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Johnson Controls P Series Service Manual
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Johnson Controls P Series Service Manual

Johnson Controls P Series Service Manual

Inverter-driven air conditioning units
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Service Manual
"P" SERIES
9K - 12K - 115V
INVERTER-DRIVEN AIR
CONDITIONING UNITS
Type
INDOOR UNITS
Type
DCP09CSB11S
DHP09CSB11S
OUTDOOR UNITS
DCP12CSB11S
DHP12CSB11S
Type
CONTROLLER
PLEASE READ AND
UNDERSTAND THIS
MANUAL BEFORE USING
THIS INVERTER-DRIVEN
AIR CONDITIONING UNIT.
KEEP THIS MANUAL FOR
FUTURE REFERENCE.
Model
DCP09NWB11S
DHP09NWB11S
DCP12NWB11S
DHP12NWB11S
Model
Model
DRCPX

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  • Page 1 Service Manual "P" SERIES 9K - 12K - 115V INVERTER-DRIVEN AIR CONDITIONING UNITS Type Model DCP09NWB11S DHP09NWB11S INDOOR UNITS DCP12NWB11S DHP12NWB11S Model Type DCP09CSB11S DHP09CSB11S OUTDOOR UNITS DCP12CSB11S DHP12CSB11S Type Model DRCPX CONTROLLER PLEASE READ AND UNDERSTAND THIS MANUAL BEFORE USING THIS INVERTER-DRIVEN AIR CONDITIONING UNIT.
  • Page 2 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 Service Manual Table of Contents Safety Summary ......................i 1. Technical Information ..................1 2. Specifications ......................2 2.1 Specification Sheet ......................2 2.2 Operation Characteristic Curve ..................6 2.3 Capacity Variation Ratio According to Temperature ............6 2.4 Cooling and Heating Data Sheet in Rated Frequency .............7 2.5 Noise Curve ........................7 3.
  • Page 4 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.
  • Page 9 Service Manual Technical Information 1. Summary Indoor Unit DCP09NWB11S DHP09NWB11S DCP12NWB11S DHP12NWB11S Outdoor Unit DCP09CSB11S DHP09CSB11S DCP12CSB11S DHP12CSB11S Controller DRCPX...
  • Page 10 Service Manual 2. Specifications 2.1 Specification Sheet DCP09NWB11S DHP09NWB11S Model DCP09CSB11S DHP09CSB11S Rated Voltage Power Supply Rated Frequency Phases Power Supply Mode Outdoor Outdoor Btu/h Cooling Capacity(Min~Max) 9000(2764~10918) 9000(2764~10918) Btu/h Heating Capacity(Min~Max) 9600(2081~12263) Cooling Power Input(Min~Max) 823(350~1270) 895(350~1270) Heating Power Input(Min~Max) 852(280~1250) Cooling Power Current 10.93...
  • Page 11 Service Manual Model of Outdoor Unit DHP09CSB11S DCP09CSB11S ZHUHAI LANDA COMPRESSOR ZHUHAI LANDA COMPRESSOR Compressor Manufacturer/Trademark CO.,LTD CO.,LTD QXA-A091zE190 QXA-A091zE190 Compressor Model FVC68D or RB 68EP FVC68D or RB 68EP Compressor Oil Compressor Type Rotary Rotary Compressor Locked Rotor Amp (L.R.A) Compressor RLA 5.00 5.00...
  • Page 12 Service Manual DCP12NWB11S DHP12NWB11S Model DCP12CSB11S DHP12CSB11S Rated Voltage Power Supply Rated Frequency Phases Power Supply Mode Outdoor Outdoor Btu/h Cooling Capacity(Min~Max) 12000(3753~12500) 12000(3753~12500) Btu/h Heating Capacity(Min~Max) 13000(3412~15013) Cooling Power Input(Min~Max) 1155(380~1300) 1193(380~1300) Heating Power Input(Min~Max) 1250(350~1350) Cooling Power Current 12.40 12.40 Heating Power Current...
  • Page 13 Service Manual DCP12CSB11S DHP12CSB11S Model of Outdoor Unit ZHUHAI LANDA COMPRESSOR ZHUHAI LANDA COMPRESSOR Compressor Manufacturer/Trademark CO.,LTD CO.,LTD QXA-A091zE190 QXA-A091zE190 Compressor Model FVC68D or RB 68EP FVC68D or RB 68EP Compressor Oil Compressor Type Rotary Rotary Compressor Locked Rotor Amp (L.R.A) Compressor RLA 5.00 5.00...
  • Page 14 Service Manual 2.2 Operation Characteristic Curve Cooling Heating 220V 220V • Conditions Indoor : DB80˚F/WB66.9˚F Outdoor : DB95˚F Indoor air flow : High Pipe length : 24.6ft 230V 230V 240V • Conditions Indoor : DB70˚F/WB60˚F 240V Outdoor : DB19.94˚F/WB19.04˚F Indoor air flow : High Pipe length : 24.6ft Compressor frequency(Hz) Compressor frequency(Hz)
  • Page 15 Service Manual 2.4 Cooling and Heating Data Sheet in Rated Frequency Cooling: Pressure of gas pipe Inlet and outlet pipe Rated cooling Compressor temperature of heat Fan speed of Fan speed of connecting indoor and condition(°F) (DB/WB) revolution Model outdoor unit exchanger indoor unit outdoor unit...
  • Page 16 Service Manual 3. Outline Dimension Diagram 3.1 Indoor Unit 4 7/8 21 5/16 7 1/16 6 5/8 18 1/4 6 1/4 Φ2 3/16 Φ2 3/16 Φ2 3/16 Φ2 3/16 1 3/8 1 3/8 2 1/8 2 1/8 3 1/4 4 15/16 5 7/8 3 9/16 Models...
  • Page 17 Service Manual 3.2 Outdoor Unit 12 5/8 33 3/8 21 1/4 Unit:inch...
  • Page 18 Service Manual 4. Refrigerant System Diagram Cooling unit Outdoor unit Indoor unit Gas pipe side Valve Di s charge Heat exchanger Suction (evaporator) Accumlator Compressor Heat exchanger Liquid pipe (condenser) side Valve Capillary Strainer Cooling and heating unit Outdoor unit Indoor unit Gas pipe side...
  • Page 19 Service Manual 5. Electrical Parts 5.1 Wiring Diagram ● Instruction Symbol Symbol Color Symbol Symbol Color Symbol Name White Jumper cap Green Yellow Brown COMP Compressor Blue Grounding wire Black YEGN Yellow/Green Violet Orange Note: Jumper cap is used to determine fan speed and the swing angle of horizontal louver for this model. ●...
  • Page 20 Service Manual ● Outdoor Unit DCP09CSB11S DCP12CSB11S Please don't touch any electronic component and terminal when the machine is running , stopping or has been powered off for less than 30 minutes to prevent electric shock! N(1) ground NOTE: Motor only applies to the iron shell motor.
  • Page 21 Service Manual 5.2 PCB Printed Diagram Indoor Unit ● Top view Neutral wire 2 Control interface of PG motor 3 Jumper interface 4 Temperature sensor Interface of up and down swing terminal 6 Feedback interface of indoor fan 7 Wired zone controller 8 Interface of display Interface of indoor unit and outdoor unit communication...
  • Page 22 Service Manual Outdoor Unit ● Top view Name Name Name Name Terminal of temperature Terminal of 6 Terminal of neutral wire 11 Terminal of live wire communication wire sensor Externally connect Terminal of electric Terminal of 7 Terminal of live wire positive terminal of heating(only for cooling grounding wire...
  • Page 23 Service Manual 6. Function and Control 6.1 Controller Introduction ON/OFF button MODE button FAN button SWING button TURBO button ▲/ button SLEEP button TEMP button I FEEL button LIGHT button CLOCK button TIMER ON / TIMER OFF button Introduction for icons on display screen Set fan speed I feel Send signal...
  • Page 24 Service Manual 1. ON/OFF button Pressing this button can turn on or turn off the air conditioner. After turning on the air conditioner, operation indicator " "on indoor unit’s display is ON (green indicator). The color is different for different models, and indoor unit will give out a sound. 2.
  • Page 25 Service Manual 7. SLEEP button Under COOL, HEAT or DRY mode, press this button to start up sleep function. " " icon is displayed on remote controller. Press this button again to cancel sleep function and " " icon will disappear. 8.
  • Page 26 Service Manual Function introduction for combination buttons 1. Energy-saving function Under cooling mode, press "TEMP" and " CLOCK" buttons simultaneously to start up or turn off energy-saving function. When energy- saving function is started up, "SE" will be shown on controller, and air conditioner will adjust the set temperature automatically according to factory setting to reach to the best energy-saving effect.
  • Page 27 Service Manual 6.2 Brief Description of Modes and Functions ● Indoor Unit 1.Basic function of system (1)Cooling mode (1) Under this mode, fan and swing operate at setting status. (2) During malfunction of outdoor unit or the unit is stopped because of protection, indoor unit keeps original operation status. (2)Drying mode (1) Under this mode, fan operates at low speed and swing operates at setting status.
  • Page 28 Service Manual (8)I FEEL control mode I FEEL mode is the hand-held remote taking over the sensing instead of the indoor air sensor. The indoor remote needs to be in the line of sight of the indoor unit no more than 24ft away. Remember not to put the remote near any type of heat source. (9)Compulsory defrosting function (1) Start up compulsory defrosting function Under ON status, set heating mode with remote controller and adjust the temperature to 60.8...
  • Page 29 Service Manual Outdoor Units 1. Input Parameter Compensation and Calibration (1) Check the ambient temperature compensation function Indoor ambient temperature compensation function. a. In cooling mode, the indoor ambient temperature participating in computing control = (T – ⊿ T indoor ambient temperature cooling indoor ambient temperature compensation b.
  • Page 30 Service Manual 3. Special Functions Defrosting Control ① Conditions for starting defrosting After the time for defrosting is judged to be satisfied, if the temperature for defrosting is satisfied after detections for continuous 3minutes, the defrosting operation will start. ② Conditions of finishing defrosting The defrosting operation can exit when any of the conditions below are satisfied: ≥...
  • Page 31 Service Manual 1. Starting estimation: After the compressor stopped working for 180s, if T > [T (the temperature of hysteresis is 35.6ºF )], the frozen-preventing frequency-limited temperature inner pipe machine is only allowed to start for operation, otherwise it should not be started. It should be stopped to treat according to the freeze- preventing protection: Clear the trouble under the mode of power turn-off / heating, and the protection times are not counted.
  • Page 32 Service Manual 1. Frequency limited If [T ]≤T <[T ] , you should limit the frequency raising of heating overload frequency-limited temperature heating overload frequency reducing temperature at normal speed inner pipe compressor. 2. Reducing frequency at normal speed and stopping machine: If T[ ]≤T <[T...
  • Page 33 Service Manual (6)Voltage sag protection After starting the compressor, if the time of DC link Voltage sag [U ] is measured to be less than t Voltage sag protection Sagging protection voltage time, the machine should be stopped at once, hand on the voltage sag trouble, reboot automatically after 30 minutes. (7)Communication fault When you have not received any correct signal from the inner machine in three minutes, the machine will stop for communication fault.
  • Page 34 Service Manual (12) Start-up Failure Protection for Compressor Stop the compressor after its start-up fails, restart it after 20s if the fault doesn’t show, and if they are all failing for the successive start 3 times, it shall be reported as Start-up Failure, and then restart up it after 3 min. When it still doesn't operate through carry out the above process for 5 times, it is available if pressing ON/OFF.
  • Page 35 Service Manual 6. Electric Heating Function of Chassis (1) When T ≤32ºF , the electric heating of chassis will operate; outdoor amb. (2) When T >35.6ºF , the electric heating of chassis will stop operation; outdoor amb. (3)When 32ºF <T ≤35.6ºF, the electric heating of chassis will keep original status.
  • Page 36 Service Manual 7. Maintenance 7.1 Precautions before Maintenance There are high-capacity electrolytic capacitors on the outdoor mainboard. Thus, even if the power is cut off, there is high voltage inside the capacitors and it needs more than 20 min. to reduce the voltage to safety value. Touching the electrolytic capacitor within 20 min. after cutting the power will cause electric shock.
  • Page 37 Service Manual 7.2 Error Code List Display of lamp (the times of blinking) Display of Name of malfunction Indoor Outdoor indoor unit Anti-freezing protection Block or Low pressure of refrigerant system Compressor exhaust high temperature protection AC over-current protection Communication failure between indoor unit and outdoor unit Anti-high temperature protection No feedback of indoor fan motor Jumper cap malfunction protection...
  • Page 38 Service Manual 7.3 Troubleshooting Procedures Indoor unit (1) Malfunction of Temperature Sensor F1, F2 Main detection points: ● Is the wiring terminal between the temperature sensor and the controller loosened or poorly contacted ● Is there short circuit due to trip-over of the parts ●...
  • Page 39 Service Manual (2) Malfunction of Blocked Protection of IDU Fan Motor H6 Main detection points: ● SmoothlyIs the control terminal of PG motor connected tightly ● SmoothlyIs the feedback interface of PG motor connected tightly ● The fan motor can t operate ●...
  • Page 40 Service Manual (3) Malfunction of Protection of Jumper Cap C5 Main detection points: ● Is there jumper cap on the mainboard ● Is the jumper cap inserted correctly and tightly ● The jumper is broken ● The motor is broken ●...
  • Page 41 Service Manual (4) Malfunction of Zero-crossing Inspection Circuit Malfunction of the IDU Fan Motor U8 Main detection points: ● Instant energization afte de-energization while the capacitordischarges slowly ● The zero-cross detectioncircuit of the mainboard is defined abnormal Malfunction diagnosis process: Start Turn power off for 1minute,the turn...
  • Page 42 Service Manual 4. Communication malfunction E6 Start Cut off power supply. Check if connection line of IDU and ODU and the wire inside electric box are correctly connected. Connect the line Correct connection? according to Malfunction eliminated? wiring diagram. Main board matches Match correctly with display board? Main board of Malfunction eliminated?
  • Page 43 Service Manual Outdoor unit: (1) Capacitor charge fault (Fault with outdoor unit) (AP1 below refers to the outdoor control panel) Main Check Points: ●Use AC voltmeter to check if the voltage between terminal L and N on the wiring board is within 210VAC~240VAC. ●Is the reactor (L) correctly connected Is the connection loose or fallen Is the reactor (L) damaged Fault diagnosis process: Turn on the unit...
  • Page 44 Service Manual (2) IPM Protection, Out-of-step Fault, Compressor Phase Overcurrent (AP1 below refers to the outdoor control panel) Main check points: ●Is the connection between control panel AP1 and compressor COMP secure Loose Is the connection in correct order ●Is the voltage input of the machine within normal range (Use AC voltmeter to measure the voltage between terminal L and N on the wiring board XT) ●Is the compressor coil resistance normal Is the insulation of compressor coil against the copper tube in good condition ●Is the working load of the machine too high Is the radiation good...
  • Page 45 Service Manual Energize and switch on Use AC voltmeter If the voltage Check the supply to measure the IPM protection between terminal L voltage and voltage between occurs after the and N on wiring terminal L and N machine has run for restore it to board XT is within a period of time?
  • Page 46 Service Manual (3) High temperature and overload protection diagnosis (AP1 hereinafter refers to the control board of the outdoor unit) Mainly detect: ●Is outdoor ambient temperature in normal range ●Are the outdoor and indoor fans operating normally ●Is the heat dissipation environment inside and outside the unit good Fault diagnosis process: Overheat and high temperature protection...
  • Page 47 Service Manual (4) Start-up failure (following AP1 for outdoor unit control board) Mainly detect: ●Whether the compressor wiring is connected correct ●Is compressor broken ●Is time for compressor stopping enough Fault diagnosis process: Power on the unit Restart it up after Is stop time of the compressor 3 minutes longer than 3 minutes?
  • Page 48 Service Manual (5) Out of step diagnosis for the compressor (AP1 hereinafter refers to the control board of the outdoor unit) Mainly detect: ●Is the system pressure too high ●Is the input voltage too low Fault diagnosis process: Out of step occurs in Out of step occurs once the operation unit is powered on.
  • Page 49 Service Manual (6) Overload and air exhaust malfunction diagnosis (following AP1 for outdoor unit control board) Mainly detect: ●Is the PMV connected well or not Is PMV damaged ●Is refrigerant leaked Fault diagnosis process: 20 minutes after the complete unit is powered off Is the terminal FA for the Connect the...
  • Page 50 Service Manual (7) Power factor correct or (PFC) fault (a fault of outdoor unit) (AP1 hereinafter refers to the control board of the outdoor unit) Mainly detect: ●Check if the reactor (L) of the outdoor unit and the PFC capacitor are broken Fault diagnosis process: Start Check wiring of the...
  • Page 51 Service Manual (8) Communication malfunction: (following AP1 for outdoor unit control board) Mainly detect: ●Is there any damage for the indoor unit mainboard communication circuit Is communication circuit damaged ●Detect the indoor and outdoor units connection wire and indoor and outdoor units inside wiring is connect well or not, if is there any damage Fault diagnosis process: Start...
  • Page 52 Service Manual (9) Malfunction of Overcurrent Protection Main detection points: ● Is the supply voltage unstable with big fluctuation ● Is the supply voltage too low with overload ● Hardware trouble Malfunction diagnosis process: Start Normal fluctuation should be within 10 Is malfunction Is the supply voltage unstable of the rated voltage on the nameplate...
  • Page 53 Service Manual 7.4 Troubleshooting for Normal Malfunction 1. Air Conditioning Unit Doesn't Start Possible Causes Discriminating Method (Air conditioner Status) Troubleshooting Confirm whether it s due to power failure. If yes, No power supply, or poor After energization, operation indicator isn’t bright wait for power recovery.
  • Page 54 Service Manual 4. ODU Fan Motor Doesn't Operate Possible causes Discriminating method (air conditioner status) Troubleshooting Connect wires according to wiring diagram to Check the wiring status according to circuit Wrong wire connection, or poor make sure all wiring terminals are connected connection diagram firmly...
  • Page 55 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. 8.1 Removal Procedure of Indoor Unit NOTE: Take A6 panel for an example. Steps Procedure 1.
  • Page 56 Service Manual Steps Procedure 4. Remove electric box cover 2 Screw Electric box cover 2 Remove the screws on the electric box cover 2 to remove the electric box cover 2. 5. Remove front case sub-assy Screws Remove the screws fixing front case. Note: 1.Open the screw caps before removing the screws around the air outlet.
  • Page 57 Service Manual Steps Procedure 7. Remove vertical louver Loosen the connection clasps between vertical louver and bottom case to remove Bottom vertical louver. case Vertical louver Vertical Clasps louver 8. Remove electric box assy Screw Loosen the connection clasps between shield cover of electric box sub-assy and Clasps electric box, and then remove the shield...
  • Page 58 Service Manual Steps Procedure Some wiring terminals of this product have a lock catch and other devices. Circlip The pulling method is as below: Holder ① Remove the soft sheath for some terminals at first, hold the circlip and then pull out the terminals.
  • Page 59 Service Manual Steps Procedure 10. Remove motor and cross flow blade Remove the screws fixing motor clamp Screws and then remove the motor clamp. Motor clamp Cross flow Remove the screws at the connection Screw Motor place of cross flow blade and motor; lift Holder the motor and cross flow blade upwards sub-assy...
  • Page 60 Service Manual 8.2 Removal Procedures of Outdoor Unit Warning: Be sure to wait for a minimum of 20 minutes after turning off all power supplies and discharge the refrigerant completely before removal. Steps Procedure 1.Remove cable cross plate sub-assy and valve cover cable cross plate sub-assy Remove the screws fixing cable cross plate...
  • Page 61 Service Manual Steps Procedure 4.Remove front panel front panel Remove connection screws connecting the front panel with the chassis and the motor support, and then remove the front panel. 5.Remove right side plate Remove connection screws connecting the right side plate right side plate with the valve support and the electric box.
  • Page 62 Service Manual Steps Procedure 7.Remove motor and motor support motor support tor Pull out the lead-out wire and remove themotor. Remove the 2 tapping screws securing the motor support. Lift the motor support to remove it. motor 8.Remove electric box assy electric box assy Remove the 2 screws fixing the cover of electric box.
  • Page 63 Service Manual Steps Procedure 10.Remove 4-way valve assy 4-way valve assy Unscrew the fastening nut of the 4-way Valve Assy coil and remove the coil. Wrap the 4-way Valve Assy with wet cotton and unsolder the 4 weld spots connecting the 4-way Valve Assy to take it out.
  • Page 64 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 Fahrenheit Fahrenheit Fahrenheit display display display Celsius( Celsius( Celsius( temperature temperature temperature 60.8 69/70 69.8 78/79 78.8 62/63...
  • Page 65 Service Manual Appendix 3: Pipe Flaring Method Pipe Note: Improper pipe flaring is the main cause of refrigerant leakage. Please Pipe cutter flare the pipe according to the following steps: Leaning Uneven Burr A:Cut the pipe ● Confirm the pipe length according to the distance of indoor unit and outdoor unit. ●...
  • Page 66 Service Manual Appendix 4: List of Resistance for Temperature Sensor Resistance Table of Ambient Temperature Sensor for Indoor and Outdoor(15K) Resistance(kΩ) Resistance(kΩ) Resistance(kΩ) Resistance(kΩ) Temp.( Temp.( Temp.( Temp.( -2.2 138.1 18.75 138.2 3.848 208.4 1.071 -0.4 128.6 69.8 17.93 3.711 210.2 1.039 121.6...
  • Page 67 Service Manual Resistance Table of Tube Temperature Sensors for Indoor and Outdoor (20K) Resistance(kΩ) Resistance(kΩ) Resistance(kΩ) Resistance(kΩ) Temp.( Temp.( Temp.( Temp.( -2.2 181.4 25.01 138.2 5.13 208.4 1.427 -0.4 171.4 69.8 23.9 4.948 210.2 1.386 162.1 71.6 22.85 141.8 4.773 1.346 153.3 73.4...
  • Page 69 Product improvement, specifications and appearance in this manual are subject to change without prior notice. LIT - 12012190 © Johnson Controls, Inc. USA...

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