 Compressor Trademark ZHUHAI LANDA COMPRESSOR CO.,LTD...
- Page 13 Service Manual Cross-sectional Area of Power Cable Conductor sq in 0.0051 Recommended Power Cable(Core) Connection Pipe Connection Method Flare Connection Not Additional Gas Connection Pipe Length 16.4 Connection Pipe Gas Additional Charge oz/ft. Outer Diameter of Liquid Pipe1 inch (Metric) Outer Diameter of Liquid Pipe2 inch (Metric)
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Page 14: Outline Dimension Diagram
Service Manual 3. Outline Dimension Diagram DHW18CMB21S 35 1/8 13 3/7 15 3/5 Unit:inch DHW24CMB21S 13 3/7 35 1/8 17 1/3 38 4/7 Unit:inch Technical Information... -
Page 15: Refrigerant System Diagram
Service Manual 4. Refrigerant System Diagram outdoor indoor filter A heat exchanger filter outdoor heat exchanger 4-way valve B heat exchanger filter high pressure switch Note: Not available for 14K/18K model discharge silencer C heat exchanger discharge temperature sensor filter D heat exchanger gas -liquid separator filter... -
Page 16: Electrical Parts
Service Manual 5. Electrical Parts 5.1 Wiring Diagram Description Symbol Symbol Color Symbol Symbol Color Symbol Name White GREEN COMP Compressor Yellow Brown Grouding wire Blue YEGN Yellow/Green Black Violet Orange DHW18CMB21S Technical Information... - Page 17 Service Manual DHW24CMB21S These circuit diagrams are subject to change without notice, please refer to the one supplied with the unit. Technical Information...
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Page 18: Pcb Printed Diagram
Service Manual 5.2 PCB Printed Diagram DHW18CMB21S Terminal of compressor TOP VIEW Terminal of low-temperature cooling temperature sensor Overload protection terminal of compressor Temperature sensor terminal of outdoor unit High pressure protection terminal Low pressure protection terminal Terminal of outdoor unit... -
Page 19: Service Manual
Service Manual DHW24CMB21S Terminal of compressor TOP VIEW Low pressure protection terminal High pressure protection terminal Overload protection terminal of compressor Temperature sensor terminal of outdoor unit Electric heating terminal of chassis Electric heating terminal of compressor Terminal of outdoor unit Terminal of 4-way valve Temperature sensor for liquid valve and gas valve for unit A... -
Page 20: Function And Control
Service Manual 6. Function and Control 1 Basic functions of the system 1.1 Cooling Mode 1.1.1 Cooling conditions and process: When turning on the unit for cooling operation, if any of the indoor units calls for cooling the system will start in cooling mode. In this case, the electronic expansion valve, the outdoor fan and the compressor start operation. -
Page 21: Fan Mode
Service Manual 1.3.3 Outdoor fan control in heating mode The outdoor fan starts before 5s of the compressor starting and then it will run in high speed for 40s. The fan will run at every speed for at least 80s. When the compressor stops, the outdoor fan stops after 1min. -
Page 22: Overcurrent Protection
Service Manual 2.4 Communication malfunction Detection of the quantity of installed indoor units: After 3min of energizing, if the outdoor unit does not receive the communication data of a particular indoor unit, the outdoor unit will judge that the indoor unit is not installed and the out door unit will give an error code. If the outdoor unit receives the communication data of that indoor unit later, the outdoor unit will treat that unit as if it is installed. -
Page 23: Troubleshooting
7. Troubleshooting 1. Requirement of malfunction display When several malfunctions happen at the same time, malfunction codes will be displayed circularly. 2. Malfunction display method (1) Hardware malfunction: it will be displayed immediately, please refer to “Malfunction status sheet”; (2) Operation status: it will be displayed immediately, please refer to “Malfunction status sheet”; (3) Other malfunction: It will be displayed after the compressor has been stopped for 200s, please refer to “Malfunction status sheet”. -
Page 24: Malfunction Checking And Elimination
Viewing malfunction code through remote controller within Compressor overload protection 200s Wrong connection of communication wire or malfunction of Hardware malfunction electronic expansion valve Detection status of wrong connection of communication wire Operation status or malfunction of electronic expansion valve t c i n i l l i o... - Page 25 ● If the resistance of compressor coil is normal? If the isolation of compressor coil with copper pipe is good? ● If the unit is overloaded? If the heat radiation of the unit is good? ● If the refrigerant charge is suitable? Energize the unit Flow chart: Please check:...
- Page 26 2. PFC protection malfunction, capacity charging malfunction Main checking points: If the wiring of the induction is connected well and if the induction is broken; If the mainboard is broken; Flow chart: Start Check if power supply is normal Turn on the unit after power supply Power supply is abnormal? resumes normal...
- Page 27 Start Check If the power supply is normal Turn on the unit after the power supply resumes to Power supply is abnormal normal situation Check if the outdoor induction is broken Malfunction is eliminated Replace the outdoor mainboard...
- Page 28 3. Compressor desynchronizing malfunction Main checking points: If the pressure of the system is too high; If the eletric expansion valve is working normally or it is broken; If the radiation of the unit is good; Flow chart: The unit appears desynchronizing as soon as energizing and starting The stop duration of the compressor is longer than 3min?
- Page 29 Desynchronizing happens during operation Check if fan Replace the fan capacitor Outdoor unit is working? terminal is connected well Improve radiation situation of the unit Unit radiation is good? (such as cleaning Replace the outdoor unit the heat exchanger, improve ventilation Turn on the unit after the power Input voltage is normal?
- Page 30 4. Compressor overload, diacharge protectionmalfunction Main checking points: If the eletric expansion valve is connected well or it is broken; If there is refrigerant leakage; If the overload protector is broken; Flow chart: Start If the overload protector is connected well? Check the resistance between the two ends of the overload protector in ambient temperature, if the resistance is below 1k...
- Page 31 5. Start failuremalfunction Main checking points: If the connection wire of the compressor is connected properly; If the stop duration of the compressor is sufficient; If the compressor is broken; If the refrigerant charging amount is too much; Flow chart: Energize and start the unit If the stop duration of the compressor...
- Page 32 6. Temperature sensor malfunction Main checking points: If the temperature sensor is damaged or broken If the terminal of the temperature sensor is loosended or not connected; If the mainboard is broken; Flow chart: Start Check whether the wiring terminal between temperature sensor and controller is loosened or poorly contacted? Insert the temperature...
- Page 33 7. DC fan malfunction Main checking points: If the outdoor fan is blocked by foreign objects; The connection wire of DC fan is connected reliably? If it is loose? Flow chart: Start Turn on the unit Check if the after removing the outdoor fan is blocked by foreign objects foreign objects?
- Page 34 8. Communication malfunction Main checking points: If the connection wire between the indoor unit and outdoor unit is connected well, if the wires inside the unit is connected well; If the indoor mainboard or outdoor main board is broken; Flow chart: Communication malfunction of some indoor units De-energize,check if the connection...
- Page 35 All the indoor units appear communication malfunction De-energize,check if the connection wire of indoor and outdoor unit and the wire of the eletric box is connected correctly Reconnect according to Eliminate the malfunction Connected correctly? the wiring diagram De-energize, check if the connection wire between the outdoor mainboard and the filter board according to the wiring diagram Reconnect according to...
- Page 36 9. Anti-high temperatureand overload malfunction Main checking points: If the outdoor ambient temperature is within the normal range; If the indoor fan and outdoor fan are running normally; If the indoor and outdoor radiation environment is good; Flow chart: Start It is a normal protection, please If the outdoor ambient temperature operate the unit after the outdoor...
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Page 37: Maintenance Method For Normal Malfunction
7.3 Maintenance Method for Normal Malfunction 1. Air Conditioning Unit Doesn't Start Discriminating Method (Air Conditioner Status) Possible Causes Troubleshooting No power supply, or poor After energization, operation indicator isn’t bright wait for power recovery. If not, check power connection for power plug supply circuit and make sure the power plug is connected well. - Page 38 4. ODU Fan Motor Doesn't Operate Discriminating Method (Air Conditioner Status) Possible causes Troubleshooting Connect wires according to wiring diagram to Wrong wire connection, or poor Check the wiring status according to circuit make sure all wiring terminals are connected connection diagram Measure the capacity of fan capacitor with an...
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Page 39: Removal Procedures
Service Manual 8. Removal Procedures Warning: Be sure to wait for a minimum of 20 minutes after turning off all power supplies and discharge the refrigerant completely before removal. DHW18CMB21S Steps Procedure 1.Remove big handle and wire connection cover Before disassembly plate to remove the big handle. - Page 40 Service Manual Steps Procedure 2.Remove top cover top cover and right side plate, to remove top cover. 3.Remove grille the grille on the panel. grille 4.Remove panel support, to remove the panel. panel...
- Page 41 Service Manual Steps Procedure 5.Remove right side plate support and grille guard, to remove the right side plate. right side plate 6.Remove guard grille gaurd plate to remove grille guard. grille guard 7.Remove left side plate support, to remove the left side plate. left side plate...
- Page 42 Service Manual Steps Procedure 8.Remove condenser support remove the condenser support. condenser support 9.Remove axial fan blade wrench to remove the fan blade. axial fan blade 10.Remove motor and motor support sub-assy pin of leading wire for motor and remove the screws and motor support sub-assy.
- Page 43 Service Manual Steps Procedure 11.Remove electric box sub-assy electric box sub-assy loosen the wire binds, pull out the terminal, lift to remove the electric box sub-assy. 12.Remove PFC electrical inductance and isolation sheet, to remove the PFC electrical inductance. PFC electrical inductance 13.Remove four-way valve sub-assy four-way valve sub-assy...
- Page 44 Service Manual Steps Procedure 14.Remove suction pipe sub-assy Welding cut the welding point jointing the suction pipe sub-assy, compressor and liquid receiver, to remove the suction pipe sub-assy. suction pipe sub-assy 15.Remove liquid receiver receiver and lift to remove the liquid receiver. liquid receiver 16.Remove the isolation sheet assy Remove the screws fixing isolation sheet and...
- Page 45 Service Manual Steps Procedure 17.Remove compressor compressor feet chassis with wrench, as well as the foot cushion, to remove the compressor. 18.Remove valve support assy valve support assy chassis sub-assy, to remove the valve support assy. 19.Remove EXV assy Welding cut the welding point jointing EXV sub-assy and refrigerant collection pipe, to remove the EXV assy.
- Page 46 Service Manual DHW24CMB21S Steps Procedure 1. Remove valve cover and top panel Twist off the screws used for fixing and valve cover , pull v alve cover up ward to remove it. top panel Remove the 3 screws connecting the top panel with the front panel and the right side plate, and then remove the top panel.
- Page 47 Service Manual Remove the 5 screws connecting the panel with the chassis and the motor support, and then remove the panel. panel 3. Remove right side plate and left side plate right side plate Remove the scre ws connecting the right side plate with the chassis, the valve support and the electric box, and then remove the right side plate assy .
- Page 48 Service Manual 4. Remove fan motor and axial flow blade axial flow blade Remove the nuts fixing the blade and then remove the axial flow blade. fan motor fixing frame Remove the 4 tapping screws fixing the motor; disconnect the leading wire insert of the motor and then remove the motor.
- Page 49 Service Manual 6. Remove insulation and 4-way valve assy insulation Since the piping ports on the insulation tear easily, remove the insulation carefully 4-way valv e assy Discharge the refrigerant completely; unsolder the pipelines connecting the compressor and the condenser assy, and then remove the 4-way valve assy.
- Page 50 Service Manual 8. Remove Cut-off Valve and Valve Support Remove the 2 bolts fixing the valve subassemblies. Unsolder the welding joint connecting the gas valve and the return air pipe. Remove the gas valve. (Note: When unsoldering the soldering joint, wrap the gas valve with wet cloth completely to avoid damage Valve Support to the valve caused by high temperature.)
- Page 51 Service Manual condenser sub-assy 11.Remove condenser sub-assy Remove the chassis sub-assy and condenser sub-assy. chassis sub-assy...
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Page 52: Appendix
Service Manual Appendix: Appendix 1: Reference Sheet of Celsius and Fahrenheit Conversion formula for Fahrenheit degree and Celsius degree: Tf=Tcx1.8+32 Set temperature Fahrenheit Fahrenheit Fahrenheit display Fahrenheit display Fahrenheit display Fahrenheit Celsius Celsius Celsius temperature temperature temperature 60.8 69/70 69.8 78/79 78.8 62/63... -
Page 53: Appendix 3: Pipe Expanding Method
Service Manual Appendix 3: Pipe Flaring Method Pipe Note: flaring Pipe cutter flare the pipe according to the following steps: Leaning Uneven Burr A:Cut the pipe B:Remove the burrs Pipe Shaper Downwards C:Put on suitable insulating pipe. D:Put on the flare nut Union pipe the flare nut on the pipe. -
Page 54: Appendix 4: List Of Resistance For Ambient Temperature Sensor
Service Manual Appendix 4: List of Resistance for Temperature Sensor Resistance Table of Ambient Temperature Sensor for Indoor and Outdoor (15K) Temp( Temp( Temp( Temp( 138.1 18.75 3.848 1.071 128.6 17.93 3.711 1.039 121.6 17.14 3.579 1.009 16.39 3.454 0.98 108.7 15.68 3.333... - Page 55 Service Manual Resistance Table of Tube Temperature Sensors for Indoor and Outdoor (20K) Temp( Temp( Temp( Temp( 181.4 25.01 5.13 1.427 171.4 23.9 4.948 1.386 162.1 22.85 4.773 1.346 153.3 21.85 4.605 1.307 20.9 4.443 1.269 137.2 4.289 1.233 129.9 19.14 4.14 1.198...
- Page 56 Service Manual Resistance Table of Discharge Temperature Sensor for Outdoor(50K) Temp( Temp( Temp( Temp( 853.5 18.34 4.75 799.8 93.42 17.65 4.61 89.07 16.99 4.47 703.8 84.95 16.36 4.33 660.8 81.05 15.75 4.20 620.8 77.35 15.17 4.08 580.6 73.83 14.62 3.96 548.9 70.5 14.09...
- Page 58 Product improvement, specifications and appearance in this manual are subject to change without prior notice. LIT - 12012186 © Johnson Controls, Inc. USA...
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