INVERTER-Y TRAINING 2009. TOPICS Introduction to Y-Inverter Introduction to Y-Inverter Control...

Inverter-Y Training 2009Inverter-Y Training 2009

INVERTER-Y INVERTER-Y

TRAINING 2009TRAINING 2009


TOPICS

• Introduction to Y-InverterIntroduction to Y-Inverter

• Control AlgorithmControl Algorithm

• TroubleshootingTroubleshooting


INTRODUCTION


• What is inverter ?

• What are the advantages ?

• Differences between Conventional & Inverter A/C

• Basics of Inverter Technology

INTRODUCTION


• 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

What is Inverter?What is Inverter?

INTRODUCTION


AdvantagesAdvantages

• Enhanced room temperature comfort

- More precise room temperature control

- Temperature fluctuation is kept within ± 0.5C from set temperature

ConventionalConventional

InverterInverter

INTRODUCTION


Time

Compressor capacity

Full capacity

Conventional compressor

Slow down as temperature drops

Smooth ramp up from zero to high rotational speed

Compressor capacity

TimeTimeMaintain room temperature at low speed

Inverter

Room temperature control: switching compressor ON & OFF

Room temperature control: Control compressor rotational speed smoothly


• Less on / off cycle

INTRODUCTION


Compressor frequency

(rps)

Time (min)Time (min)


• Starting frequency

INTRODUCTION

00

2020

3535

5555

Max.Max.

Target frequencyTarget frequency

6

21

1.0 hp – 68 rps

1.5 hp – 74 rps



• Fast cooling

Room temperature

TimeTime

Set temperature

Conventional non-inverter

A/C

Inverter A/C

Quick cooling

INTRODUCTION


Running current

Hours of operation

Conventional A/C:•High starting current•Frequent on/off cycle

Inverter A/C:•Low starting current•Smooth operation


• Low starting current

INTRODUCTION


Less compressor start – stop cycle

Low starting current

Longer compressor motor lifespan


• Higher reliability

INTRODUCTION



• 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

Resulting in significantly LESS compressor start/stop – low

energy consumption

Lowest operating frequency = 60 Hz

INTRODUCTION



• Protection

Additional software protection against

Over current

Over heating

INTRODUCTION


Description Inverter A/C Conventional A/C

Outlook feature Almost same

ControllerVariable

frequency controlRelay sequence

control

Compressor Inverter 3-Phase 1 or 3-Phase

Frequency 0 ~ 204/222 Hz 50 or 60Hz

Differences OverviewDifferences Overview

INTRODUCTION


Basics of Inverter TechnologyBasics of Inverter Technology

Inverter-driven Compressor

Electronic Expansion Valve (EXV)

IPM (Inverter Power Module)

INTRODUCTION


Adjust capacity according to actual load by

• Controlling the EXV opening

• Controlling the refrigerant flow

Power supply

Rectifier circuit

IPMCompressor

Motor


INTRODUCTION


Inverter system block diagram

Energy Source

RectifyingCircuit

InverterCircuit

Compressor

Control & Protection Circuitry

Feedback


INTRODUCTION


M

IN

OUT

Rectifier Inverter

U

W

V

Inverter drive power circuitInverter drive power circuit


INTRODUCTION



What are Rectifier / Inverter?

Rectifier:

Inverter:

Rectifying with smoothingChanging AC DC

Inverse transformation with P.W.M.Changing DC AC

INTRODUCTION


Inverter drive power circuit - componentsInverter drive power circuit - components


M

IN

OUT

U

W

V

Diode ReactorElectrolytic capacitor

IPM(Inverter Module)

INTRODUCTION


The system

u

compressor motor input

Inverter

AC/DCRectifiert t

Power supplyInput frequency50Hz t1

50 Hz 222 Hz 60 Hz

Inverter Output Frequency

222 Hz 60 Hz

DC/ACInverter

IPM


INTRODUCTION


Indoor PCB


INTRODUCTION


Outdoor PCB


INTRODUCTION


CONTROL ALGORITHM


• The compressor is frequency-controlled during normal operation. The target frequency is set based on following parameters:i) Outdoor ambient temperatureii) Set temperatureiii) 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.

Frequency Principle

CONTROL ALGORITHM


• The system has 2 operating modes. The mode selection is done in Inverter (indoor) controls.

• The operating modes are:

–Cool

–Fan

Operating Modes

CONTROL ALGORITHM


• 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

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.

Function – Cool Mode

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.

CONTROL ALGORITHM

Compressor Capacity

Time

Tr <= Ts - 2°CComp will stop

Lowest Freq


Function - Fan Mode• 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.

CONTROL ALGORITHM


• 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.

Protection Control - Data Communication Error Between Indoor and Outdoor

Indoor

Outdoor

Send SignalSend SignalAcknowledgeAcknowledge

PROTECTION


• 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.

Protection Control - Data Communication Error Between Indoor and Outdoor

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.

PROTECTION


Input Current Control

PROTECTION

No. Unit Capacity I1 I2 I3

11.0HP 9.5A 6.5A 5.5A

21.5HP 10A 7A 6A


Input Current Control

PROTECTION

• 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.


• If input current <I3, the compressor frequency is reset based on the OD ambient, set and room temperature.


Compressor Discharge Temperature Control

PROTECTION


PROTECTION

• 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.


• If the compressor discharge temperature < 90°C, the compressor frequency will be reset based on the OD ambient, set and room temperature.

Compressor Discharge Temperature Control


PROTECTION

High Pressure Protection


PROTECTION

• 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.


High Pressure Protection


PROTECTION

• 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.

IPM error


TROUBLESHOOTING


TROUBLESHOOTING

When any error occurs, indoor LED display will keep blinking

Fault display by indoor unitFault display by indoor unit

LED blinks here


Fault diagnosis by remote controllerFault diagnosis by remote controller

Hold down ON TIMER CLR or OFF TIMER CLR for 5 seconds

TIMER CANCEL button

TROUBLESHOOTING


Fault diagnosis by remote controllerFault diagnosis by remote controller

• Press TIMER CANCER repeatedly until ID buzzer produces long beep

• The handset temperature display section will indicate the error code

• 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

Error code

TROUBLESHOOTING


Fault diagnosis using outdoor 7-segment displayFault diagnosis using outdoor 7-segment display

TROUBLESHOOTING


Fault diagnosis using outdoor 7-segment displayFault diagnosis using outdoor 7-segment display

7-segment display

Flashes error code when error occurs

When there is no error, compressor running frequency is displayed, unit: rps

TROUBLESHOOTING


Fault diagnosis – stored last state errorFault diagnosis – stored last state error

TROUBLESHOOTING

• Remove battery from remote controller

• Replace battery again into remote controller

• Press Mode & ON/OFF buttons together

• Press Mode button to 5:00

• Press ON/OFF once

• Repeat the fault diagnosis by remote controller steps

Mode button TIMER

CANCEL buttonON/OFF

button


Error CodesError Codes

TROUBLESHOOTING

Error code Error descriptionA1 INDOOR PCB ERRORA3 DRAIN PUMP ABNORMALA5 ANTIFREEZEA6 INDOOR FAN MOTOR ABNORMALC4 INDOOR HEAT EXCHANGER THERMISTOR SHORT / OPENC9 INDOOR ROOM THERMISTOR SHORT / OPENE6 COMPRESSOR START-UP ERRORE7 OUTDOOR DC FAN MOTOR LOCKE8 AC INPUT OVER CURRENTEA 4 WAY VALVE ERRORF3 DISCHARGE PIPE OVERHEATF6 HIGH PRESSURE PROTECTIONH8 AC CURRENT SENSOR ERRORH9 OUTDOOR AIR THERMISTOR SHORT / OPENJ3 COMPRESSOR DISCHARGE PIPE THERMISTOR SHORT / OPEN / MISPLACEDJ6 OUTDOOR HEAT EXCHANGER THERMISTOR SHORT / OPENL4 HEAT SINK OVERHEATL5 IPM ERROR / IGBT ERRORP4 HEAT SINK THERMISTOR SHORT / OPENU0 INSUFFICIENT GASU2 DC VOLTAGE OUT OF RANGEU4 COMMUNICATION ERRORUA INSTALLATION ERROR


Outdoor 7-segment displayOutdoor 7-segment display

TROUBLESHOOTING

Parameter Description

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

09 °C10 Pulse

07 °C

08 °C

05 °C

06 °C

03 A

04 °C

01 r/s

02 VDC

Parameter

NumberUnit/ range

00 r/s

• Press on the tact switch

• Display parameter by flashing of 7-segment

• Parameter 125, display as 25, follow by 01


EquipmentsEquipments

• Digital clamp meter

• Digital multi-meter

• Pressure gauge

AC CURRENT

RESISTANT

AC VOLTAGE

TROUBLESHOOTING


Error C4 – ID coil thermistor short /Error C4 – ID coil thermistor short / openopen

- 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

TROUBLESHOOTING


Resistance - temperatureResistance - temperature

At 25C

Resistance value: 10 k

TROUBLESHOOTING


Error C9 – Room thermistor short /Error C9 – Room thermistor short / openopen

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

TROUBLESHOOTING


Error H9 – OD air thermistor short /Error H9 – OD air thermistor short / openopen

Error J3 – Compressor discharge pipe thermistor Error J3 – Compressor discharge pipe thermistor

short / short / open / misplacedopen / misplaced

Error J6 – OD coil thermistor short /Error J6 – OD coil thermistor short / openopen

TROUBLESHOOTING

Share a same connector

Connection to PCB


Error H9 – OD air thermistor short /Error H9 – OD air thermistor short / openopen

- Remove the OD air thermistor from PCB


- Measure both terminals on the sensor using multi-meter test leads.



TROUBLESHOOTING

Thermistor


Error J3 – Compressor discharge pipe thermistor Error J3 – Compressor discharge pipe thermistor

short / short / open / misplacedopen / misplaced

- Remove the compressor discharge pipe thermistor from PCB





TROUBLESHOOTING

Thermistor


Error J6 – OD coil thermistor short /Error J6 – OD coil thermistor short / openopen

- Remove the OD coil thermistor from PCB





TROUBLESHOOTING

Thermistor


Error P4 – Heat sink thermistor short /Error P4 – Heat sink thermistor short / openopen

- Remove the heat sink thermistor from PCB





TROUBLESHOOTING


Error E8 – AC input over currentError E8 – AC input over current

- 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 rangeError U2 – DC voltage out of range

- 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 220-240 V. It is acceptable

TROUBLESHOOTING

positive lead (+)

negative lead (-)


Error F6 – High pressure protectionError 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

TROUBLESHOOTING


Error L5 – IPM / IGBT errorError 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

TROUBLESHOOTING

Heat sink

IPM


Error UO – Insufficient gasError UO – Insufficient gas

- 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

Check pressure reading at rated capacity

Press & hold

TROUBLESHOOTING


Error U4 – Communication errorError U4 – Communication error

- Maximum communication wire length up to 30 meters

- Make sure the recommended type of wire is used

- External interference or noise

- Check for loose connection

TROUBLESHOOTING


Error UA – Installation errorError UA – Installation error

Y5WMY10/15J

Y5SLY10/15D

TROUBLESHOOTING


Thank YouThank You

Q & AQ & A

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INVERTER-Y TRAINING 2009. TOPICS Introduction to Y-Inverter Introduction to Y-Inverter Control...

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