Heat Controller VMC09SB-1 Service Manual
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Heat Controller VMC09SB-1 Service Manual

Heat Controller VMC09SB-1 Service Manual

Wall mounted mini-split system single-zone air conditioning/heat pump
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HEAT CONTROLLER, INC.
Wall Mounted
Mini-Split System
Single-Zone
Air Conditioning/Heat Pump
Service Manual(General)
VMC09SB-1/VMH09SB-1
VMC12SB-1/VMH12SB-1
VMC18SB-1/VMH18SB-1
VMC24SB-1/VMH24SB-1
VMC30SB-1/VMH30SB-1
Before servicing the unit, read the
"safety precautions" in this manual.
Only for authorized service personnel.

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Summary of Contents for Heat Controller VMC09SB-1

  • Page 1 HEAT CONTROLLER, INC. Wall Mounted Mini-Split System Single-Zone Air Conditioning/Heat Pump Service Manual(General) VMC09SB-1/VMH09SB-1 VMC12SB-1/VMH12SB-1 VMC18SB-1/VMH18SB-1 VMC24SB-1/VMH24SB-1 VMC30SB-1/VMH30SB-1 Before servicing the unit, read the “safety precautions” in this manual. Only for authorized service personnel.

  • Page 2: Table Of Contents

    Air Conditioner Service Manual CONTENTS Part 1 General Information 1. Safety Precautions......................4 Part 2 Functions & Controls 1. List of Functions & Controls..................8 2. Basic Mode Controls ....................9 3. Special Mode Controls ....................11 4. Utility Functions ......................12 5. Protection Functions & Controls................15 Part 3 Test Run 1.

  • Page 3: Part 1 General Information

    Part 1 General Information 1. Safety Precautions ......................4 - 3 - Only for training and service purposes...

  • Page 4: Safety Precautions

    Part 1 General Information 1. Safety Precautions To prevent injury to the user other people and property damage, the following instructions must be followed. I Incorrect operation due to ignoring instruction will cause harm or damage. The seriousness is classified by the follow- ing indications.
  • Page 5 Part 1 General Information Do not use a defective or underrated circuit breaker. Use the correctly rated breaker and fuse. Otherwise there is a risk of fire or electric shock. Install the panel and the cover of control box securely. Otherwise there is risk of fire or electric shock due to dust, water etc.
  • Page 6 Part 1 General Information 1.2 Inspections after Repair Check to see if the power cable plug is not dirty or loose. If the plug is dusty or loose it can cause an electrical shock or fire. Do not use a joined power cable or extension cable, or share the same power outlet with other electrical appliances.

  • Page 7: Part 2 Functions & Controls

    Part 2 Functions & Controls 1. List of Controls & Functions ..................8 2. Basic Mode Controls......................9 3. Special Mode Controls....................11 4. Utility Functions ......................12 5. Protection Functions & Controls .................15 - 7 - Only for training and service purposes...

  • Page 8: List Of Functions & Controls

    Part 2 Functions & Controls 1. List of Functions & Controls Category Function Description Remark Cooling Mode Cooling operation Heating Mode Heating operation Basic mode Healthy Dehumidification Dry operation controls Auto Changeover Cooling mode is automatically changed to heating mode and vice versa Jet Cool Powerful cooling mode...

  • Page 9: Basic Mode Controls

    Part 2 Functions & Controls 2. Basic Mode Controls 2.1 Cooling Mode Thermo ON +0.5°C(1°F) Setting Temp. -0.5°C(-1°F) Thermo OFF INV. Comp. High Comp. OFF High Frequency • Operating frequency of compressor depends on the load condition, like the difference between the room temp. and the set temp., frequency restrictions.
  • Page 10 Part 2 Functions & Controls 2.3 Healthy Dehumidification operation • When the dehumidification operation is set by the remote controller, the intake air temperature is detected and the set- ting temp. is automatically set according to the intake air temperature. Intake air Temp.

  • Page 11: Special Mode Controls

    Part 2 Functions & Controls 3. Special Mode Controls 3.1 Jet Cool operation • In the heating mode or Fuzzy operation, the Jet cool function does not work. When it is input while in other mode of operation (cooling, dehumidification, ventilation), the Jet cool operation takes place.

  • Page 12: Utility Functions

    Part 2 Functions & Controls 4. Utility Functions 4.1 Forced operation • To operate the appliance manually if the remote control is lost. The forced operation selection switch is on the main unit of the appliance and will operate the appliance in the standard conditions. •...
  • Page 13 Part 2 Functions & Controls 4.3 Air volume control Step Description • Indoor fan motor control have 6 steps. Very low, In heating mode • Air volume is controlled "SH", "H", "Med", "Low" by the remote con- troller. • "LL" step is selected automatically in Hot start operation. High Super high 4.4 Natural Air Control(Auto Wind)
  • Page 14 Part 2 Functions & Controls 4.6.2 Sleep timer operation for heating cycle Heatpump Only • While in heating mode, 60 min. after the start of the sleep timer, the setting temperature decreases by 1¡Æ C(2¡Æ F). After another 60minutes lapse, it decreases again by 1°C(2¡Æ F). Setting temp.

  • Page 15: Protection Functions & Controls

    Part 2 Functions & Controls 5. Protection Functions & Controls 5.1 Five Seconds Stand-by (fan) • The indoor unit fan will begin to rotate after 5 seconds of the unit being turned on. 5.2 Two Minutes Stand-by (comp.) • After the compressor cycles off, it will not restart for a minimum of 2 minutes. 5.3 Hot start Heatpump Only •...
  • Page 16 Part 2 Functions & Controls 5.5 Compressor Preheating Heatpump Only 5.5.1 9,12kBtu/h Model With low outdoor temperature, preheating the compressor compressor is neccessary to maintain the oil viscosi- ty before the unit starts. The preheating Mode preheats the compressor motor coil/windings by electric current without compressor run- ning.
  • Page 17 Part 2 Functions & Controls 5.5 Automatic defrost Heatpump Only 5.5.1 9,12kBtu/h Model • While in heating mode operation, in order to protect the evaporator pipe of the outdoor unit from freezing, the unit is reversed to the cooling cycle to defrost the evaporator pipe of the outdoor unit. •...
  • Page 18 Part 2 Functions & Controls 5.5.2 18,24,30kBtu/h Model • Starting the defrosting operation 1) Defrost operation will start when the conditions below are met: a) Accumulation time of operation and the period after completion of defrost = 35 min. b) After 10 minutes from re-starting the compressor and over 35 minutes of accumulated operating time, defrosting operation starts after 10 minutes.
  • Page 19 Part 2 Functions & Controls • Defrosting Control Algorithm 1) Lowering the compressor frequency starts the defrosting operation. Constant speed compressor is ON 10 seconds. 2) The EEV has an opening 350 pulse (Option) when starting the defrosting operation. 3) Reversing valve is OFF after 5 seconds from the compressor reaching an operating frequency of 30 Hz. Then the indoor fan turns OFF (including when the indoor unit is OFF, except if the remote controller is OFF).
  • Page 20 Part 2 Functions & Controls 5.6 Power Relay Control • Power relay turns on 1 second later after the power is supplied to the outdoor unit. • Control sequence : power on ¡ PTC operating ¡ power relay on 5.7 Inverter U V W 3Ø...
  • Page 21 Part 2 Functions & Controls 5.8 Overheating Protection (Power Module) 5.8.1 9,12kBtu/h Model • If the temperature of the heat sink thermistor reaches over Toff, the Compressor stop instantly. • The compressor operating frequency is limited according to the heat sink thermistor. (refer to below FIG.) •...
  • Page 22 Part 2 Functions & Controls 5.8.2 18,24,30kBtu/h Model • Function : Power module failure is protected by checking the temperature of heat sink via a temperature sensor. • Heat sink sensor failure error Short Check : if temperature ≥130°C(266°F) Open Check : if temperature < - 30°C(-22°F) System will go in self diagnosis (Error code 65) is displayed and product stops.
  • Page 23 Part 2 Functions & Controls 5.9 Total Current Control (Over Current Protection) 5.9.1 9,12kBtu/h Model 1) CT1 control • If the operating current reaches CT1, the operating frequency of the compressor decreases. • After decreasing the operating frequency by 4Hz, if operating current is below I1 for 60 seconds continuously, the operating frequency of compressor increases to setting frequency.
  • Page 24 Part 2 Functions & Controls 5.9.2 18,24,30kBtu/h Model 1) Detection : check the output DC voltage of Current Transformer(CT). 2) Current Transformer Sensing Error a) In initial power input, if the CT output is over 4.0V (25A) it shows. Error Code 40 (defect in CT sensing) 3) CT 1 detection : a) If total current exceeds the value of CT1, then the operating frequency will be reduced by 1 step.
  • Page 25 Part 2 Functions & Controls 5.10 DC Peak control 5.10.1 DC Peak Current Error by a fault signal of IPM • If the operating current of IPM reaches 35A ¡¾ 3A, the compressor stops instantly. • If DC PEAK occurs 5 times within 1 hour, the appliance turns off and displays Error Code 6(9,12kBtu/h Model) / Error Code 21(18,24,30kBtu/h Model).
  • Page 26 Part 2 Functions & Controls 5.11.2 Inverter Compressor (18,24,30kBtu/h Model) 1) There can be two situations (a) Temperature sensor is failed (Error Code 41) (b) Abnormal high temperature discharge temperature (error code for high discharge will be generated) Both cases unit will stop. 2) Compressor working (a) If discharge pipe temperature <...
  • Page 27 Part 2 Functions & Controls 5.11.3 Constant Compressor (only 30kBtu/h Model) 1) There can be two situations (a) Temperature sensor is failed (Error Code 41) (b) Abnormal high temperature discharge temperature (error code for high discharge will be generated) Both cases unit will stop. 2) Compressor working (a) If discharge pipe temperature <...
  • Page 28 Part 2 Functions & Controls 5.12 Low Ambient control 5.12.1 9,12kBtu/h Model • If outdoor temperature drops below a certain temperature, liquid return is prevented by On/Off control of outdoor fan. • It can prevent frosting of evaporator and keep cooling operation Model Mode-in Condition Mode-out Condition...
  • Page 29 Part 2 Functions & Controls 5.13 Oil return control(30kBtu/h Model) Heatpump Only 5.13.1 Operating Contion 1) When the continuous running time is over 3hr.(option), oil returning operation is run for 3min. In case of the initial operation, oil returning operation is run, after completing initial operation. 2) After defrost and oil returning operation, the continuous running time is reset.

  • Page 30: Part 3 Test Run

    Part 3 Test Run Part 3 Test Run 1. Check before Test Run....................31 2. Test Run Flow chart .......................32 3. Test Run Detail........................33 - 30 - Only for training and service purposes...

  • Page 31: Check Before Test Run

    Part 3 Test Run 1. Check before Test Run Check to see whether there is any refrigerant leakage, and check whether the power or transmission cable is connected properly. Check whether the liquid pipe and gas pipe valves are fully opened. NOTE: Be sure to tighten caps.

  • Page 32: Test Run Flow Chart

    Part 3 Test Run 2. Test Run Flow chart START Test operation for indoor unit Refer to part4, Section 7: Electronic Operate the unit in cooling mode. Troubleshooting Guide Does Test operation start? Is cold air discharged for more than 3 minutes ? Refer to part4, Section 5: Cycle Troubleshooting Guide Is there any temperature...

  • Page 33: Test Run Detail

    Part 3 Test Run 3. Test Run Detail 1. Check that all tubing and wiring have been properly con- NOTE: If the actual pressure is higher than shown, the nected. system is most likely over-charged, and charge should be removed. 2.
  • Page 34 Part 4 Trouble Shooting 1. 2-Way, 3-Way Valve ......................35 2. Pumping Down ......................36 3. Evacuation ........................37 4. Gas Charging (After Evacuation) .................38 5. Cycle Troubleshooting Guide..................39 6. Electronic Parts Troubleshooting Guide ..............40 7. Self-diagnosis Function....................45 - 34 - Only for training and service purposes...

  • Page 35: Way, 3-Way Valve

    Part 4 Trouble Shooting 1. 2-Way, 3-Way Valve 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...

  • Page 36: Pumping Down

    Part 4 Trouble Shooting 2. Pumping Down Liquid side Indoor unit Open Outdoor unit 2-Way valve Gas side Closed 3-Way valve CLOSE CLOSE Purge the air • Procedure (6) Operate the air conditioner at the cooling (1) Confirm that both the 2-way and 3-way valves cycle and stop it when the gauge indicates are set to the open position.

  • Page 37: Evacuation

    Part 4 Trouble Shooting 3. Evacuation Liquid side Indoor unit Outdoor unit 3-Way valve Open Gas side 3-Way valve Open Vacuum pump Vacuum Gage OPEN OPEN • 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 38: Gas Charging (After Evacuation)

    Part 4 Trouble Shooting 4. Gas Charging (After Evacuation) Liquid side Indoor unit Outdoor unit Open 3-Way valve Gas side Open 3-Way valve Check valve Charging cylinder Vacuum Gage 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 39: Cycle Troubleshooting Guide

    Part 4 Trouble Shooting 5. Cycle Troubleshooting Guide Trouble analysis 1. Check temperature difference between intake and discharge air, and operating current. Temp. difference : approx. 0°C(1°F) All amount of refrigerant leaked out. Current : less than 80% of Check refrigeration cycle. rated current Temp.

  • Page 40: Electric Parts Troubleshooting Guide

    Part 4 Trouble Shooting 6. Electronic Parts Troubleshooting Guide The Product doesn’t operate at all. (9~30kBtu/h Model) Trouble 1 Turn off the main power and wait until LED on outdoor PCB is off. Turn on the main power again. "Beeping" sound is from the indoor unit? Flashing LED mounted on the outdoor PCB? •...
  • Page 41 Part 4 Trouble Shooting Product doesn't operate with the remote controller. (9~30kBtu/h Model) Trouble 2 Turn on main power. Wait 2 minutes for the compressor to turn on. When the compressor is stopped stopped, the Indoor Fan is driven by a low speed. At this point the air speed is not controlled by the remote controller.
  • Page 42 Part 4 Trouble Shooting The Compressor/Outdoor Fan does not operate (9, 12kBtu/h Model) Trouble 3 Turn on the main power. Using the remote controller, set the indoor set point to at least 15˚C(5˚F) less than the indoor air temperature. When in air circulation mode, compressor/outdoor fan is stopped. Check that the sensor for Indoor temperature sensor is attatched and as close to the heat exchanger (EVA.) as possible.
  • Page 43 Part 4 Trouble Shooting The Compressor/Outdoor Fan does not operate (18, 24, 30kBtu/h Model) Trouble 4 Turn on the main power. Using the remote controller, set the indoor set point to at least 15˚C(5˚F) less than the indoor air temperature. When in air circulation mode, compressor/outdoor fan is stopped.
  • Page 44 Part 4 Trouble Shooting When indoor Fan does not operate.(9~30kBtu/h Model) Trouble 5 Turn off main power. Check the connection of CN-FAN. Check the Fan Motor. Check the Fuse(AC250V, T2A). Check the related circuit of indoor Fan Motor. • The pin No. of micom and the Q01M that drives the SSR.

  • Page 45: Self-Diagnosis Function

    Part 4 Trouble Shooting 7. Self-diagnosis Function I Error Indicator • The error indicator assists with self-diagnoisis of the air conditioner and identifies if there is any trouble. • The error indicator location is near the ON/OFF button by the LED on the evaporator and will signal as shown in the table below.
  • Page 46 Part 4 Trouble Shooting I 18,24,30kBtu/h Model Indoor Error LED1 LED2 Indoor Error code Descrition INV TPS (Red) (Green) Status No Error ¡Ü Indoor Room themistor error ¡Ü 1time ¢Å Indoor in-piping sensor error ¡Ü 2times ¢Å Communcation error between indoor and outdoor units ¡Ü...
  • Page 47 Part 4 Trouble Shooting LED02G Outdoor Error LED01G Contents Case of error (Green) Status code (Red) CT Circuit (open/ short) 4 times CT Circuit malfunction Sensor INV. (open/ short) 4 times 1 time Open / Short Air sensor (open/ short) 4 times 4 times Open / Short...
  • Page 48 Part 4 Trouble Shooting I Troubleshooting Guide(9,12kBtu/h Model) Error code Description Cause of error • Indoor thermistor (sensor) is short or open Indoor thermistor is short • Indoor thermistor (sensor) is not connected to the indoor pcb assembly • Damage or defect on the sensing circuit of indoor pcb assembly. or open (R01H, R02H, R03H, R04H, C01H, C02H) Check flow...
  • Page 49 Part 4 Trouble Shooting Error code Description Cause of error • Heat-sink thermistor is damaged(short or open). Heat-sink Temp. is over 95°C(203°F) • Heat-sink Temp. is over 95°C(203°F) Heat-sink thermistor • Damage or defect on the sensing circuit of outdoor pcb assembly. is open or short (R01H, R02H, C01H) Check flow...
  • Page 50 Part 4 Trouble Shooting Error code Description Cause of error • Wrong or missing wiring between indoor and outdoor unit cable • Defect of communication components in indoor pcb assembly • Defect of communication components in outdoor pcb assembly Communication Error •...
  • Page 51 Part 4 Trouble Shooting Error code Description Cause of error Cause of error • Supplied power is not normal • Comp Connector (CN-U,V,W) is disconnected or inserted into the wrong position DC Peak Error • Compressor is damaged (coil short) ➔ replace compressor •...
  • Page 52 Part 4 Trouble Shooting Error code Description Cause of error • Supplied power is not normal Over current Error • Indoor/outdoor fan is locked • Too much refrigerant (CT2) • Defect in current sensing circuit in outdoor pcb assembly Check flow Supplied voltage to Does indoor / outdoor fan work Outdoor pcb is about...
  • Page 53 Part 4 Trouble Shooting Error code Description Cause of error • Indoor fan is locked or separated Indoor fan is locked • Fan connector is not connected to indoor pcb assembly (BLDC fan model only) • Defective DC-fan driving circuit Check flow Indoor fan is rotating ? (1) Indoor fan is rotating ? (2)
  • Page 54 Part 4 Trouble Shooting Error code Description Cause of error • Discharge pipe temp. is short or open Discharge pipe temp. is • Discharge pipe temp. is not connected to the outdoor pcb assembly short or open • Damage or defect on the sensing circuit of outdoor pcb assembly Check flow Discharge pipe temp.
  • Page 55 Part 4 Trouble Shooting I Troubleshooting Guide(18,24,30kBtu/h Model) 1) Troubleshooting CH01, CH02, CH06 Error Title Cause of error Check point & Normal condition code • Open / Short Normal resistor : 10kΩ/ at 25°C(77°F) (Unplugged) Indoor air sensor • Soldered poorly Normal voltage : 2.5VDC / at 25°C(77°F) (plugged) •...
  • Page 56 Part 4 Trouble Shooting 2) Troubleshooting CH05, CH53 Error Title Cause of error Check point & Normal condition code • Power input AC 208~230V. (Outdoor, Indoor) • The connector for transmission is disconnected. • The connecting wires are misconnected. Communication •...
  • Page 57 Part 4 Trouble Shooting 3) Troubleshooting CH21 Error Title Cause of error Check point & Normal condition code • An instant over current in the U,V,W phase - Comp lock • Instant over current - The abnormal connection of U,V,W •...
  • Page 58 Part 4 Trouble Shooting 4) Troubleshooting CH21, CH22 Error Title Cause of error Check point & Normal condition code check if the compressor is locked or operating. Check the compressor insulation and motor wire Compressor output resistance. DC_Peak current over.(30A¡è ) Check if the outdoor fan is locked or operating.
  • Page 59 Part 4 Trouble Shooting 5) Troubleshooting CH23, CH28 Error Title Cause of error Check point & Normal condition code DC Link • Check the power source. • DC link volt. is Low voltage. • Check the DC Link Voltage. 140VDC or lower. DC Link •...
  • Page 60 Part 4 Trouble Shooting 6) Troubleshooting CH24, CH25 Error Title Cause of error Check point & Normal condition code • Check the connection of “CN_Press”. • Low / High press Press S/W Open • Check the components. S/W open. • Abnormal Input voltage •...
  • Page 61 Part 4 Trouble Shooting 7) Troubleshooting CH26, CH27 Error Title Cause of error Check point & Normal condition code • Check the connection of comp wire “U,V,W” DC Compressor • Compressor • Malfunction of compressor Position position detect error • Check the component of “IPM”, detection parts. Check the Reactor spec.
  • Page 62 Part 4 Trouble Shooting 8) Troubleshooting CH32, CH33, CH40 Error Title Cause of error Check point & Normal condition code • Check the discharge pipe sensor for INV. • Check the installation conditions for over loads. Discharge pipe (Inverter) • Check for leakage of refrigerant. •...
  • Page 63 Part 4 Trouble Shooting 9) Troubleshooting CH41, CH44, CH45, CH46, CH47, CH65 Display Title Cause of error Check point & Normal condition code • Open / Short • Normal resistor : 200kΩ / at 25°C(77°F) (Unplugged) Discharge pipe sensor • Soldered poorly •...
  • Page 64 Part 4 Trouble Shooting Inverter/Constant Air R-T Table Discharge pipe R-T Table Temperature(˚C/˚F) Resistance(kΩ) Temperature(˚C/˚F) Resistance(kΩ) 20/68 12.5 20/68 30/86 30/86 164.8 40/104 40/104 50/122 50/122 80.6 60/140 60/140 58.3 70/158 70/158 42.9 80/176 80/176 32.1 90/194 90/194 24.4 100/212 100/212 18.9 110/230...
  • Page 65 Part 4 Trouble Shooting 11) Troubleshooting CH61, CH62 Display Title Cause of error Check point & Normal condition code Condenser • Condenser pipe sensor • Check the load condition. pipe sensor detected high • Check the sensor of Condenser pipe sensor. temp.
  • Page 66 Specifications and performance data subject to change without notice. HEAT CONTROLLER, INC. 1900 WELLWORTH AVENUE • JACKSON, MICHIGAN 49203 THE QUALITY LEADER IN CONDITIONING AIR P/NO : MFL41161604 20/02/2008...

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