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Willis WST12MC16S Service Manual

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WST12MC16S
WST09MH16S
WST12MH16S
Willis Air Conditioning

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  • Page 1 Service Manual MODEL: WST12MC16S WST09MH16S WST12MH16S Willis Air Conditioning...

  • Page 2: Table Of Contents

    Table of Contents Summary and features ..................1 Part 1 Safety Precautions ..................2 Part 2 Specifications .....................3 2.1 Unit Specifications....................3 2.2 Operation Characteristic Curve................15 2.3 CapacityVariation Ratio AccordingtoTemperature..........15 2.4 Operation Date.....................16 2.5 Noise criteria curve tables for both models............16 Part 3 Construction Views ..................17 3.1 Indoor Unit ......................17 3.2 Outdoor Unit ......................17...
  • Page 3 Table of Contents Part 8 Exploded Views and Parts List ..............42 8.1 Indoor unit......................42 8.2 Outdoor unit......................49 Part 9 Troubleshooting ....................57 9.1 Precautions Before Performing Inspection or Repair...........57 9.2 Confirmation......................57 9.3 Judgement by Flashing LED of Indoor/Outdoor Unit...........57 9.4 How to Check Simply the Main Part..............59 9.5 2-way, 3-way Valve Appearance................63 Part10 Removal Procedure ..................70...

  • Page 4: Summary And Features

    Summary and features Summary and features Indoor Unit WST12MC16S WST09MH16S WST12MH16S Outdoor Unit WST12MC16S WST09MH16S WST12MH16S Remote control window AUTO HEALTH X-FAN HUMIDITY FILTER TURBO HOUR ON/OFF ON/OFF MODE X-FAN TEMP TIMER TURBO SLEEP LIGHT YB1F2F...

  • Page 5: Part 1 Safety Precautions

    Safety Precautions 1.Safety Precautions Important! or rubbish. The unit should be installed according to the instructions This air conditioning system meets strict safety and in order to minimize the risk of damage from earthquakes, operating standards. As the installer or service person, typhoons or strong winds.

  • Page 6: Part 2 Specifications

    Specifications Specifications 2.1 Unit Specifications...
  • Page 7 Specifications...
  • Page 8 Specifications Parameter Unit Value WST12MC16S WST12MH16 S Model CB409002101 CB409N02100 CB409002201 CB409N02200 Product Code Rated Voltage 208~230 208~230 Power Rated Frequency Supply Phases Power Supply Mode outdoor outdoor Cooling Capacity (Min Max) Btu/h 12000(3300 12500) 12000(3300 12500) Heating Capacity (Min Max)

  • Page 9: Operation Characteristic Curve

    Specifications 2.2 Operation Characteristic Curve Cooling Heating Condition Condition Indoor:DB 20 Indoor:DB 27 WB19 Indoor air flow: Super High Indoor air flow: Super High Pipe length:7.5m Pipe length:7.5m Voltage:230V Voltage:230V Compressor Speed(rps) Compressor Speed(rps) 2.3 Capacity Variation Ratio According to Temperature Cooling Heating Condition...

  • Page 10: Operation Date

    Specifications 2.4 Operation Date Cooling Temp. Condition( ) Standard Indoor Fan Outdoor Compressor Model Pressure(Mpa) Mode Fan Mode Revolution(rps) Indoor Outdoor 0.9 to 1.1 27/19 35/24 Super High 930rpm 0.8 to 1.0 Heating Temp. Condition( ) Standard Indoor Fan Outdoor Compressor Model Pressure(Mpa)

  • Page 11: Part 3 Construction Views

    Constrction views 3. Construction Views 3.1 Indoor Unit 126.5 548.5 3.2 Outdoor Unit...

  • Page 12: Part 4 Refrigerant System Diagram

    Refrigerant System Diagram 4. Refrigerant System Diagram (1)Cooling Only Models INDOOR UNIT OUTDOOR UNIT GAS SIDE 3-WAY VALVE Muffler Di s charge HEAT EXCHANGE (EVAPORATOR) Accumlator Suction COMPRESSOR HEAT EXCHANGE (CONDENSER) LIQUID SIDE 2-WAY VALVE Strainer Capillary Strainer COOLING (2)Cooling & Heating Models INDOOR UNIT OUTDOOR UNIT GAS SIDE...

  • Page 13: Part 5 Schematic Diagram

    Schematic Diagram 5. Schematic Diagram 5.1 Electrical Date Indoor Unit Symbol Color symbol Symbol Color symbol WHITE BROWN YELLOW BLUE BLACK YELLOW GREEN PROTECTIVE EARTH YEGN Outdoor Unit Symbol Parts name Symbol Color symbol REACROR WHITE PCB1~PCB2 PRINTED CIRCUIT BOARD YELLOW CONNECTOR S10/S11S40/S70/S80/S90...
  • Page 14 Schematic Diagram Outdoor Unit POWER PCB1 N(1) PCB2 YEGN YEGN YEGN U V W YEGN CLAPBOARD ELECTRICAL BOX YEGN SUB-ASSY YEGN COMP. MOTOR OUTDOOR UNIT POWER PCB1 N(1) PCB2 YEGN YEGN YEGN U V W YEGN CLAPBOARD ELECTRICAL BOX YEGN SUB-ASSY YEGN COMP.

  • Page 15: Printed Circuit Board

    Schematic Diagram 5.3 Printed Circuit Board TOP VIEW Interface of input live wire Interface of communication wire Interface of input neutral wire PG motor control interface Feedback interface from PF motor Interface of pipe temperature sensor Interface of ambient temperature sensor Interface of air guide motor Display interface...
  • Page 16 Schematic Diagram neutral wire live wire communication ground wire wire Display board infrared receiver...
  • Page 17 Schematic Diagram TOP VIEW BOTTOM VIEW...
  • Page 18 Schematic Diagram FRONT VIEW BOTTOM VIEW...
  • Page 19 Schematic Diagram TOP VIEW BOTTOM VIEW...

  • Page 20: Part 6 Function And Control

    Function and Control 6. Function and Control 6.1 Remote Controller Description ON/OFF Press this button to start or stop operation. MODE Press it to select operation mode (AUTO/COOL/DRY/FAN/HEAT). AUTO : Press it to decrease temperature setting. HEALTH X-FAN HUMIDITY : Press it to increase temperature setting. FILTER TURBO HOUR...
  • Page 21 Function and Control Press this button to decrease set temperature.Holding it down above 2 seconds rapidly decreases set temperature. In AUTO mode, set temperature is not adjustable. Press this button to increase set temperature.Holding it down above 2 seconds rapidly increases set temperature. In AUTO mode, set temperature is not adjustable.
  • Page 22 Function and Control TIMER: Press TIMER button at unit ON to set TIMER OFF, HOUR OFF blinking. Press TIMER button at unit OFF to set TIMER button changes time setting. Holding down either button rapidly ON, HOUR ON blinking. In this case, pressing + or - changes time setting (time setting range 0.5-24hours).
  • Page 23 Function and Control 6.3 Unit indlcation section 1. When the unit is energized, all the display marks will be shown and only the RUN LED lights. 2. When the unit is turned on remotely, the RUN LED goes out while the current setting running mode is displayed.

  • Page 24: Description Of Each Control Operation

    Function and Control DESCRIPTION OF EACH CONTROL OPERATION * Anti-cold air function The rotational speed of indoor electromotor is decided based on the When room temperature-preset temperature -2 , the unit stops running; indoor pipe temperature. The indoor fan can run at low speed or stop the outdoor fan will delay the stop running, indoor fan runs at the preset fan running.
  • Page 25 Function and Control Timer off: the timer off function can be set when the unit is on. When the setting time for timer off is reached, the unit will stop. The timing interval is After energization, the motor of upper and lower swing will enable the air 0.5hour, and the setting range is 0.5~24hours.
  • Page 26 Function and Control Temperature sensor malfunction detection (1) Indoor temperature sensor Detect malfunctions of temperature sensor any time. (2) Indoor pipe temperature sensor In defrosting period, the temperature sensor malfunction will not be detected. 5 min after finishing defrosting, the system begins to detect the temperature sensor malfunction.
  • Page 27 Function and Control Discharge Pipe Control Outline The discharge pipe temperature is used as the compressor’s internal temperature. If the discharge pipe temperature rises above a certain level, the operating frequency upper limit is set to keep this temperature from going up further. Detail Divide the Zone Stop zone...
  • Page 28 Function and Control During cooling operation, the signals being sent from the indoor unit allow the operating frequency limitation and then prevent freezing of the indoor heat exchanger. (The signal from the indoor unit must be divided into the zones as the followings.) Detail Conditions for Start Controlling Judge the controlling start with the indoor heat exchanger temperature after 2 sec from operation start.
  • Page 29 Function and Control PI control Frequency 60sec. 50sec. 600sec. 50sec. Compressor Four way valve 5sec. 5sec. 450pps 350pps 450pps Electronic expansion valve opening Initial opening Fan Control Outline Fan control is carried out according to the following priority. 1. Fan ON control for electric component cooling fan 2.

  • Page 30: Part 7 Installation Manual

    Installation Manual 7. Installation Manual 7.2 Installation Position Selection Important Notices (1)The air inlet and outlet vent should be far from the obstruction, make sure that the air can be blown through the whole room. (2)Select a position where the condensing water can be easily 1.
  • Page 31 Installation Manual Recommended mounting plate retention spots and Burr removal 1.Completely remove all burrs from the cut cross section of dimensions Use tape measure pipe/tube. as shown. Recommended mounting plate Place a leveler Position the end of retention spots (5 spots in all) on raised tab.
  • Page 32 Installation Manual 3.2 Connection of piping 5. Insert the connecting cable fully into the terminal block and 1.Align the center of the pipes and sufficiently tighten the flare nut secure it tightly with screws. by hand. 6. Tightening torque: 1.2 N•m (0.12 kgf•m). 7.
  • Page 33 Installation Manual How to replace the drain plug and drain hose In the case of bending or curing refrigerant pipes, keep the fol- • How to remove the drain cap Clamp drain cap with needle-nose pliers, and pull out. lowing precautions in mind. Abnormal sound may be generated if improper work is conducted.

  • Page 34: Installation Of Outdoor Unit

    Installation Manual Mounting plate Drain-water hole Marking Bottom frame Drain plug Hose (available commercially, inner dia. 16mm) 2) Swing the indoor unit to right and left to confirm that it is firmly hooked on the installation plate. Remove the Valve cover from the unit by loosening the screw. 3)While pressing the indoor unit onto the wall, hook it at the lower Align the center of the pipings and sufficiently tighten the flare part on the installation plate.

  • Page 35: Test Operation

    Installation Manual 1. Connect the charge hose from the manifold valve to the service 1) Strip the insulation from the wire (20mm). port of the gas side packed valve. 2. Connect the charge hose to the port of the vacuum pump. 2) Connect the connection wires between the indoor and outdoor units so that the terminal numbers match.

  • Page 36: Part 8 Exploded Views And Parts List

    Exploded Views and Parts list 8. Exploded Views and Parts List 8.1 Indoor Unit...
  • Page 37 Exploded Views and Parts list...
  • Page 38 Exploded Views and Parts list PartCode Description WST12MC16S WST12MH16S CB146N0550 Product Code CB146N0540 Front panel 2 2001251001 2001251001 Front Case 2001237501 2001237501 Remote Controller 30510062 30510062 Rear grill sub-assy 2 11002001 11002001 Main Board 30138131 30138129 Ambient Temperature Sensor 390000453...

  • Page 39: Outdoor Unit

    Exploded Views and Parts list 8.2 Outdoor Unit (1) Cooling Only Models Models:WST12MC16S...
  • Page 40 Exploded Views and Parts list (2) Cooling & Heating Models Models:WST09MH16S WST12MH16S...

  • Page 41: Part 9 Troubleshooting

    Troubleshooting 9. Troubleshooting 9.1 Precautions before Performing Inspection or Repair Be cautious during installation and maintenance. Do operation following the regulations to avoid electric shock and casualty or even death due to drop from high attitude. * Static maintenance is the maintenance during de-energization of the air conditioner. For static maintenance, make sure that the unit is de-energized and the plug is disconnected.
  • Page 42 Troubleshooting code malfunction Error display Repair method code malfunction Error display Repair method Dual Dual display display Storage slug Heating Replace indoor Sync failure Heating Check if the resistance of compressor and LED-pause 3s main board LED-pause 3s resistance to ground is normal. If the and blink 15 and blink compressor is normal, the outdoor main...
  • Page 43 Indoor fan does not rotate without feedback n detection point: Is the control panel reliably connected with the electromotor? Is it loose? Is the connecting sequence correct? Is the input voltage within the normal range (measure the voltage between L and N of the wiring block XT with AC voltage gauge.) Malfunction diagnosis process: Energize the unit and start it...
  • Page 44 Troubleshooting Energize the unit and start it Check connecting state Indoor unit of indoor display F1/F2 temperature sensor ndoor unit reliable display F4/F5 connected? Adjust connecting stat Check connect i ng state of outdoor temperature sensor Replace Adjust Reliable Remove error? connected? connecting state temperature sensor...
  • Page 45 Troubleshooting Energize the unit and start it Is the stop time of compressor more Start it 3 min later than 3min Startup failure? Connect it according Is compressor wire COMP(UVW) to line chart connected correctly? Replace parts if outdoor electric box Remove the error? Replace compressor...
  • Page 46 Troubleshooting (5) Diagnosis of overload and discharge malfunction Main detection points: 20min after de-energization of complete unit Is electric expansion valve well connected? Is it damaged? Is refrigerant leaked? Is overload wire connection normal? Is electric expansion Malfunction diagnosis process: valve well connected? Is overload wire reliably connected?

  • Page 47: 2-Way, 3-Way Valve Appearance

    Troubleshooting 9.5 2-way, 3-way Valve Appearance 2-way Valve (Liquid Side) 3-way Valve (Gas Side) Valve cap Hexagonal wrench (4mm) Open position Flare nut Flare nut Closed position Open position Closed position piping piping Service Service connection connection port cap port To outdoor unit To outdoor unit Works...
  • Page 48 Troubleshooting Liquid side Indoor unit Clsed Outdoor unit 2-way valve Gas side Clsed 3-way valve Vacuum pump OPEN CLOSE * Procedure CAUTION: (1)Connect the charge hose from the manifold valve to the ser- If gas leakage are discovered in step 5 above, take the vice port of the gas side packed valve.
  • Page 49 Troubleshooting Liquid side Indoor unit Outdoor unit Open 2-Way valve Gas side Closed 3-Way valve CLOSE CLOSE Purge the air • Procedure (1) Confirm that both the 2-way and 3-way valves are set to (7) Immediately set the 3-way valve to the closed position. –...
  • Page 50 Troubleshooting Liquid side Indoor unit Closed Outdoor unit 3-Way valve Gas side Closed 3-Way valve Gas cylinder R410A OPEN CLOSE • Procedure (6) Disconnect the charge set and the gas cylinder, and set (1) Confirm that both the liquid side valve and the gas side balve are set to the closed position.
  • Page 51 Troubleshooting Balance Refrigerant of the 3-way Valve (Gas leakage) Liquid side Indoor unit Outdoor unit 3-Way valve Open Gas side 3-Way valve Open OPEN CLOSE • Procedure (1) Confirm that both the 2-way and 3-way valves (3) Open the valve (Lo side) on the charge set and are set to the back seat.
  • Page 52 Troubleshooting Evacuation (All amount of refrigerant leaked) Liquid side Indoor unit Outdoor unit 3-Way valve Open Gas side 3-Way valve Open Vacuum pump OPEN CLOSE • Procedure (1) Connect the vacuum pump to the center hose (3) Close the valve (Lo side) on the charge set, of charge set center hose turn off the vacuum pump, and confirm that the gauge needle does not move (approxima-...
  • Page 53 Troubleshooting Gas Charging (After Evacuation) Liquid side Indoor unit Open Outdoor unit 3-Way valve Gas side Open 3-Way valve Check valve Charging cylinder OPEN CLOSE • Procedure This is different from previous procedures. (1) Connect the charge hose to the charging Because you are charging with liquid refrigerant cylinder.

  • Page 54: Part10 Removal Procedure

    Removal Procedure 10. Removal Procedure 10.1 Removal Procedure of Indoor Unit Warning Be sure to wait 10 minutes or more after turning off all power supplies before disassembling work. 1. External features If ON/OFF button is kept pushing for 5 seconds, aforced cooling op- eration willbe carried out for approx.
  • Page 55 Removal Procedure 3. Opening and shuttingfront panel Support the front panel by one hand, while remove the rotation Pull down horizontal blade axis at the upper center by the by pulling forward. other hand. And pull out the front panel forward to remove.
  • Page 56 Removal Procedure 4. Opening and closing of service cover screws Remove a service cover mounting screw. Open service cover upward. A switch for field setting is not provided in particular. screws 5. Removal of front grille assembly Remove the 3 screws, in the right and the left, Screw stoppers inside the which fix the main body...
  • Page 57 Removal Procedure 6. Remove the Vertical blade Hooks Unfasten the hooks at the upper 2 positions. A set of vertical blade has 6 fins as on ASSY. (It is impossible to replace only one fin.) The set of vertical blades is not marked for difference between right and left.
  • Page 58 Removal Procedure 7. Remove electrical box Disconnect the Cable clamp Pay attention to the direction of the retainer of the thermistor so that the retainer will not touch the harness (same as the existing models.) Terminal board Disconnect the connection wires. Connecting wires Take care not to lose the clip...
  • Page 59 Removal Procedure Remove fan motor Signal fan motor Signal Wire Wire Remove a screw on the electrical box. Bottom frame Pull up the electrical box forward to remove. Hook...
  • Page 60 Removal Procedure 8. Remove the shield plate. Unfasten the hooks at Hooks the upper 2 positions of the shield plate. Remove the electrical box according to the “Removal of Electrical Box”. shield plate (1) Unfasten the hook at the lower position, and remove the shield plate (1).
  • Page 61 Removal Procedure Take off Wiring terminal Display PCB ASSY Remove Display PCB Sub-Assy. Remove Swing motor. Swing motor...
  • Page 62 Removal Procedure The control PCB is To remove the control integrated with the power PCB, unfasten the 2 hooks at the upper part supply PCB. from the rear side. Lift up the upper part of the control PCB, and remove it. Control PCB...
  • Page 63 Removal Procedure 9. Disconnect the refrigerant piping. CAUTION If gas leaks, repair the spot of Lift the indoor unit by a leaking, then collect all wooden base. refrigerant from the unit. After conducting vacuum drying, recharge proper amount of refrigerant. CAUTION Wooden base Do not contaminate any gas...
  • Page 64 Removal Procedure 9. Remove the indoor unit. When the pipings are disconnected, protect the Remove the indoor unit both openings from entering from the installation moisture. plate. Liquid piping Gas piping (R8019) Auxiliary piping Piping fixture Release the hook of the piping fixture on the back of the unit.
  • Page 65 Removal Procedure Loosen the 2 screws, in the right and the left, which fix the Evaporator Assy. Auxiliary piping Widen the auxiliary piping to the extent of 10°~20°. Pull the heat exchanger Heat exchanger to the front side to undo the hooks completely, and then lift it.
  • Page 66 Removal Procedure 10. Remove Cross Flow Fan Fan Motor Remove Cross Flow Fan Fan Motor 11. Remove Ring of Bearing Bearing 12. Remove Cross Flow Fan and Motor Sub-Assy screw.
  • Page 67 Removal Procedure 13. Remove Motor Sub-Assy Remove Motor Sub-Assy 14. Remove Fan Motor...

  • Page 68: Removal Procedure Of Outdoor Unit

    Removal Procedure 10.2 Removal Procedure of Outdoor Unit Warning Be sure to wait 10 minutes or more after turning off all power supplies before disassembling work. 1. Features The stop valve cover has 6 hooks. Handle Loosen the screw of the stop valve cover.
  • Page 69 Removal Procedure Loosen the 1 screws and remove the discharge grille. Lift the front panel and Loosen the 5 screws of remove it while pushing the the front panel. right side panel inwards. Procedure Points Step Front panel. Remove the 5 screws from the edge between right-side board and condenser and from valve.
  • Page 70 Removal Procedure M4×16 Remove the 4 tapping screws fixing the motor. Pull out the DC fan motor lead-out wire and remove the Fan motor fixing frane motor. Remove the 2 tapping screws fixing the motor support. Lift to remove the motor support. Fan motor 5.Remove the electrical box.
  • Page 71 Removal Procedure 7.Remove the sound blanket. Since the piping ports on Lift and remove the the sound blanket are sound blanket (top). torn easily, remove the blanket carefully. Untie the strings and open the sound blanket. Lift and remove the sound blanket (body) as it is opened.
  • Page 72 Removal Procedure Remove compressor Solder off the welding spot of capillary and valve and outlet pipe of condenser. Remove the 2 screws fixing the gas valve. Solder off the weld spot connecting gas valve and air return pipe and remove the gas valve.

  • Page 73: Part11 Care And Cleaning

    11. Care and Cleaning 11 Cleaning Refrigeration System In addition to replacement of compressor, capillary and strainer, the whole refrigeration system shall be completely cleaned, as the refrigerant in the system is contaminated by a lot of acid HEAT EXCHANGE (EVAPORATOR) oxydum generated from insulation breakdown, turn-to-turn short circuit or burning out of winding of compressor’s motor during malfunction.
  • Page 74 Willis Air Conditioning Add:2105 chemin de la cote de liesse, Montréal, QC H4N 2M5 Canada. Tel: 514 735 7147...

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