TCL TAC-07CS Service Manual
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TCL TAC-07CS Service Manual

Wall mounted split-type air conditioners
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TCL
WALL MOUNTED SPLIT-TYPE AIR CONDITIONERS

SERVICE MANUAL

Models
TAC-07CS/K
TAC-09CS/K
TAC-12CS/K
TAC-18CS/K
TAC-24CS/K
TAC-07CSC/K
TAC-09CSC/K
TAC-12CSC/K
TAC-18CSC/K
TAC-24CSC/K
TAC-07CHS/K
TAC-09CHS/K
TAC-12CHS/K
TAC-18CHS/K
TAC-24CHS/K
TAC-07CHSC/K
TAC-09CHSC/K
TAC-12CHSC/K
TAC-18CHSC/K
TAC-24CHSC/K
CONTENTS
2. TECHNICAL SPECIFICATION
3. DIMENSIONS
················································8
5. PERFORMANCE CURVES ····························12
7. WIRING DIAGRAM
9. PARTS LIST
10. ANNEX 1 THERMISTOR CHARACTERISTIC
13. ANNEX 4 R407C REFRIGERANT
14. ANNEX 5 INSTALLATION INSTRUCTION Part 1
No.TE031229
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············· 9
·············16
······························23
···················29
·································33

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Summary of Contents for TCL TAC-07CS

  • Page 1: Service Manual

    WALL MOUNTED SPLIT-TYPE AIR CONDITIONERS SERVICE MANUAL No.TE031229 Models TAC-07CS/K TAC-07CHS/K TAC-09CS/K TAC-09CHS/K TAC-12CS/K TAC-12CHS/K TAC-18CS/K TAC-18CHS/K TAC-24CS/K TAC-24CHS/K TAC-07CSC/K TAC-07CHSC/K TAC-09CSC/K TAC-09CHSC/K TAC-12CSC/K TAC-12CHSC/K TAC-18CSC/K TAC-18CHSC/K TAC-24CSC/K TAC-24CHSC/K CONTENTS 1. IMPORTANT NOTICE ···································2 2. TECHNICAL SPECIFICATION ·····················3 3. DIMENSIONS ················································8...

  • Page 2: Important Notice

    TCL Air Conditioner Service Manual IMPORTANT NOTICE This service manual is intended for use by individuals possessing adequate backgrounds of electrical, electronic and mechanical experience. Any attempt to repair the appliance may result in personal injury and property damage. The manufacturer or seller cannot be responsible for the interpretation of this information, nor can it assume any liability in connection with its use.

  • Page 3: Technical Specifications

    TCL Air Conditioner Service Manual Technical Specifications Model No. TAC-07CS/K TAC-07CHS/K TAC-09CS/K TAC-09CHS/K Type Cooling Only Heating Pump Cooling Only Heating Pump Control type Remote Remote Remote Remote Rated cooling capacity Btu/h 7,000 7,000 9,000 9,000 Rated heating capacity Btu/h...
  • Page 4 TCL Air Conditioner Service Manual Model No. TAC-07CSC/K TAC-07CHSC/K TAC-09CSC/K TAC-09CHSC/K Type Cooling Only Heating Pump Cooling Only Heating Pump Control type Remote Remote Remote Remote Rated cooling capacity Btu/h 7,000 7,000 9,000 9,000 Rated heating capacity Btu/h 7,500 9,500 EER for cooling Btu/h.w...
  • Page 5 TCL Air Conditioner Service Manual Model No. TAC-12CS/K TAC-12CHS/K TAC-18CS/K TAC-18CHS/K Type Cooling Only Heating Pump Cooling Only Heating Pump Control type Remote Remote Remote Remote Rated cooling capacity Btu/h 12,000 12,000 18,000 18,000 Rated heating capacity Btu/h 12,800 19,000 EER for cooling Btu/h.w...
  • Page 6 TCL Air Conditioner Service Manual Model No. TAC-12CSC/K TAC-12CHSC/K TAC-18CSC/K TAC-18CHSC/K Type Cooling Only Heating Pump Cooling Only Heating Pump Control type Remote Remote Remote Remote Rated cooling capacity Btu/h 12,000 12,000 18,000 18,000 1,9000 Rated heating capacity Btu/h 12,800 EER for cooling Btu/h.w...
  • Page 7 TCL Air Conditioner Service Manual Model No. TAC-24CS/K TAC-24CHS/K TAC-24CSC/K TAC-24CHSC/K Cooling Only Cooling Only Type Heating Pump Heating Pump Control type Remote Remote Remote Remote Rated cooling capacity Btu/h 24,000 24,000 24,000 24,000 Rated heating capacity Btu/h 26,000 26,000 EER for cooling Btu/h.w...

  • Page 8: Product Dimensions

    TCL Air Conditioner Service Manual Product Dimensions Indoor Unit 16mm 54 mm 124mm Outdoor Unit Unit: mm Capacity 7K&9K 770865 250 1036 1036...

  • Page 9: Heat Pump

    TCL Air Conditioner Service Manual Refrigerating Cycle System Heat Pump Reversing valve OUTDOOR UNIT INDOOR UNIT Refrigerant pipe (4- way valve) (Option) (with heat insulator) Indoor coil thermistor Indoor heat exchanger Distributor Outdoor Flared connection heat exchanger Room temperature thermistor...
  • Page 10 TCL Air Conditioner Service Manual MAX. REFRIGERANT PIPING LENGTH Refrigerant piping Piping size O.D : mm Length of connecting pipe : m Models Max. length : m Outdoor unit Indoor unit Liquid 9.52 6.35 0.40 12.7 15.88 9.52 MAX. HEIGHT DIFFERENCE...
  • Page 11 TCL Air Conditioner Service Manual EVACUATION PROCEDURES(AIR PURGE) Connect the refrigerant pipes (both the liquid and gas pipes) between the indoor and the outdoor units. Remove the service port cap of the stop valve on the side of the outdoor unit gas pipe.(The stop valve will not...

  • Page 12: Performance Curves

    TCL Air Conditioner Service Manual PERFORMANCE CURVES The standard data contained in these specifications apply only to the operation of the air conditioner under normal conditions, since operating conditions vary according to the areas where these units are installed. The following information has been pro- vided to clarify the operating characteristics of the air conditioner under the conditions indicated by the performance curve.
  • Page 13 TCL Air Conditioner Service Manual 12.0 14.0 11.4 12.7 10.4 11.5 10.3 19.9 25.5 28.7 28.0 28.0 23.5 26.5 25.9 25.9 18.4 16.9 21.6 24.3 23.7 23.7 15.3 19.6 22.5 21.6 21.6 13.8 17.6 19.9 19.4 19.4 12.3 15.6 17.7 17.2...
  • Page 14 TCL Air Conditioner Service Manual (kgf/F•G)(MPa•G) 220V 240V 220/240V Ambient temperature(˚C) Ambient temperature(˚C) Ambient humidity(%) Ambient humidity(%) (kgf/F•G)(MPa•G) 220V 240V 220/240V Ambient temperature(˚C) Ambient temperature(˚C) Ambient humidity(%) Ambient humidity(%) (kgf/F•G)(MPa•G) 220/240V 220V 240V Ambient temperature(˚C) Ambient temperature(˚C) Ambient humidity(%) Ambient humidity(%) (kgf/F•G)(MPa•G)
  • Page 15 TCL Air Conditioner Service Manual HEAT operation Outdoor:Dry bulb temperature 7,15,20°C Condition indoor:Dry bulb temperature 20.0°C Wet bulb temperature 6,12,14.5°C Wet bulb temperature 14.5°C 220V 220V 240V 240V Ambient temperature(˚C) Ambient temperature(˚C) 220V 220V 240V 240V Ambient temperature(˚C) Ambient temperature(˚C)

  • Page 16: Operation Details

    TCL Air Conditioner Service Manual Operation Details Remote controller Remote controller The remote controller transmits signals to the system. ON/OFF button Used to start and stop operation when pressed. TIMER button SLEEP TIMER ON TMIER OFF FEEL AUTO HIGH COOL Used to select TIMER operation.
  • Page 17 TCL Air Conditioner Service Manual Elctronic Controller 1. Safety Control (1) Time Delay Safety Control 3 minutes delay for compressor---The compressor is ceased for 3minutes to balance the pressure in the refrigeration cycle in order to protect the compressor. 2 minutes delay for 4-way valve---The 4-way valve is ceased for 2 minutes to prevent the refrigerant-gas abnormal noise when the HEATING operation is OFF or switch to the other operation mode.
  • Page 18 TCL Air Conditioner Service Manual Room Temp. Set TEMP. £ « 1 ¡ æ Set TEMP. £ - 1 ¡ æ Time More than 2 min More than 2 min More than 2 min More than 2 min More than 2 min...
  • Page 19 TCL Air Conditioner Service Manual (5) Defrost Defrosting of the outdoor heat exchange is controlled by the microprocessor with detection by the defrost sensor. Defrost starting conditions When the conditions of a) or b) is satisfy, the defrosting operation starts.
  • Page 20 TCL Air Conditioner Service Manual The indoor fan motor always turns on at the set speed and the vane motor turns on at the set fattle. 7. 4-way Valve contro HEATING COOLING/DRY The 4-way valve reverses for 5 seconds right before start-up of the compressor as following chart:...
  • Page 21 TCL Air Conditioner Service Manual 11. Auto Vane Operation Control (1) Vane motor drive The unit is equipped with a stepping motor for the vane. The rotating direction, speed and angle of the motor are controlled by pulse signal transmitted from indoor microprocessor.
  • Page 22 TCL Air Conditioner Service Manual moment power has restored after power failure. Then, the unit will restart automatically. Auto-restart presetting: The appliance is preset as no auto-restart function by manufacture. If Auto-restart function is needed, follow the below step to active this function: 1) Make sure air conditioner is turned off.

  • Page 23: Wiring Diagram

    TCL Air Conditioner Service Manual Wiring Diagram Mode No.: TAC-07CS/K, TAC-09CS/K, TAC-12CS/K TAC-07CSC/K, TAC-09CSC/K, TAC-12CSC/K INDOOR UNIT Yellow/Green Blue transformer P2-1 Brown P2-2 N.O. Yellow/Green Display PCB Blue Brown Room Temp.Sensor Pipe Temp.Sensor Power supply evaporator protector Vane Motor Fan Motor...
  • Page 24 TCL Air Conditioner Service Manual Mode No.: TAC-07CHS/K, TAC-09CHS/K, TAC-12CHS/K TAC-07CHSC/K, TAC-09CHSC/K, TAC-12CHSC/K INDOOR UNIT Yellow/Green Blue P2-1 Yellow Transformer Brown CN11 P2-2 Theimistor Blue CN10 NO Yellow/Green Display PCB Brown Room Temp. sensor Power Supply Pipe Temp. sensor Evaporator Protecter ¦...
  • Page 25 TCL Air Conditioner Service Manual Mode No.: TAC-18CS/K, TAC-18CSC/K INDOOR UNIT Transformer Fan Motor White Brown Blue Blue AC(N) Yellow/Green Yellow/Green Relay Yellow/Green Yellow/Green Blue Blue Vane Motor 2 3 4 Brown Brown Room Temp. Sensor Display PCB Pipe Temp. Sensor...

  • Page 26: Indoor Unit

    TCL Air Conditioner Service Manual Mode No.: TAC-18CHS/K, TAC-18CHSC/K INDOOR UNIT White Brown O.FAN Transformer Yellow Yellow Blue Blue AC(N) Fan Motor Yellow/Green Yellow/Green Yellow/Green Yellow/Green Blue Blue Vane Motor Brown Brown Room Temp. Sensor Display PCB Pipe Temp. Sensor...
  • Page 27 TCL Air Conditioner Service Manual Mode No.: TAC-24CS/K, TAC-24CSC/K INDOOR UNIT Transformer White White Blue Blue AC(N) Fan Motor Brown Brown Yellow/Green Yellow/Green Vane Motor 1 2 3 4 Room Temp. Sensor Display PCB Pipe Temp. Sensor OUTDOOR UNIT Yellow/Green...
  • Page 28 TCL Air Conditioner Service Manual Mode No.: TAC-24CHS/K, TAC-24CHSC/K INDOOR UNIT White White Transformer O.FAN Yellow Yellow Blue Blue AC(N) Fan Motor Brown Brown Yellow/Green Yellow/Green Vane Motor To Outdoor Unit Room Temp. Sensor Display PCB Pipe Temp. Sensor OUTDOOR UNIT...
  • Page 29 TCL Air Conditioner Service Manual INDOOR UNIT TAC-07CS/K,TAC-07CSH/K,TAC-07CSC/K,TAC-07CHSC/K,TAC-09CS/K,TAC-09CHS/K,TAC-09CSC/K, TAC-09CHSC/K, TAC-12CS/K, TAC-12CHS/K, TAC-12CSC/K, TAC-12CHC/K,...
  • Page 30 TCL Air Conditioner Service Manual INDOOR UNIT TAC-18CS/K, TAC-18CSC/K, TAC-18CHS/K, TAC-18CHSC/K TAC-24CS/K, TAC-24CSC/K, TAC-24CHS/K, TAC-24CHSC/K...
  • Page 31 TCL Air Conditioner Service Manual Outdoor Unit £ º TAC-07CS/K, TAC-07CSC/K, TAC-09CS/K, TAC-09CSC/K, TAC-12CS/K, TAC-12CSC/K, TAC-18CS/K, TAC-18CSC/K, TAC-24CS/K, TAC-24CSC/K 20 ¡ « 28...
  • Page 32 TCL Air Conditioner Service Manual Outdoor Unit: TAC-07CHS/K, TAC-07CHSC/K, TAC-09CHS/K, TAC-09CHSC/K, TAC-12CHS/K TAC-12CHSC/K, TAC-18CHS/K, TAC-18CHSC/K, TAC-24CHS/K, TAC-24CHSC/K 19 ¡« 28...
  • Page 33 TCL Air Conditioner Service Manual Parts List Indoor Unit- TAC-07CS/K, TAC-09CS/K Part No. Part Name Q’ty Remark 1080030003 Installation Plate 1210250103 Base 1070020017 Cross Fan 1070100010 Bearing Mount 1210230101 Evaporator 1070250102 Water Drainage Assembly 1070320105 Vertical Vane Assembly 1070250104 Face Frame...
  • Page 34 TCL Air Conditioner Service Manual Indoor Unit- TAC-07CHS/K, TAC-09CHS/K Part No. Part Name Q’ty Remark 1080030003 Installation Plate 1210250103 Base 1070020017 Cross Fan 1070100010 Bearing Mount 1210230101 Evaporator 1070250102 Water Drainage Assembly 1070320105 Vertical Vane Assembly 1070250104 Face Frame 1070320112...
  • Page 35 TCL Air Conditioner Service Manual Indoor Unit- TAC-07CSC/K , TAC-09CSC/K Part No. Part Name Q’ty Remark 1080030008 Installation Plate 1210320107 Base 1070020016 Cross Fan 1070100010 Bearing Mount 1210320601 Evaporator 1070320103 Water Drainage Assembly 1070320105 Vertical Vane Assembly 1070320107 Face Frame...
  • Page 36 TCL Air Conditioner Service Manual Indoor Unit- TAC-07CHSC/K, TAC-09CHSC/K Part No. Part Name Q’ty Remark 1080030008 Installation Plate 1210320107 Base 1070020016 Cross Fan 1070100010 Bearing Mount 1210320601 Evaporator 1070320103 Water Drainage Assembly 1070320105 Vertical Vane Assembly 1070320107 Face Frame 1070320112...
  • Page 37 TCL Air Conditioner Service Manual Indoor Unit- TAC-12CS/K, TAC-12CSC/K Part No. Part Name Q’ty Remark 1080030008 Installation Plate 1210320107 Base 1070020016 Cross Fan 1070100010 Bearing Mount 1210320601 Evaporator 1070320103 Water Drainage Assembly 1070320105 Vertical Vane Assembly 1070320107 Face Frame 1070320112...
  • Page 38 TCL Air Conditioner Service Manual Indoor Unit- TAC-12CHS/K , TAC-12CHSC/K Part No. Part Name Q’ty Remark 1080030008 Installation Plate 1210320107 Base 1070020016 Cross Fan 1070100010 Bearing Mount 1210320601 Evaporator 1070320103 Water Drainage Assembly 1070320105 Vertical Vane Assembly 1070320107 Face Frame...
  • Page 39 TCL Air Conditioner Service Manual Indoor Unit- TAC-18CS/K ,TAC-18CSC/K , TAC-24CS/K , TAC-24CSC/K Part No. Part Name Q’ty Remark 1080030001 Installation Plate 1073090101 Base 1070020014 Cross Fan 1070100010 Bearing Mount 1213090106 Evaporator 1073090104 Water Drainage Assembly 1073090106 Vertical Vane Assembly...
  • Page 40 TCL Air Conditioner Service Manual Indoor Unit- TAC-18CHS/K,TAC-18CHSC/K, TAC-24CHS/K, TAC-24CHSC/K Part No. Part Name Q’ty Remark 1080030001 Installation Plate 1073090101 Base 1070020014 Cross Fan 1070100010 Bearing Mount 1213090106 Evaporator 1073090104 Water Drainage Assembly 1073090106 Vertical Vane Assembly 1073090110 Face Frame...
  • Page 41 TCL Air Conditioner Service Manual Outdoor Unit- TAC-07CS/K, TAC-09CS/K Part No. Part Name Q’ty Remark 1083510901 Grille Optional 1080050016 Top Cover 1210250112 Condenser 1080050015 Outdoor Motor Supporter 1170040062 Outdoor Motor 1070030006 Propeller Fan 1080050012 Left Plate 1080050018 Front Plate 1080050019...
  • Page 42 TCL Air Conditioner Service Manual Outdoor Unit- TAC-07CSC/K, TAC-09CSC/K Part No. Part Name Q’ty Remark 1083510901 Grille Optional 1080050011 Top Cover 1210350207 Condenser 1080050004 Outdoor Motor Supporter 1170040059 Outdoor Motor 1070030012 Propeller Fan 1080050012 Left Plate 1080050009 Front Plate 1080320112...
  • Page 43 TCL Air Conditioner Service Manual Outdoor Unit- TAC-07CHS/K , TAC-09CHS/K Part No. Part Name Q’ty Remark 1083510901 Grille 1080050016 Top Cover 1210250112 Condenser 1080050015 Outdoor Motor Supporter 1170040062 Outdoor Motor 1070030006 Propeller Fan 1080050012 Left Plate 1080050018 Front Plate 1080050019...
  • Page 44 TCL Air Conditioner Service Manual Outdoor Unit- TAC-07CHSC/K, TAC-09CHSC/K Part No. Part Name Q’ty Remark 1083510901 Grille Optional 1080320105 Top Cover 1210320101 Condenser 1080050004 Outdoor Motor Supporter 1170040058 Outdoor Motor 1070030016 Propeller Fan 1080050001 Left Plate 1080320113 Front Plate 1080320112...
  • Page 45 TCL Air Conditioner Service Manual Outdoor Unit- TAC-12CS/K Part No. Part Name Q’ty Remark 1083510901 Grille Optional 1080320105 Top Cover 1210320106 Condenser 1080050004 Outdoor Motor Supporter 1170040058 Outdoor Motor 1070030016 Propeller Fan 1080050001 Left Plate 1080320113 Front Plate 1080320112 Fan Guard...
  • Page 46 TCL Air Conditioner Service Manual Outdoor Unit- TAC-12CSC/K Part No. Part Name Q’ty Remark 1083510901 Grille Optional 1080050011 Top Cover 1210350207 Condenser 1080050004 Outdoor Motor Supporter 1170040059 Outdoor Motor 1070030012 Propeller Fan 1080050012 Left Plate 1080050009 Front Plate 1080320112 Fan Guard...
  • Page 47 TCL Air Conditioner Service Manual Outdoor Unit- TAC-12CHS/K Part No. Part Name Q’ty Remark 1083510901 Grille Optional 1080320105 Top Cover 1210320101 Condenser 1080050004 Outdoor Motor Supporter 1170040058 Outdoor Motor 1070030016 Propeller Fan 1080050001 Left Plate 1080320113 Front Plate 1080320112 Fan Guard...
  • Page 48 TCL Air Conditioner Service Manual Outdoor Unit- TAC-12CHSC/K Part No. Part Name Q’ty Remark 1083510901 Grille Optional 1080050011 Top Cover 1210350207 Condenser 1080050004 Outdoor Motor Supporter 1170040059 Outdoor Motor 1070030012 Propeller Fan 1080050001 Left Plate 1080050009 Front Plate 1080320112 Fan Guard...
  • Page 49 TCL Air Conditioner Service Manual Outdoor Unit- TAC-18CS/K Part No. Part Name Q’ty Remark 1080050026 Grille Optional 1080050011 Top Cover 1210500107 Condenser 1080050004 Outdoor Motor Supporter 1170040054 Outdoor Motor 1070030012 Propeller Fan 1080050001 Left Plate 1080050009 Front Plate 1080320112 Fan Guard...
  • Page 50 TCL Air Conditioner Service Manual Outdoor Unit- TAC-18CSC/K Part No. Part Name Q’ty Remark 1084530501 Grille Optional 1084530504 Top Cover 1210700102 Condenser 1084530510 Outdoor Motor Supporter 1170040063 Outdoor Motor 1070030017 Propeller Fan 1084530516 Left Plate 1084530514 Front Plate 1084530515 Fan Guard...
  • Page 51 TCL Air Conditioner Service Manual Outdoor Unit- TAC-18CHS/K Part No. Part Name Q’ty Remark 1080050026 Grille Optional 1080050011 Top Cover 1210500107 Condenser 1080050004 Outdoor Motor Supporter 1170040054 Outdoor Motor 1070030012 Propeller Fan 1080050001 Left Plate 1080050009 Front Plate 1080320112 Fan Guard...
  • Page 52 TCL Air Conditioner Service Manual Outdoor Unit- TAC-18CHSC/K Part No. Part Name Q’ty Remark 1084530501 Grille Optional 1084530504 Top Cover 1210700202 Condenser 1084530510 Outdoor Motor Supporter 1170040063 Outdoor Motor 1070030017 Propeller Fan 1084530516 Left Plate 1084530514 Front Plate 1084530515 Fan Guard...
  • Page 53 TCL Air Conditioner Service Manual Outdoor Unit- TAC-24CS/K Part No. Part Name Q’ty Remark 1084530501 Grille Optional 1084530504 Top Cover 1210700102 Condenser 1084530510 Outdoor Motor Supporter 1170040063 Outdoor Motor 1070030017 Propeller Fan 1084530516 Left Plate 1084530514 Front Plate 1084530515 Fan Guard...
  • Page 54 TCL Air Conditioner Service Manual Outdoor Unit- TAC-24CSC/K Part No. Part Name Q’ty Remark 1084530501 Grille Optional 1084530504 Top Cover 1210700102 Condenser 1084530510 Outdoor Motor Supporter 1170040063 Outdoor Motor 1070030017 Propeller Fan 1084530516 Left Plate 1084530514 Front Plate 1084530515 Fan Guard...
  • Page 55 TCL Air Conditioner Service Manual Outdoor Unit- TAC-24CHS/K Part No. Part Name Q’ty Remark 1084530501 Grille Optional 1084530504 Top Cover 1210700202 Condenser 1084530510 Outdoor Motor Supporter 1170040063 Outdoor Motor 1070030017 Propeller Fan 1084530516 Left Plate 1084530514 Front Plate 1084530515 Fan Guard...
  • Page 56 TCL Air Conditioner Service Manual Outdoor Unit- TAC-24CHSC/K Part No. Part Name Q’ty Remark 1084530501 Grille Optional 1084530504 Top Cover 1210700202 Condenser 1084530510 Outdoor Motor Supporter 1170040063 Outdoor Motor 1070030017 Propeller Fan 1084530516 Left Plate 1084530514 Front Plate 1084530515 Fan Guard...

  • Page 57: Table Of Contents

    TCL Air Conditioner Service Manual ANNEX 2 GENERAL INDEX 1. Type of air conditioner 2. Four elements of air conditioning 3. Principle of refrigerating cycle 4. Definition of terms 5. The term of unit 6. The term of function 7. Mollier diagram 8.

  • Page 58: Type Of Air Conditioner

    TCL Air Conditioner Service Manual 1. Type of air conditioner 1.1 Distribution according to function Cooling 27 c 20 c Cooling + Heating (Electric heater) Cooling + Heating (Heat pump) 40 c 19 c Cooling+Heating Cooling 1.2 Distribution according to installation type...

  • Page 59: Four Elements Of Air Conditioning

    TCL Air Conditioner Service Manual 2. Four elements of air conditioning 1) Temperature : The dry-bulb temperature by cooling or heating room air. 2) Humidity : A comfortable humidity condition of room air is generally kept by the relative humidity of air, and the room air is controlled into a given relative humidity condition.

  • Page 60: Refrigerating Cycle

    TCL Air Conditioner Service Manual 3.2 Refrigerating cycle 1) Refrigerating cycle ROOM AIR CONITIONER CYCLE OF REFRIGERATION EVAPORATOR COILS CONDENSER COILS VAPOR INLET SUCTION LINE COMPLETE LIQUID COOL LOW PRESSURE VAPOR DISCHARGED BOIL OFF POINT COOLED ROOM AIR HEAT LOAD...

  • Page 61: Definition Of Terms

    TCL Air Conditioner Service Manual 4. Definition of terms 1) Air conditioning : Keeping room air in an optimum condition, depending on the use or purpose. (Cooling, heat- ing, humidity regulating, air cleaning, etc.) 2) Cooling (Heating) capacity : Calorie which is able to be released (or added) per a unit time in room.

  • Page 62: The Term Of Unit

    TCL Air Conditioner Service Manual 5. The term of unit 1) Kcal : Adding or releasing heat to or from a substance changes its temperature. This change of temperature is in proportion the heat added or released. This heat is called calorie which is expressed in Kcal or cal.

  • Page 63: The Term Of Function

    TCL Air Conditioner Service Manual 6. The term of function 1) Compressor : Absorb and compress the low pressure refrigerant gasified in evaporator and flow into con- denser. At this time, the low pressure needed is kept in evaporator and the refrigerant gas flows into con- denser as high pressure condition.
  • Page 64 TCL Air Conditioner Service Manual 9) Motor : Drive a rotating force by electric power and supply the driving force to fan and blower in both indoor and outdoor of air conditioner. 10) Fan : Serve to blow air through condenser and blow out the heat generated with refrigerant liquified in con- denser.
  • Page 65 TCL Air Conditioner Service Manual 19) Solenoid valve : Regulate the refrigerant flow by refrigerant on/off in cycle which refrigerant flows according as the valve operates through a coil unit being powered on. Mainly it is used when reversing the 4 way valve of a cooling/heating model or constructing each unit cycle of multi model.

  • Page 66: Mollier Diagram

    TCL Air Conditioner Service Manual 7. Mollier diagram 7.1 Refrigerant state transition on Mollier diagram 1) Refrigerant changes iso-barically and iso-thermally in evaporator, so enthalpy (the heat absorbed from evapora- tor) increases as shown in Figure 7.1 below. 2) In compressor, as the running speed of compressor is fast, it is thought there is no thermal input/output from or to the outside within a short time, which is regarded as an adiabatic change.
  • Page 67 TCL Air Conditioner Service Manual 3) Discharged gas state (the state at compressor outlet or condenser inlet) : An adiabatic change is almost seen in compressor, so the state of discharged gas follows the isentropic line at point B of Figure 7.4.
  • Page 68 TCL Air Conditioner Service Manual For the refrigerating cycle a b e f as shown in Figure 7.7, if the cooling capacity of condenser increases by the temperature down of saturated liquid, cooling water or air and then the temperature of condenser outlet refrigerant liquid decreases, the refrigerating cycle will be a b e f.
  • Page 69 TCL Air Conditioner Service Manual 4) Circulation amount of refrigerant : An amount of refrigerant to be evaporated in evaporator to obtain the refrigerating capacity needed. It is expressed in the weight by the unit time. Q ............................. (7.6) G: Circulation amount of refrigerant (kg/h)
  • Page 70 TCL Air Conditioner Service Manual Example) By using the Mollier diagram of R-22, find the compression ratio, refrigeratiny effect, work of compres- sion, calorie of condensation, circulation amount of refrigerant, coefficient of performance, and refriger- ating effect per 1KW. Condensation pressure : Pd = 18.1kg/cm Evaporation pressure : Ps = 6.5kg/cm...
  • Page 71 TCL Air Conditioner Service Manual (kgf/cm...
  • Page 72 TCL Air Conditioner Service Manual 8. Psychrometric chart 8.1 Psychrometric chart Psychrometric chart shows the characteristics of moist air by a diagram, including i-x, t-x, and t-i diagram. The i-x diagram is shown in the right side. A point express-...
  • Page 73 TCL Air Conditioner Service Manual 8.3 Dewing The most damp condition of air is at the saturated air condition of relative humidity 100% which is unable to contain moisture any longer. As a result, the water vapor (moisture) in the air is condensed and turned into liquid as waterdrop which can be seen.
  • Page 74 TCL Air Conditioner Service Manual Psychrometric chart Steam partial pressure Pw [mmHg]...

  • Page 75: Noise Characteristics

    TCL Air Conditioner Service Manual 9. Noise characteristics 9.1. Sound composition : The physical amount of sound is expressed in a logarithm and the sound level (dB) is calculated by simple addition or subtraction. Lc, the sum of n sounds L1, L2, ..Ln (dB) is calculated by the following equation.

  • Page 76: Sound Attenuation

    TCL Air Conditioner Service Manual 9.2 Sound attenuation The sound pressure level Lp[dB] at r[m]from a point sound source is composed of the following equation. Lp = Lw + 10 log (Q/4πr2 + 4/R) Lw : Power level of sound source...

  • Page 77: Load Calculation

    TCL Air Conditioner Service Manual 10. Load calculation 10.1 Cooling/Heating load calculation 1) Calorie from wall body 2) Calorie from glass 3) Calorie by clearance wind 4) Calorie generated from human body 5) Calorie generated from thermal instruments 6) Shaft heat load of wall body...
  • Page 78 TCL Air Conditioner Service Manual Example) Calculation of simple cooling capacity By using a simple cooling capacity calculation table, calculate the cooling load. North Entrance door (Opening/shutting door) Wall Living room Double window (Without pent roof) Wall (inner wall) No sunshine ( unit : m ) Condition : .•...
  • Page 79 TCL Air Conditioner Service Manual 10.2 Simple cooling capacity calculation table Item Area (m2) Coeff. Load(Kcal/h) Calculation method Max.direc (1) Calculate each window load for one Sun- tion of direction only of maximum load. shine sunshine (2) For all the other windows, calculate as load “Others”...
  • Page 80 TCL Air Conditioner Service Manual 10.3 Aircon selection 1) Calorie required per 1m 100 ~ 130 Kcal/h/m 2) Considerations in capacity selection • A place of good insulation, an apartment ¡ 90~105 kcal/h/m • A place of poor insulation, a slate building ¡ 135~150 kcal/h/m •...

  • Page 81: The Coordination Coefficient Of Cooling Capacity

    TCL Air Conditioner Service Manual 11. The coordination coefficient of cooling capacity You can use the cooling selection guide chart to determine the size unit best suited for the consumer's application. 1900 1900 1800 1800 1700 1700 1600 1600 1500...
  • Page 82 TCL Air Conditioner Service Manual ANNEX 3 TROUBLE SHOOTING INDEX 1. Electric parts 2. Refrigerant system 3. Troubleshooting 4. Installation Fundamentals...

  • Page 83: Electric Parts

    TCL Air Conditioner Service Manual 1. Electric parts It is compressor and motor fan that finally drives after power is supplied. And it is necessary to check the inter- nal factors like switches, protectors, or lead wires that are needed to reach the compressor and motor fan to see if their connections are normal and the external factors to see if voltage is normally supplied.
  • Page 84 TCL Air Conditioner Service Manual 3) Wire thickness required Rated current appliance(A) Nominal cross-sectional area(mm Up to and including 6 0.75 Over 6 up to and including 10 Over 10 up to and including 16 Over 16 up to and including 25...
  • Page 85 TCL Air Conditioner Service Manual 1.2.3 Running capacitor 1) Earth inspection between terminal and body As shown in Figure 1, connect a resistor between one side terminal and body of condenser to check for continuity. 2) Capacity inspection (1) Remove the lead wire from both terminals of condenser to be checked.
  • Page 86 TCL Air Conditioner Service Manual Measuring main coil resistance : White Black Measuring sub coil resistance : Brown Black Black Brown Measuring control coil resistance : Red Black O.L.P White 1.2.5 Thermostat There are 3 kinds of thermostat malfunction. 1) Leak of gas charged in sensor part...
  • Page 87 TCL Air Conditioner Service Manual 1.3 Compressor trouble diagnosis 1.3.1 Electrical troubles 1) Ground test Test single phase and three phase in the same manner. (1) Shut off the power supply to product. (2) Remove the wires connected to the compres- sor terminal.
  • Page 88 TCL Air Conditioner Service Manual 1.3.2 Mechanical troubles 1) Not starting (1) Phenomenon : Compressor is not started but the starting current continues to flow. (2) Checking a) Check capacitor. (for a type where a capacitor for compressor starting or operating is used) b) If there is no trouble, it is judged as lock due to the wear of compressor inside or the damage of lubricating device.

  • Page 89: Refrigerant System

    TCL Air Conditioner Service Manual 2. Refrigerant system 2.1 Refrigerant system troubleshooting Check the following items when troubleshooting the refrigerant system. 1) The thermostat setting or remocon temperature setting is not wrong? 2) Air filter is not cleaned? 3) Blower fan control switch is not at "low"?
  • Page 90 TCL Air Conditioner Service Manual 2.1.2 Pressure and temperature of refrigerant Capillary Tube High pressure (Liquid side)tube Accumulator Low pressure(Gas side) tube Compressor The pressure in normal condition shows the figure in the right side Measuring place Pressure(kg/cm table, but the pressure (P1) of high pressure side tube is affected greatly by the temperature change and about 16kg/cm .G in a low...
  • Page 91 TCL Air Conditioner Service Manual • Pressure measurement of low pressure side Closed Closed As shown in Figure above, connect the manifold gauge to the low pressure (gas side) tube of condenser and mea- sure the pressure. 2.1.3 Symptoms and actions 1) Short of refrigerant The short of refrigerant appears in a slightly different symptom as (1) no refrigerant or (2) short of refrigerant.
  • Page 92 TCL Air Conditioner Service Manual 3) Overcharge (1) Symptoms : • The temperature difference of suction-discharge air is 8°C or less, the running current is higher than the specified current, the pressure of low pressure side is high, and the compressor and suction pipe are cold.
  • Page 93 TCL Air Conditioner Service Manual 2.1.4 Summary of check items by cause Check item Suction/discharge air Rated current Low pressure High pressure temp.diff. of evaporator Cause Cooling Heating Cooling Heating Cooling Heating Cooling 8°C Heating 14°C Short of refrigerant ¢...

  • Page 94: Troubleshooting

    TCL Air Conditioner Service Manual 3. Troubleshooting 3.1 Product does not operate at all. Power receptable voltage Product input voltage Power supply voltage check Evaportor-condenser connecting pipe PCB assy (fuse, varistor, pattern) Power input voltage Connector contact check Driving load terminal Display PCB connector AC about 14±3V...
  • Page 95 TCL Air Conditioner Service Manual 3.2 Room fan does not operate at all. Motor output connector Connector contact check Motor capacitor Motor bearing inserted Motor-related parts check state Fan(Blower) fixed state Fan(Blower) contact state Coil resistance (TP) Motor detail check...
  • Page 96 TCL Air Conditioner Service Manual 3.3 Compressor or outdoor fan does not operate at all. Re-input after power off Set the desired temperature of remocon to be lower by 2°C or over than room temperature, and start the cooling operation.
  • Page 97 TCL Air Conditioner Service Manual 3.4 Up/down vane does not operate at all. Vane bending, structures interferance check Motor shaft assembly check If a constant torque is felt when rotating vane by hands, the assembled condition is normal. Connector check...
  • Page 98 TCL Air Conditioner Service Manual 3.5 Left/right louver does not operate at all. Louver/link/cam assembly check Motor shaft assembly check If a constant torque is felt when rotating louver by hands, the assembled condition is normal. Connector check (Disconnection/short circuit/malconnection)
  • Page 99 TCL Air Conditioner Service Manual 3.6 Function setting by remocon is disable. Power input after power off Operation ON by remocon • UCheck the transmission signal of remocon - If there is no remocon transmission signal, - Liquid crystal remocon: signal blinked check the battery or remocon operation.
  • Page 100 TCL Air Conditioner Service Manual 3.7 Cooling/heating conversion is disable. Heating operation ON by remocon If the reversing valve (4-way valve) is ON, "tick" sounds. Connector check 4-way valve connection check outdoor unit connecting wire check PCB ass'y check 4-way valve relay output = ON Switchover into cooling operation by remocon, and after about 30 sec., check the 4-way valve...
  • Page 101 TCL Air Conditioner Service Manual 4. Installation Fundamentals Leakage /Freon - 1/4 Case-1 Key Factor Pipe cutting Troubles & Gas leaks due to the mal-flared copper pipes with non-rectangular section. Causes Defect Details Pipe cutter Cutting curved pipe leads mal-rectangular section.
  • Page 102 TCL Air Conditioner Service Manual Leakage /Freon - 2/4 Case-2 Key Factor Removing burrs of pipes. Troubles & Gas Leaks due to the burrs caused by cutting and not removing properly. Causes Defect Details Burrs not removed properly after cutting.
  • Page 103 TCL Air Conditioner Service Manual Leakage /Freon - 3/4 Case-3 Factor Flaring works Troubles & Gas leaks and connecting troubles on tubings caused by the inaccurate sizing during flaring Causes works. Defect Details Pipe worked with small sized Pipe worked with large...
  • Page 104 TCL Air Conditioner Service Manual Leakage /Freon - 4/4 Case-4 Factor Flare nut's fastening. Troubles & Damaged flares by over-fastening make gas leakages. Causes And incompletely fastened nuts too. Defect Details Damaged Flares by over-fastening Incompletely fastened nuts Outdoor Side...
  • Page 105 TCL Air Conditioner Service Manual Case-5 Leakage / Drainage - 1/5 1. Indoors leveling Factor 2. Drain hose connecting. Troubles & Water leaks caused by the inclined indoor unit and the drain hose's bad connecting. Causes Defect Details 2. Mal-linked drain hose 1.
  • Page 106 TCL Air Conditioner Service Manual Case-6 Leakage / Drainage - 2/5 1. Drain hose extend(adding another hose). Factor 2. Drain hose laying. Troubles & Water leaks came from the extending or laying work of drain hose. Causes Defect Details 2. Curved or upward drain hose.
  • Page 107 TCL Air Conditioner Service Manual Leakage / Drainage - 3/5 Case-7 Factor Drain piping and ending. Troubles & Water leaks caused by upwarded drain hose along the wall-through hole and clogged drain Causes hose with water. Defect Details 1. Upwarded drain hose along the wall-through 2.
  • Page 108 TCL Air Conditioner Service Manual Leakage / Drainage- 4/5 Case-8 Factor Insulation work on connecting parts and hidden parts of tubings. Troubles & Water leaks caused by wrong insulation works on tubing lines. Causes Defect Details 1. Incomplete insulation works on tube 2.
  • Page 109 TCL Air Conditioner Service Manual Leakage / Drainage -5/5 Case-9 Factor Tubing and taping works against the waterdrops. Troubles & Water leaks by the waterdrops led by wrong tubing and taping works. Causes Defect Details 1. Pipe from upside lead waterdrops(rain, drainage etc.) into the room.
  • Page 110 TCL Air Conditioner Service Manual Freon shortage Case-10 Factor Tube Extending and freon adding. Troubles & Cooling capacity downs by the freon shortage. Causes Defect Details 1. Not adding freon for extended tubings. 2. Gas leakage on welded points for extending tubings.
  • Page 111 TCL Air Conditioner Service Manual Case-11 Cooling capacity - 1/5 Factor Spacing for the air flows in split type air conditioners. Troubles & Cooling capacity downs by bad air flows. Causes Defect Details 1. The space for air intake is too narrow.
  • Page 112 TCL Air Conditioner Service Manual Cooling capacity - 2/5 Case-12 Factor Spacing for the air flows in window type air conditioners. Troubles & Cooling capacity downs by bad air flows. Causes Defect Details 1. The space for air intake is too narrow.
  • Page 113 TCL Air Conditioner Service Manual Cooling capacity - 3/5 Case-13 Factor Improper installation and awning for outdoor unit. Troubles & Cooling capacity downs by improper air flows and awning. Causes Defect Details 1. The outdoor shut in a verandah does not work normally.
  • Page 114 TCL Air Conditioner Service Manual Cooling capacity - 4/5 Case-14 Factor Using crushed tubes and changed tubes. Troubles & Cooling capacity downs by the crushed tubes and changed tubes. Causes Defect Details 1. Crushed tube by improper bending works. Crushed area 2.
  • Page 115 TCL Air Conditioner Service Manual Case-15 Cooling capacity - 5/5 Factor Long distance tubings. Troubles & Cooling capacity downs by long distance tubings. Causes Defect Details Installed too high beyond recommended height difference between indoor and outdoor unit. Nth. 3rd.
  • Page 116 TCL Air Conditioner Service Manual Noise - 1/2 Case-16 Factor Unstable installing units. Troubles & Noise from the unstably installed parts and units. Causes Defect Details 1. Unstable installed outdoor unit. 2. Released fittings and fasteners. Duct Indoor unit Slanted Guidelines Install the unit balanced stably using specified legs etc.
  • Page 117 TCL Air Conditioner Service Manual Noise - 2/2 Case-17 Factor Unstably fixed tubings. Troubles & Noise and vibration form the tubings. Causes Defect Details Unstable fixing of surplus tubings will make vibrations and noises during the compressor's running. Guidelines Cut away the surplus tubings.
  • Page 118 TCL Air Conditioner Service Manual Case-18 Wiring mistake -1/2 Factor Wiring in 3 phase electric power lines. Troubles & Major electrical problems(not operating properly) by bad wirings. Causes Defect Details 1. Not firmly fixed screws of electric power 2. Wiring mistake of fan's electric power lines lines.(It can be led to critical accidents)
  • Page 119 TCL Air Conditioner Service Manual TCL Air Conditioner Service Manual Wiring mistake -2/2 Case-19 Factor Poor electric insulation. Troubles & Major electrical problems(not operating properly) by bad insulations of connecting cables. Causes Defect Details Poor electric insulations of connecting cables between indoor and outdoor.
  • Page 120 TCL Air Conditioner Service Manual Bad smells & Gases Case-20 Factor Bad smells and gases delivered by drain line. Troubles & Bad smells and gases from outside(Ex. ditch) are discharged from the system. Causes (Be careful not to be confused as if it's from the system).
  • Page 121 TCL Air Conditioner Service Manual ANNEX 4 R407C REFRIGERANT 1 General out and stored in a disposal cylinder (do not ventilate in R-407c is a blend of three basic constituents: R32, R125, ambient). R-134a with respectively weight composition 23%, 25%, 52%.
  • Page 122 TCL Air Conditioner Service Manual 2 Main differences between R-407c and R22 refrigerant R-407c R-22 1. Refrigerant charging procedure 2. Refrigerant composition R-407c R125 R-134a 52% 3. Partial refrigerant charge NOT PERMITTED! YES! Only complete refrigerant charge Possible partial refrigerant charge 4.
  • Page 123 TCL Air Conditioner Service Manual ANNEX 5 INSTALLATION INSTRUCTION Part 1 Wall-mounted Split Type...
  • Page 124 TCL Air Conditioner Service Manual INSTALLATION 1. Characteristics of refrigerant 1.1 Temperature-pressure relationships in saturated condition Saturation curve R-22 R-12 Temperature(°C) 1.2 Strong/weak points of freon 1.2.1 Strong points 1) Chemical stability 2) No toxicity 3) By little corrosive action on metals, it is applicable to almost all metals.

  • Page 125: Tools Required

    TCL Air Conditioner Service Manual 2. Tools required 2.1 Tools Screw driver Hand drill Ruler, knife Gas leak detector Thermometer Hex. wrench & soup water (Large side: 4mm, 5mm) Ruler: Length & Temperature distance measurement at Assembly, Indoor installation Leak inspection Service valve measurement.

  • Page 126: Select The Best Location

    TCL Air Conditioner Service Manual 3. Split type installation 6) Rooftop Installations: If the outdoor unit is installed on a roof structure, be 3.1 Select the best location sure to level the unit. Ensure the roof structure and anchoring method are adequate for the unit location.

  • Page 127: How To Fix Installation Plate

    TCL Air Conditioner Service Manual 3.3 How to fix installation plate • The position of the center of the hole. The wall you select should be strong and solid enough to prevent vibration Left holecore position Right holecore position 3.3.1 Mount the installation plate on the wall with four type A screws.

  • Page 128: Flaring Work And Connection Of Piping

    TCL Air Conditioner Service Manual 3.5 Flaring work and connection of piping 3.5.1 Flaring work D. Flaring work Main cause for gas leakage is due to defect in flaring • Carry out flaring work using flaring tool as shown work. Carry out correct flaring work in the following below.
  • Page 129 TCL Air Conditioner Service Manual 3.5.2 Connection of piping--Indoor C. Tape the tubing, drain hose and the connecting cable. Be sure that the drain hose is located at the 1) Preparing the indoor unit's piping and drain hose for lowest side of the bundle. Locating at the upper installation through the wall.

  • Page 130: For Left Rear Piping

    TCL Air Conditioner Service Manual • Tighten the flare nut with a wrench. • Wrap the area which accommodates the rear piping housing section with vinyl tape. Indoor Connection Spanner (fixed) unit pipe pipe Vinyl tape Wrap with vinyl tape...
  • Page 131 TCL Air Conditioner Service Manual Pipe Size[Torque] C. Insert the connecting cable into the indoor unit. Capacity 1) Don't connect the cable to the indoor unit. (Btu/h) LIQUID 2) Make a small loop with the cable for easy connection 3/8"[4.2kg . m] 1/4"[1.8kg .
  • Page 132 TCL Air Conditioner Service Manual • Bundle the piping and drain hose together by wrapping 3.5.3 Connection of the pipes-Outdoor them with cloth tape over the range within which they fit A. Align the center of the pipings and sufficiently tighten into the rear piping housing section.
  • Page 133 TCL Air Conditioner Service Manual 3.6 Connecting the cable between indoor CAUTION unit and outdoor unit The power cord connected to the indoor unit should be 3.6.1 Connect the cable to the Indoor unit. complied with the following specifications • Connect the cable to the indoor unit by connecting...
  • Page 134 TCL Air Conditioner Service Manual 3.6.2 Connect the cable to the outdoor unit A. Remove the control cover from the unit by loosen- Outdoor unit Terminal block ing the screw. Connect the wires to the terminals on the control board individually.
  • Page 135 TCL Air Conditioner Service Manual 3.7 Checking the Drainage and forming 3.7.2 Form the piping the pipings A. Form the piping by wrapping the connecting portion 3.7.1 Checking the drainage of the indoor unit with insulation material and secure A. To remove the front panel from the indoor unit, it with two kinds of vinyl tapes.

  • Page 136: Air Purging

    TCL Air Conditioner Service Manual 3.8 Air purging • Do a leak test of all joints of the tubing(both indoor and outdoor) and both gas and liquid side service valves. 3.8.1 Air purging Bubbles indicate a leak. Be sure to wipe off the soap with a clean cloth.
  • Page 137 TCL Air Conditioner Service Manual Soap water method (1) Remove the caps from the 2-way and 3-way valves. Outdoor unit Cover control (2) Remove the service-port cap from the 3-way valve. (3) To open the 2-way valve turn the valve stem counter- clockwise approximately 90°, wait for about 2~3 sec, and...

  • Page 138: Test Running

    TCL Air Conditioner Service Manual 3.9 Test running 3. Ensure the difference between the intake temperature and the discharge is more than 8°C (Cooling) or 1) Check that all tubing and wiring have been properly reversely (Heating). connected. 2) Check that the gas and liquid side service valves are fully open.

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