Transcript Inverter-Y Training

INVERTER-Y
TRAINING 2009
Inverter-Y Training 2009
TOPICS
• Introduction to Y-Inverter
• Control Algorithm
• Troubleshooting
Inverter-Y Training 2009
INTRODUCTION
Inverter-Y Training 2009
INTRODUCTION
• What is inverter ?
• What are the advantages ?
• Differences between Conventional &
Inverter A/C
• Basics of Inverter Technology
Inverter-Y Training 2009
INTRODUCTION
What is Inverter?
•
•
•
Electrical supply has fix frequency
Inverter type air conditioner have frequency changer
which can change the electrical frequency to control
the speed of the compressor
This in turn, can control the capacity accordingly
Inverter-Y Training 2009
INTRODUCTION
Advantages
•
Enhanced room temperature comfort
- More precise room temperature control
- Temperature fluctuation is kept within ± 0.5C from set temperature
Conventional
Inverter
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INTRODUCTION
Advantages
•
Less on / off cycle
Conventional compressor
Compressor capacity
Room temperature
control:
switching compressor
ON & OFF
Full capacity
Time
Compressor
capacity
Smooth ramp up
from zero to high
rotational speed
Inverter
Slow down
as
temperature
drops
Inverter-Y Training 2009
Maintain room
temperature at low
speed
Room temperature
control:
Control compressor
rotational speed
smoothly
Time
INTRODUCTION
Advantages
•
Starting frequency
Compressor
frequency
(rps)
1.0 hp – 68 rps
1.5 hp – 74 rps
Max.
55
35
Target frequency
20
0
Time (min)
1 2
6
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INTRODUCTION
Advantages
•
Fast cooling
Conventional
non-inverter
A/C
Inverter A/C
Room
temperature
Set temperature
Time
Quick
cooling
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INTRODUCTION
Advantages
•
Low starting current
Running
current
Conventional A/C:
•High starting current
•Frequent on/off cycle
Inverter A/C:
•Low starting current
•Smooth operation
Hours of operation
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INTRODUCTION
Advantages
•
Higher reliability
Less compressor start – stop cycle
Low starting current
Longer compressor motor lifespan
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INTRODUCTION
Advantages
•
Low energy consumption with superior efficiency
 Frequency of supply current is varied according to load
requirements – excellent efficiency
 Range is between
0 – 68 rps (204 Hz) for 1.0 hp
0 – 74 rps (222 Hz) for 1.5 hp
Lowest operating frequency = 60 Hz
 Resulting in significantly LESS compressor start/stop – low
energy consumption
Inverter-Y Training 2009
INTRODUCTION
Advantages
•
Protection
Additional software protection against
Over current
Over heating
Inverter-Y Training 2009
INTRODUCTION
Differences Overview
Description
Inverter A/C
Outlook feature
Conventional A/C
Almost same
Controller
Variable
frequency control
Relay sequence
control
Compressor
Inverter 3-Phase
1 or 3-Phase
Frequency
0 ~ 204/222 Hz
50 or 60Hz
Inverter-Y Training 2009
INTRODUCTION
Basics of Inverter Technology
Inverter-driven
Compressor
IPM (Inverter
Power Module)
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Electronic Expansion
Valve (EXV)
INTRODUCTION
Basics of Inverter Technology
Power
supply
Rectifier
circuit
IPM
Compressor
Motor
Adjust capacity according to actual load by
• Controlling the EXV opening
• Controlling the refrigerant flow
Inverter-Y Training 2009
INTRODUCTION
Basics of Inverter Technology
Inverter system block diagram
Energy
Source
Rectifying
Circuit
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Inverter
Circuit
Compressor
Control &
Protection
Circuitry
Feedback
INTRODUCTION
Basics of Inverter Technology
Inverter drive power circuit
IN
U
V
W
Rectifier
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Inverter
M
OUT
INTRODUCTION
Basics of Inverter Technology
What are Rectifier / Inverter?
Rectifier:
Rectifying with smoothing
Changing AC  DC
Inverter:
Inverse transformation with P.W.M.
Changing DC  AC
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INTRODUCTION
Basics of Inverter Technology
Inverter drive power circuit - components
IN
U
V
W
Diode
Reactor
IPM(Inverter Module)
Electrolytic capacitor
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M
OUT
INTRODUCTION
Basics of Inverter Technology
The system
Inverter Output
Frequency
Power supply
Input frequency
50Hz
u
t
Inverter
AC/DC
Rectifier
222 Hz
t1
DC/AC
Inverter
50 Hz
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t
222 Hz
IPM
60 Hz
60 Hz
compressor
motor input
INTRODUCTION
Basics of Inverter Technology
Indoor PCB
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INTRODUCTION
Basics of Inverter Technology
Outdoor PCB
Inverter-Y Training 2009
CONTROL ALGORITHM
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CONTROL ALGORITHM
Frequency Principle
•
•
The compressor is frequency-controlled during normal
operation. The target frequency is set based on
following parameters:
i) Outdoor ambient temperature
ii) Set temperature
iii) Room temperature
When the frequency increases, the rotation speed of
compressor increases resulting in an increased
refrigerant circulation, this lead to higher amount of
heat transfer and vice versa when frequency
decreases.
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CONTROL ALGORITHM
Operating Modes
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•
The system has 2 operating modes. The mode
selection is done in Inverter (indoor) controls.
The operating modes are:
– Cool
– Fan
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CONTROL ALGORITHM
Function – Cool Mode
•
•
When Tr >= Ts – 1.5°C
- Comp, ID Fan and OD Fan ON
When Tr <= Ts - 2°C
- Comp and OD Fan OFF
- ID Fan remain ON
Tr = Room Temperature
Ts = Set Temperature
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CONTROL ALGORITHM
Function – Cool Mode
•
•
At beginning of cooling operation, compressor
frequency will be increased smoothly to the target
frequency so that the room temperature is reduced.
When set temperature is achieved, operation
frequency will be reduced to stabilize the room
temperature.
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CONTROL ALGORITHM
When will Compressor Stop?
• When cooling load is too small, even with lowest
operation frequency and the room temperature still fall
below compressor cut off point, compressor will stop.
Compressor Capacity
Lowest Freq
Time
Tr <= Ts - 2°C
Comp will stop
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CONTROL ALGORITHM
Function - Fan Mode
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•
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Only High, Medium and Low fan speeds are allowed.
When changing cool mode to fan mode, the compressor
will stop and OD fan stops after 30s.
Compressor will only ON if the minimum stop time is > 3
minutes and the user change back to cool mode.
Fan speed will maintain same as during fan mode.
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PROTECTION
Protection Control - Data Communication Error
Between Indoor and Outdoor
•
•
Master by outdoor unit.
Indoor controller board will transmit signal to outdoor
controller board every 0.5s. Outdoor unit will response to
indoor once the valid data is received.
Indoor
Acknowledge
Send Signal
Outdoor
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PROTECTION
Protection Control - Data Communication Error
Between Indoor and Outdoor
•
•
•
If the data communication line between indoor and outdoor
occurs error for 15s continuously, compressor will
stop, OD fan stop after 30s. ID LED blinks error.
If the communication resumes after 15s, error code is clear
and compressor restarts after 3 minutes.
If the communication is not resume after 15s, unit unable to
restart and the error keep blinking.
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PROTECTION
Indoor Coil Frost Prevention
•
•
•
•
Only available in cooling mode.
When the indoor coil temperature < 2°C, the compressor
starts to drop the frequency.
This protection is activated when:
- Indoor coil temperature < 0°C for more than 180s.
Compressor will stop, OD fan stop after 30s and indoor
fan can only run at super low fan speed.
The unit can only be restarted after 3 minutes.
When the indoor coil temperature >13°C, the
compressor frequency will be reset based on the OD
ambient, room and set temperature.
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PROTECTION
Input Current Control
No. Unit Capacity I1
1 1.0HP
9.5A
2 1.5HP
10A
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I2
6.5A
7A
I3
5.5A
6A
PROTECTION
Input Current Control
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•
•
•
When the input current for running compressor exceeds
I2, running frequency will be reduced by 1 step. If current
still exceeds I2, frequency will be reduced by another 1
step until total current falls between I2 and I3.
This protection is activated when the input current
exceeds I1 for 2 seconds. Compressor will stop and it is
considered total current overload.
The unit can only be restarted after 3 minutes.
If input current <I3, the compressor frequency is reset
based on the OD ambient, set and room temperature.
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PROTECTION
Compressor Discharge Temperature Control
Inverter-Y Training 2009
PROTECTION
Compressor Discharge Temperature Control
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•
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If compressor discharge temperature >102°C, running
frequency will be reduced by 1 step. If compressor
discharge temperature still >102°C, frequency will be
reduced by another 1 step until temperature falls
between 99°C and 90°C.
This protection is activated when the compressor
discharge temperature > 110°C. The compressor will
stop and considered trip.
The unit can only be restarted after 3 minutes.
If the compressor discharge temperature < 90°C, the
compressor frequency will be reset based on the OD
ambient, set and room temperature.
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PROTECTION
High Pressure Protection
Inverter-Y Training 2009
PROTECTION
High Pressure Protection
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•
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The compressor frequency is adjusted depend on the
coil temperature.
This protection is activated when the outdoor coil
temperature > 64°C, the compressor stop and OD fan
stop after 30s.
The unit can only be restarted after 3 minutes.
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PROTECTION
IPM error
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•
Protection on the IPM
IPM error is declared when;
i) Compressor’s motor peak current > 21A OR
ii) IPM temperature >100°C OR
iii) IGBT peak current > 16A.
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TROUBLESHOOTING
Inverter-Y Training 2009
TROUBLESHOOTING
Fault display by indoor unit
When any error occurs, indoor LED display will keep blinking
LED blinks here
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TROUBLESHOOTING
Fault diagnosis by remote controller
ON TIMER
CANCEL
button
OFF TIMER
CANCEL
button
Hold down ON TIMER CLR or
OFF TIMER CLR for 5 seconds
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TROUBLESHOOTING
Fault diagnosis by remote controller
•
•
Press ON TIMER CLR or OFF TIMER CLR repeatedly until ID
buzzer produces long beep
The handset temperature display section will indicate the error code
Error
code C4
•
•
ID unit buzzer will produce long beep if the handset error code =
unit error
A short and two consecutive beeps is not the unit error
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TROUBLESHOOTING
Fault diagnosis using outdoor 7-segment display
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TROUBLESHOOTING
Fault diagnosis using outdoor 7-segment display
7-segment
display
When there is no
error, compressor
running frequency is
displayed, unit: rps
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Flashes error code
when error occurs
TROUBLESHOOTING
Fault diagnosis – stored last state error
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•
•
Remove battery from remote controller
Replace battery again into remote controller
Press Mode & ON/OFF buttons together
ON/OFF
button
ON TIMER
CANCEL
button
•
•
•
Mode
button
OFF TIMER
CANCEL
button
Press Mode button to 5:00
Press ON/OFF once
Repeat the fault diagnosis by remote controller steps
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TROUBLESHOOTING
Error Codes
Error code
A1
A3
A5
A6
C4
C9
E6
E7
E8
EA
F3
F6
H8
H9
J3
J6
L4
L5
P4
U0
U2
U4
UA
Error description
INDOOR PCB ERROR
DRAIN PUMP ABNORMAL
ANTIFREEZE
INDOOR FAN MOTOR ABNORMAL
INDOOR HEAT EXCHANGER THERMISTOR SHORT / OPEN
INDOOR ROOM THERMISTOR SHORT / OPEN
COMPRESSOR START-UP ERROR
OUTDOOR DC FAN MOTOR LOCK
AC INPUT OVER CURRENT
4 WAY VALVE ERROR
DISCHARGE PIPE OVERHEAT
HIGH PRESSURE PROTECTION
AC CURRENT SENSOR ERROR
OUTDOOR AIR THERMISTOR SHORT / OPEN
COMPRESSOR DISCHARGE PIPE THERMISTOR SHORT / OPEN / MISPLACED
OUTDOOR HEAT EXCHANGER THERMISTOR SHORT / OPEN
HEAT SINK OVERHEAT
IPM ERROR / IGBT ERROR
HEAT SINK THERMISTOR SHORT / OPEN
INSUFFICIENT GAS
DC VOLTAGE OUT OF RANGE
COMMUNICATION ERROR
INSTALLATION ERROR
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TROUBLESHOOTING
Outdoor 7-segment display
Parameter
Parameter Description
Number
00
01
02
03
04
05
06
07
08
09
10
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•
•
Compressor Actual Rotation
Compressor Target Rotation
DC Bus Voltage
Total Current (x10)
Outdoor Air Temperature
Outdoor Heat Exchanger Temperature
Compressor Discharge Temperature
Outdoor Heatsink Temperature
Indoor Air Temperature
Indoor Heat exchanger Temperature
EXV Opening
Press on the tact switch
Display parameter by flashing of 7-segment
Parameter 125, display as 25, follow by 01
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Unit/ range
r/s
r/s
VDC
A
°C
°C
°C
°C
°C
°C
Pulse
TROUBLESHOOTING
Equipments
•
Digital clamp meter
AC CURRENT
RESISTANT
AC VOLTAGE
•
•
Digital multi-meter
Pressure gauge
Inverter-Y Training 2009
TROUBLESHOOTING
Error C4 – ID coil thermistor short / open
-
Remove the ID coil thermistor from PCB
Set digital multi-meter to ohm reading
Measure both terminals on the sensor using multi-meter test leads
The reading must comply with a particular temperature, refer Table 3
If the reading differs by ±2°C. It is acceptable
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TROUBLESHOOTING
Resistance - temperature
At 25C
Resistance value: 10 k
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TROUBLESHOOTING
Error C9 – Room thermistor short / open
Sensor RTH201
1. Possibility – low
2. Unit design with air opening at the
front panel to allow sufficient space for
air flow & measurement
3. 10 C < operating temp. < 40 C
Air intake gap for
room temperature
sensing
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TROUBLESHOOTING
Error H9 – OD air thermistor short / open
Error J3 – Compressor discharge pipe thermistor
short / open / misplaced
Error J6 – OD coil thermistor short / open
Share a same
connector
Connection to PCB
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TROUBLESHOOTING
Error H9 – OD air thermistor short / open
Thermistor
-
Remove the OD air thermistor from PCB
Set digital multi-meter to ohm reading
Measure both terminals on the sensor using multi-meter test leads.
The reading must comply with a particular temperature, refer Table 3
If the reading differs by ±2°C. It is acceptable
Inverter-Y Training 2009
TROUBLESHOOTING
Error J3 – Compressor discharge pipe thermistor
short / open / misplaced
Thermistor
-
Remove the compressor discharge pipe thermistor from PCB
Set digital multi-meter to ohm reading
Measure both terminals on the sensor using multi-meter test leads.
The reading must comply with a particular temperature, refer Table 3
If the reading differs by ±2°C. It is acceptable
Inverter-Y Training 2009
TROUBLESHOOTING
Error J6 – OD coil thermistor short / open
Thermistor
-
Remove the OD coil thermistor from PCB
Set digital multi-meter to ohm reading
Measure both terminals on the sensor using multi-meter test leads.
The reading must comply with a particular temperature, refer Table 3
If the reading differs by ±2°C. It is acceptable
Inverter-Y Training 2009
TROUBLESHOOTING
Error P4 – Heat sink thermistor short / open
-
Remove the heat sink thermistor from PCB
Set digital multi-meter to ohm reading
Measure both terminals on the sensor using multi-meter test leads.
The reading must comply with a particular temperature, refer Table 3
If the reading differs by ±2°C. It is acceptable
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TROUBLESHOOTING
Error E8 – AC input over current
-
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Set clamp meter to AC current
Clamp terminal 1 on the OD unit
terminal block
If the reading < 10 Amp. It is
acceptable
TROUBLESHOOTING
Error U2 – DC voltage out of range
-
positive
lead (+)
negative
lead (-)
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Set multi-meter to DC
voltage
Measure terminals 1 & 2 on
the OD unit terminal block
using multi-meter test leads
If the reading is within 220240 V. It is acceptable
TROUBLESHOOTING
Error F6 – High pressure protection
-
Coil overload
Possible causes: coil dirty and air short circuit
Where a wall or other
obstacle is in the path of
outdoor unit’s intake or
exhaust airflow
Follow this installation
guidelines to avoid air
short circuit
Inverter-Y Training 2009
TROUBLESHOOTING
Error L5 – IPM / IGBT error
-
Possible causes: over current or over heat
At start up: could be due to software
After running some time: could be due to over current or over heat
Heat sink
IPM
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TROUBLESHOOTING
Error UO – Insufficient gas
Check pressure reading at rated capacity
Press & hold
-
Connect pressure gauge to OD service valve
Press and hold on the ID ON/OFF button
Set to high fan mode and temperature at 16 °C using remote controller
Under cooling mode:
For 1.0 hp: at 45 rps, the pressure reading should be between 125 – 150 psi
For 1.5 hp: at 65 rps, the pressure reading should be between 125 – 150 psi
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TROUBLESHOOTING
Error U4 – Communication error
-
Maximum communication wire length up to 30 meters
-
External interference or noise
Make sure the recommended type of wire is used
Check for loose connection
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TROUBLESHOOTING
Error UA – Installation error
Y5WMY10/15J
Y5SLY10/15D
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Thank You
Q&A
Inverter-Y Training 2009