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TGM FOREST ON/OFF Series Service Manual

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FOREST ON OFF SERIES
SERVICE MANUAL

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Summary of Contents for TGM FOREST ON/OFF Series

  • Page 1 FOREST ON OFF SERIES SERVICE MANUAL...

  • Page 3: Table Of Contents

    Troubleshooting Contents Safety Caution .......................2 General Troubleshooting ..................3 Complain Record Form ..................4 Information Inquiry ....................6 Error Diagnosis and Troubleshooting Without Error Code .........7 Remote maintenance ..................7 Field maintenance ..................8 Quick Maintenance by Error Code ................9 Troubleshooting by Error Code ................14 EH 00 (EEPROM parameter error diagnosis and solution) ......14 EL 01 (Indoor and outdoor unit communication diagnosis and solution) ..15 EH 02 (Zero-crossing detection error diagnosis and solution) ......17...

  • Page 4: Safety Caution

    1. Safety Caution WARNING Be sure to turn off all power supplies or disconnect all wires to avoid electric shock. While checking indoor/outdoor PCB, please equip oneself with antistatic gloves or wrist strap to avoid damage to the board. WARNING Electricity remains in capacitors even when the power supply is off.

  • Page 5: General Troubleshooting

    2. General Troubleshooting Error Display (Indoor Unit) When the indoor unit encounters a recognized error, the operation lamp will flash in a corresponding series, the timer lamp may turn on or begin flashing, and an error code will be displayed. These error codes are described in the following tables: Operation Timer...

  • Page 6: Complain Record Form

    3. Complain Record Form Complain Record Form Request No.: Date: Installation Date: Service Date: Customer Information Name Telephone No. Home Address Email Product Information Indoor Unit Model Outdoor Unit Model Serial No. of indoor unit Serial No. of outdoor unit Working Mode □Cooling □Heating...
  • Page 7 Parameter Checking information by Remote controller Displaying code Displaying code meaning Display value Display value meaning Room temperature Indoor coil temperature Outdoor coil temperature Approval from Manufacturer □Approved □More Proof needed □Rejected Troubleshooting 5...

  • Page 8: Information Inquiry

    4. Information Inquiry • To enter information inquiry status, complete the following procedure within ten seconds: • Press LED(or DO NOT DISTURB) 3 times. • Press SWING(or AIR DIRECTION) 3 times. • Finish 1 and 2 within 10 seconds, you will hear beeps for two seconds, which means the unit goes into parameter checking mode.

  • Page 9: Error Diagnosis And Troubleshooting Without Error Code

    5. Error Diagnosis and Troubleshooting Without Error Code WARNING Be sure to turn off unit before any maintenance to prevent damage or injury. Remote maintenance SUGGESTION: When troubles occur, please check the following points with customers before field maintenance. Problem Solution Unit will not start TS10 - TS11...

  • Page 10: Field Maintenance

    Field maintenance Problem Solution Unit will not start TS12 - TS13 Compressor will not start but fans run TS12 - TS13 Compressor and condenser (outdoor) fan will not start TS12 - TS13 Evaporator (indoor) fan will not start TS12 - TS13 Condenser (Outdoor) fan will not start TS12 - TS13 Unit runs, but shortly stops...

  • Page 11: Quick Maintenance By Error Code

    6. Quick Maintenance by Error Code If you do not have the time to test which specific parts are faulty, you can directly change the required parts according the error code. You can find the parts to replace by error code in the following table. Error Code Part requiring replacement EH 00...
  • Page 12 1.Remote Maintenance Electrical Circuit Refrigerant Circuit Possible causes of trouble Unit will not start The power switch is on but fans will not start The temperature on the display board cannot be set Unit is on but the wind is not cold(hot) Unit runs, but shortly stops The unit starts up and stops frequently Unit runs continuously but insufficient cooling(heating)
  • Page 13 1.Remote Maintenance Others Possible causes of trouble Unit will not start The power switch is on but fans will not start The temperature on the display board cannot be set Unit is on but the wind is not cold(hot) Unit runs, but shortly stops The unit starts up and stops frequently Unit runs continuously but insufficient cooling(heating) Cool can not change to heat...
  • Page 14 2.Field Maintenance Refrigerant Circuit Others Possible causes of trouble Unit will not start Compressor will not start but fans run Compressor and condenser (outdoor) fan will not start Evaporator (indoor) fan will not start Condenser (Outdoor) fan will not start Unit runs, but shortly stops Compressor short-cycles due to overload High discharge pressure...
  • Page 15 2.Field Maintenance Electrical Circuit Possible causes of trouble Unit will not start Compressor will not start but fans run Compressor and condenser (outdoor) fan will not start Evaporator (indoor) fan will not start Condenser (Outdoor) fan will not start Unit runs, but shortly stops Compressor short-cycles due to overload High discharge pressure Low discharge pressure...

  • Page 16: Troubleshooting By Error Code

    7. Troubleshooting by Error Code EH 00 (Indoor EEPROM parameter error diagnosis and solution) Description: Indoor PCB main chip does not receive feedback from EEPROM chip. Recommended parts to prepare: • Indoor PCB Troubleshooting and repair: Shut off the power supply and turn it on 2 minutes later.

  • Page 17: El 01 (Indoor And Outdoor Unit Communication Diagnosis And Solution)

    EL 01 (Indoor / outdoor unit communication error diagnosis and solution) Description: The indoor unit has not received feedback from the outdoor unit for 110 seconds, four consecutive times Recommended parts to prepare: • Indoor PCB • Outdoor PCB • Reactor Troubleshooting and repair: Power off, then restart the unit after 2 minutes.
  • Page 18 Remarks: • Use a multimeter to test the DC voltage between 2 port(or S or L2 port) and 3 port(or N or S port) of outdoor unit. The red pin of multimeter connects with 2 port(or S or L2 port) while the black pin is for 3 port(or N or S port) . When AC is normal running, the voltage will move alternately between -25V to 25V.

  • Page 19: Eh 02 (Zero-Crossing Detection Error Diagnosis And Solution)

    EH 02 (Zero crossing detection error diagnosis and solution) Description: When PCB does not receive zero crossing signal feedback for 4 minutes or the zero crossing signal time interval is abnormal. Recommended parts to prepare: • Connection wires • Indoor PCB Troubleshooting and repair: S and N Check the connections and...

  • Page 20: Eh 03/F5/Ec 07 (Fan Speed Is Operating Outside Of The Normal Range Diagnosis And Solution)

    EH 03 /EC 07 (Fan speed is operating outside of the normal range diagnosis and solution) Description: When indoor fan speed keeps too low (300RPM) for certain time, the LED displays the failure code and AC turns off. Recommended parts to prepare: •...
  • Page 21 Index: 1. Indoor or Outdoor DC Fan Motor(control chip is in fan motor) Power on and when the unit is in standby, measure the voltage of pin1-pin3, pin4-pin3 in fan motor connector. If the value of the voltage is not in the range showing in below table, the PCB must has problems and need to be replaced. •...

  • Page 22: Indoor Fan Motor

    3. Indoor AC Fan Motor Power on and set the unit running in fan mode at high fan speed. After running for 15 seconds, measure the voltage of pin1 and pin2. If the value of the voltage is less than 100V(208~240V power supply) or 50V (115V power supply), the PCB must has problems and need to be replaced.

  • Page 23: Eh 60/Eh 61/Ec 52 (Open Circuit Or Short Circuit Of Temperature Sensor Diagnosis And Solution)

    EH 60/EH 61/EC 52 (Open or short circuit of temperature sensor diagnosis and solution) Description: If the sampling voltage is lower than 0.06V or higher than 4.94V, the LED displays the failure code. Recommended parts to prepare: • Connection wires •...

  • Page 24: Eh 0B (Indoor Pcb/Display Board Communication Error Diagnosis And Solution)

    EH 0b (Indoor PCB/display board communication error diagnosis and solution) Description: The display board cannot communicate with the indoor PCB. Recommended parts to prepare: • Communication wire • Indoor PCB • Display board Troubleshooting and repair: Power off, then restart the unit 2 minutes later Is it still displaying the error code? The unit functions normally...

  • Page 25: El 0C (Refrigerant Leakage Detection Diagnosis And Solution)

    EL 0C (Refrigerant leakage detection diagnosis and solution) Description: Define the evaporator coil temperature T2 of the compressor just starts running as Tcool. In the beginning 5 minutes after the compressor starts up, if T2 < Tcool-2°C does not keep continuous 4 seconds and this situation happens 3 times, the LED displays the failure code and AC turns off.

  • Page 26: Pc 03 (High Pressure Protection)

    PC 03 (High pressure protection diagnosis and solution) Description: If the current is less than setting value for 4 seconds, AC shuts off and restarts after 3 minutes in cooling mode or after 4 minutes in heating mode. If this happens 8 times, the LED displays the failure code and AC turns off. Recommended parts to prepare: •...

  • Page 27: Check Procedures

    8. Check Procedures 8.1 Temperature Sensor Check WARNING Be sure to turn off all power supplies or disconnect all wires to avoid electric shock. Operate after compressor and coil have returned to normal temperature in case of injury. 1. Disconnect temperature sensor from PCB (Refer to Chapter 5. Indoor Disassembly and Chapter 6. Outdoor Disassembly). 2.
  • Page 28 8.2 Fan Motor Check 1. Turn off outdoor unit and disconnect power supply 2. Disconnect outdoor fan motor power cord from outdoor PCB 3. Measure the resistance value between each windings. The normal value of different motor show as follows: YKFG-13-4-38L Model YKFG-15-4-28-1...
  • Page 29 Appendix Contents Temperature Sensor Resistance Value Table for T1, T2, T3, and T4 (°C – K) ..2 Temperature Sensor Resistance Value Table for TP (for some units)(°C --K) ..3 iii) Pressure On Service Port ..................4...
  • Page 30 i) Temperature Sensor Resistance Value Table for T1,T2,T3 and T4 (°C – K) °C °F K Ohm °C °F K Ohm °C °F K Ohm °C °F K Ohm 115.266 12.6431 2.35774 0.62973 108.146 12.0561 2.27249 0.61148 101.517 11.5 2.19073 0.59386 96.3423 10.9731...
  • Page 31 ii) Temperature Sensor Resistance Value Table for TP(for some units) (°C --K) °C °F K Ohm °C °F K Ohm °C °F K Ohm °C °F K Ohm °C °F K Ohm °C °F K Ohm °C °F K Ohm °C °F K Ohm...
  • Page 32 iii) Pressure On Service Port Cooling chart(R410A): ODU(DB) °F(°C) 0(-17) 5(-15) 95 (35) (-9.44) (7.22) (23.89) (29.44) (40.56) (46.11) (48.89) IDU(DB/WB) 70/59 (21.11/15) 10.1 10.6 75/63 (23.89/17.22) 10.7 11.2 80/67 (26.67/19.44) 11.2 11.9 90/73 (32.22/22.78) 10.5 10.3 10.0 10.6 12.4 13.0 70/59 (21.11/15) 75/63 (23.89/17.22)
  • Page 33 Heating chart(R410A): ODU(DB/WB) 57/53 47/43 37/33 27/23 17/13 (-8.33/- 0/-2 -17/-18 °F(°C) (13.89/11.67) (8.33/6.11) (2.78/0.56) (-2.78/-5) 10.56) (-17/-19) (-27/-28) IDU(DB) 55(12.78) 30.3 28.5 25.3 22.8 20.8 18.5 16.5 65(18.33) 32.5 30.0 26.6 25.4 23.3 20.5 19.0 75(23.89) 33.8 31.5 27.8 26.3 24.9 21.5...
  • Page 34 Cooling chart(R22): ODU(DB) °F(°C) 0(-17) 5(-15) 95 (35) (-9.44) (7.22) (23.89) (29.44) (40.56) (46.11) (48.89) IDU(DB/WB) 70/59 (21.11/15) 75/63 (23.89/17.22) 80/67 (26.67/19.44) 90/73 (32.22/22.78) 70/59 (21.11/15) 75/63 (23.89/17.22) 80/67 (26.67/19.44) 90/73 (32.22/22.78) 70/59 (21.11/15) 0.40 0.41 0.46 0.50 0.51 0.49 0.51 0.54 0.63...
  • Page 35 Heating chart(R22): ODU(DB/WB) 57/53 47/43 37/33 27/23 17/13 (-8.33/- 0/-2 -17/-18 °F(°C) (13.89/11.67) (8.33/6.11) (2.78/0.56) (-2.78/-5) 10.56) (-17/-19) (-27/-28) IDU(DB) 55(12.78) 18.9 17.8 15.8 14.3 13.0 11.6 10.3 65(18.33) 20.3 18.8 16.6 15.9 14.6 12.8 11.9 75(23.89) 21.1 19.7 17.3 16.4 15.6 13.4...
  • Page 36 Cooling chart(R32): ODU(DB) °F(°C) 0(-17) 5(-15) 95 (35) (-9.44) (7.22) (23.89) (29.44) (40.56) (46.11) (48.89) IDU(DB/WB) 70/59 (21.11/15) 10.3 10.8 75/63 (23.89/17.22) 10.9 11.4 80/67 (26.67/19.44) 11.4 12.1 90/73 (32.22/22.78) 10.7 10.5 10.2 10.8 12.6 13.3 70/59 (21.11/15) 75/63 (23.89/17.22) 80/67 (26.67/19.44) 90/73 (32.22/22.78) 70/59 (21.11/15)
  • Page 37 Heating chart(R32): ODU(DB/WB) 57/53 47/43 37/33 27/23 17/13 (-8.33/- 0/-2 -17/-18 °F(°C) (13.89/11.67) (8.33/6.11) (2.78/0.56) (-2.78/-5) 10.56) (-17/-19) (-27/-28) IDU(DB) 55(12.78) 30.9 29.1 25.8 23.3 21.2 18.9 16.8 65(18.33) 33.2 30.6 27.1 25.9 23.8 20.9 19.4 75(23.89) 34.5 32.1 28.4 26.8 25.4 21.9...
  • Page 38 System Pressure Table-R22 Pressure Temperature Pressure Temperature °C °F °C °F 14.5 -41.091 -41.964 1600 41.748 107.146 21.75 -32.077 -25.739 1650 16.5 239.25 43.029 109.452 -25.177 -13.319 1700 246.5 44.281 111.706 36.25 -19.508 -3.114 1750 17.5 253.75 45.506 113.911 43.5 -14.654 5.623 1800...
  • Page 39 System Pressure Table-R410A Pressure Temperature Pressure Temperature °C °F °C °F 14.5 -51.623 -60.921 2350 23.5 340.75 38.817 101.871 21.75 -43.327 -45.989 2400 39.68 103.424 -36.992 -34.586 2450 24.5 355.25 40.531 104.956 36.25 -31.795 -25.231 2500 362.5 41.368 106.462 43.5 -27.351 -17.232 2550...
  • Page 40 System Pressure Table-R32 Pressure Temperature Pressure Temperature °C °F °C °F 14.5 -51.909 -61.436 1850 18.5 268.25 28.425 83.165 21.75 -43.635 -46.543 1900 275.5 29.447 85.005 -37.323 -35.181 1950 19.5 282.75 30.448 86.806 36.25 -32.15 -25.87 2000 31.431 88.576 43.5 -27.731 -17.916 2050...

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