Inverter Training 08-BASIC.ppt

8/11/2019 Inverter Training 08-BASIC.ppt

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Welcome

Module

1

RAC


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Jason RobertsTraining Manager


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SAFETY

Mobile Phones

Fire Alarm

Exits

Toilets

Practical Testing Workshop

Awareness


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Support Manual

2 x Books Residential (RAC)

Commercial (PAC)

25 Codes across all products

Quick access to rectification

A5 Convenience


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CERTIFICATE

On line questionnaire One submission attempt

Certificate if passed


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Recommended

Tools


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Multimeter

Diode test function is

essential

Sharp or needlepoint

probes are recommended.


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Clamp Meter

True RMS

To monitor current draw to unit

and compressor.

A frequency function is

HIGHLY RECOMMENDED


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Inverter Checker

Connect to the inverter in placeof a DC Compressor, LEDsflash ON and OFF to indicateswitching of Inverter.

A quick visual check of Inverterfunction

DOES NOT test Inverter underload.


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Thermometer

Who has a Digitemp?

Thermometer with bead typethermocouple or touch probe

Can be attached to a pipe with a cabletie.

Can be slipped in with the factory pipetemperature sensor.


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Serial signal test lead

A serial signal test lead is used

to measure the indoor and

outdoor communication signal.

Easily made with a spare

multimeter lead and a 1000Vdiode

We will even give you a diode for

free

Invaluable for working on Fujitsu

General units


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A device that converts normal alternating

current to an adaptable voltage & frequency.

This in turn allows a motor speed to

increase or slow down.

What is an inverter?


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Inverter Benefits

Compressor speed is controlled

automatically to reduce energy consumption.

The target temperature can be achieved

more rapidly as the compressor can increase

its output to meet peak demand.

The control temperature is more accuratelycontrolled improving customer comfort.


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Inverter Block Diagram


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Power / Filter PCB

Visually check the varistors for signs of

physical damage such as splitting or burning.

A varistor will fail or blow if an excess

voltage is applied, its normally a sign of amains power supply issue.

Check for AC Voltage IN and OUT of the

Power PCB


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POWER FACTOR

CORRECTION CIRCUIT


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Posistor / Power relay

The Posistor is a safety device used to preventsubsequent damage after a component in the inverterhas failed.

The initial fault will occur and usually trip the powersupply circuit breaker to the system.

When the power supply is reset the Posistor detects theover current as the outdoor unit powers up and opencircuits preventing power flow into the inverter and anyfurther damage.

The Posistor itself does not actually fail, it is similar to aself resetting fuse and will open circuit when excesscurrent flows through it. Once the fault downstream hasbeen corrected the Posistor will reset.


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Inverter Block DiagramPOWER FACTOR

CORRECTION CIRCUIT


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Diode Bridge / Bridge Rectifier

The AC Voltage enters theDiode Bridge and is

converted into DC Voltage

240 VAC in = ~240 VDC

OUT


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Diode b r idge checks II

Multimeter lead connections

Negative lead

(BLACK)

Positive lead

(RED)

Normal / Expected

values

DIODE BRIDGE WIRE

CONNECTIONS (if

discrete module)

orSOLDER PADS (if part of

PCB)

+ (Red) ~ (Grey) All readings should

be similar

(~0.5v)+ (Red) ~ (White)

- (Black)

~ (Grey)

All readings should

be open (OL)- (Black) ~ (White)

~ (Grey) - (Black) All readings should

be similar

(~0.5v)~ (White) - (Black)

~ (Grey) + (Red)All readings should

be open (OL)

Before starting test, ensure outdoor unit is isolated

Use a digital multimeter set to Diode Check mode

Disconnect wires to component if possible


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Heat sin k paste

If there was white paste on the components you removed

then a new coating must be applied to the replacement

components

The old paste must be cleaned off the heat sink, Methylatedspirits and some rag or paper towel works well

A small artists palette knife is very handy to apply an even

coating and keeps you and the machine free from mess

Heatsink paste must be used


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ACTPM / Act ive Fi lter Modu le Check

Black

Red

White

Brown

Blue N1

Yellow P


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ACTPM / Choke Coil

Most systems have a separate power factor correction device that maybe called the ACTPM or ACTIVE FILTER MODULE.On small systems where there is only one inverter / controller pcb in theoutdoor unit, the power factor correction circuit is part of the main inverterPCBThe power factor correction circuit includes a large coil of copper wirereferred to as the Reactor, Inductor or Choke coil.


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POWER FACTOR

CORRECTION CIRCUIT


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Smoothing Capacitor

Capacitors store energy and are used to smooth out any ripplesin the DC Voltage.

Beware they BITE !

At this stage the DC power has now been boosted, correctedand smoothed and is ready to be used to drive the compressor.


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Inverter B lock Diagram

POWER FACTOR

CORRECTION CIRCUIT


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Intel l igent Pow er Module (IPM)

S1

S2

S3

S4

S5

S6

UV

VW

WU

time

ON

OFF

S1 S3 S5

S4 S6 S2

U

V W

+

-

S1 S3 S5

S4 S6 S2

U

V W

+

-

S1 S3 S5

S4 S6 S2

U

V W

+

-

S1 S3 S5

S4 S6 S2

U

V W

+

-

By changing the ON-OFF cycle of the switch, the

rotation of the motor can be varied at the desired

frequency. If the DC voltage is changed, the input

voltage of the motor can be also varied.

Practically, the motor is rotated by using 6pcs

of transistors instead of a switch, and the transistor

is alternately turned ON-OFF.

MOTOR

P

N

The IPM takes the High Voltage DC power and switches it to each phase of the

compressor creating artificial three phase power.


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Intel ligent Power Module Check


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In tel l igent Power Modu le Check II

Negative

positive

U Phase

V Phase

W Phase

This procedure performs a static test of the component only and will identify ashorted transistor which is one of the causes of an IPM error.

Before starting test, ensure outdoor unit is isolatedUse a digital multimeter set to Diode Check modeDisconnect wires to component if possible


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Multimeter lead connections

Normal valuesNegative lead

(BLACK)

Positive lead

(RED)

IPM POWER WIRE

CONNECTIONS (if discrete

module)

or

SOLDER PADS(if part of Inverter PCB)

P (Yellow) U (Red)All readings should

be similar

(~0.35-0.4v)

P (Yellow) V (White)

P (Yellow)

W (Black)

N (Blue) U (Red)All readings should

be open (OL)N (Blue) V (White)

N (Blue) W (Black)

U (Red) N (Blue)

All readings shouldbe similar

(~0.35-0.4v)

V (White) N (Blue)

W (Black) N (Blue)

U (Red) P (Yellow)All readings shouldbe open (OL)

V (White) P (Yellow)

W (Black)

P (Yellow)

In tell igent Power Modu le Checks III


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Inverter B lock Diagram

POWER FACTOR

CORRECTION CIRCUIT


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Inverter Checker

The Inverter phase checker may be used to check the switchingoperation of the Intelligent power Module.

It is plugged into the compressor harness connector or at thecompressor terminals, depending on model to simulate thecompressor

The lights will flash on and off in sequence to indicate correctswitching of the IPM.

If any lights do not light to the same brightness as the others orif any lights stay permanently ON or OFF then the IPM isdefective or it is being given incorrect switching signals from thecontroller PCB.


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Inverter Compressor test ing

Winding resistance between phases vary depending on model,they range from 0.188 Ohm (AOT54LJBYL) to 1.41 ohms(AOT24LMADL) between phases.

A Dedicated milliohm meter is the only way to accurately measurecompressor winding resistances.

Most compressor winding resistances are stated at 20 or 25 C,the compressor must be at the stated temperature for the readingto be accurate.

Insulation resistance MUST be checked using an INSULATIONTESTER (Megger) at 500V not a normal multimeter.


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Inverter B lock DiagramPOWER FACTOR

CORRECTION CIRCUIT


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Main- Inverter- Contro l ler PCB

The Controller PCB functions:

Low voltage power supply

Microprocessor Serial communication

Thermistors

Outdoor fan motor, AC or DC

Electronic expansion valve


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Break


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Practical Session


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WARNING

Some of the equipment being demonstrated today will be LIVE

Please make sure all due care and attention is taken, there willbe 240 VAC present and up to 400V DC.

Please watch others as they are watching you!

STAY SAFE!


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The serial signal is used for the indoor unit and outdoor unit to communicate

with each otherThe serial signal is modulated on an AC sine wave

Outdoor Unit

INFORMATION 1

Forward Serial signal

INFORMATION 2

Reverse Serial signalExample of Serial Signal of ASY24PBA-W/AOY24PMAL

Indoor Unit

Serial signal Communication

C S


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Communication Signal


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Diode Lead Signal Check

This test is to check the indoor unit is communicating to the outdoor unit

Place the diode lead on to the signal line

Place the black lead on to the neutral line

If the reading is approx 30 to 60 VDC the indoor unit is communicating to the outdoorunit. If the signal is 0 to 5 VDC start checking the indoor unit for defective

components.

This test is to check the outdoor unit is communicating to the indoor unit

Place the diode lead on to the neutral line

Place the black lead on to the signal line

If the reading is approx 30 to 60 VDC the outdoor unit is communicating to the indoorunit. If the signal is 0 to 5 VDC start checking the outdoor unit for defectivecomponents.


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Communication Serial signal testing


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DC Fan motors DC fan motors are self contained

inverter driven variable speedmotors.

DC Fan motors are becoming morecommon in Outdoor units and inmany Indoor units.

Distinguished by a Multi pinconnector with 5 leads

Controlled by a speed signal fromMain PCB based on compressorspeed and outdoor ambient temp.

The DC motor provides a Feedbacksignal to Main PCB.

NEVERDISCONNECT ORRE-CONNECTWHILST POWERAPPLIED


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DC Fan Motor Checks

Before disconnecting or reconnecting ANY DC Fan motorsthe power supply must be isolated and the DC voltage

within the unit drained below 40VDC

High Voltage DC330-380 VDC (RED)

DC Ground(BLACK)

DC Control Power15VDC (WHITE)

Fan motor speed signal

(YELLOW)

Fan motor feedbacksignal (BLUE)

(Or Brown)

INDOOR MOTOR


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Model

Multi-Meter Lead Connection

ValuesNegative lead

(BLACK)

Positive lead

(RED)

ASTA-B09 RED BLACK 1.05V

ASTA-B09 BLACK RED OPEN

ASTA-B09 WHITE BLACK 0.57V

ASTA-B09 BLACK WHITE 1.32V

INDOOR MOTORUSING TOPTRONIC T9005



The fan motor must be disconnected and the check carried out at the fan motor plug

INDOOR MOTOR


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Model


ValuesNegative lead

(BLACK)

Positive lead

(RED)









INDOOR MOTOR


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Model

Multi-Meter Lead

Connection

ValuesNegative

lead(BLACK)

Positive

lead(RED)

ASTA-

B18RED BLACK 1.04V

ASTA-

B18

BLACK REDOPEN

ASTA-

B18

WHITE BLACK

0.57V

ASTA-

B18

BLACK WHITE1.47V





Model

Multi-Meter Lead

Connection

ValuesNegative

lead(BLACK)

Positive

lead(RED)

ASTA-

B24RED BLACK 0.81V

ASTA-

B24

BLACK REDOPEN

ASTA-

B24

WHITE BLACK

0.23V

ASTA-

B24

BLACK WHITE0.23V

INDOOR MOTOR


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Model


ValuesNegative lead

(BLACK)

Positive lead

(RED)









OUTDOOR MOTOR


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Model


ValuesNegative lead

(BLACK)

Positive lead

(RED)

ASTA-B09 BLACK ORANGE 460 Ohms

ASTA-B09 BLACK WHITE 203 Ohms

ASTA-B09 WHITE ORANGE 258 Ohms

OUTDOOR MOTORUSING TOPTRONIC 9005


Use a digital multimeter set to Ohms Resistance mode


OUTDOOR MOTOR


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Model


ValuesNegative lead

(BLACK)

Positive lead

(RED)





OUTDOOR MOTORUSING TOPTRONIC T9005




OUTDOOR MOTOR


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Model


ValuesNegative lead

(BLACK)

Positive lead

(RED)





OUTDOOR MOTORUSING TOPTRONIC T9005





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Electronic expansion valve

The EEV is a motor driven needlevalve powered by an external stepmotor coil. Full valve operating rangeis 0 to 480 pulses.

On initialisation the valve is driven fullyclosed then fully open. The valve will

remain fully open until the compressoris required to start. It then drivesclosed to a pre-set start positiondetermined by the ambienttemperature & the mode.

During operation the EEV ismodulated to maintain a targetcompressor discharge temperature,which is calculated from thecompressor speed, outdoor ambientand unit operating mode.


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EEV Tests Checks Check for the tick-tick-tick noise as the valve

is driven fully closed then opened to itsmaximum position.

The EEV coil must be seated correctly on thebody of the valve, it is held in place either by

a clip over the inlet pipe or a tab screwed tothe body of the valve.

The winding resistances of the coils of theexpansion valve can be measured. Consultthe service instructions for each model as theresistances can vary.


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Thermistors


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ASTA / ASTB series error display

The OPERATION and TIMER light flash a coded message.

The number of flashes of each light must be counted as the

OPERATION light is the first digit of the error display and theTIMER light is the second digit of the error display

The OPERATION light may not always be lit

eg Operation = OFF, Timer = 2 x ON indicates Reverse serial

communication error at start-up.

Wi d t t l E Di l


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Wired remote control Error Display

0:01E

Communication

error (Serial reverse

transfer error)


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Testing and Checking Inverters

Initial power up checks

Serial Communication checks

Power PCB

Power Relay / Posistor

DC Fan motors

EEV


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Initial power up checks

Stop Look and Listen

When power is applied, the power relay in the outdoor unit will

be energised.

You will hear a Click sound

The Electronic Expansion valve will go through its initialisation

sequence.

You will hear a Tick, Tick, Tick sound

Double check by placing your hand on the body of the valve or

at the side of the outdoor unit near the liquid service valve Sometimes the serial communication chip will make a sound,

listen for the Crickets

The only wildlife that should ever find inside an inverter assembly


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All compressors have a frequency range

Depending on the mode

SELECTION


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Cooling mode


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Heating Mode


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Step 1.

Maximum frequency limit set

Cooling


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Cooling Mode

Maximum frequency limitMeasure outside air temp

Tempfalling

Temp

rising


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Cooling Mode

Maximum frequency limitCheck indoor fan speed setting


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Step 2.

Capacity Control Cooling


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Cooling Mode

Capacity Control

If the Room Temperature is 2C or higher than the set

temperature, the compressor will ramp up to the maximumfrequency in step 1.


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Cooling Mode

Capacity Control

If the Room Temperature is 2.5C lower than the

set temperature, the compressor will be stopped.

If the Room Temperature does not require the unitto work at maximum output, the compressor will be

controlled within the frequency range.


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Step 1.

Maximum frequency limit set

Heating


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Heating Mode

Outside air temp

Indoor fan speed setting


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Step 2.

Capacity Control Heating


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Heating Mode

Capacity Control

If the Room Temperature is 3C or more lower than the settemperature, the compressor will ramp up to the maximum

frequency in step 1.


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Heating Mode

Capacity Control

If the Room Temperature is 2.5C higher than the set

temperature, the compressor will be stopped.

If the Room Temperature does not require the unit to work at

maximum output, the compressor will be controlled within thefrequency range.


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FREQUENCY CONTROL

AFTER START-UP

Total Time 6.8min (ASTA18LCC)


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Heat Exchanger Temperature Control


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DEFROST CYCLE


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OTHER NEW

PRODUCT FEATURES

New Wall Mounted Option Parts


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e a ou ted Opt o a tsWired Remote Controller

Optional kit - UTY-XCBXE (Communication box kit)

ControllerUTB-TUD

Please Note: ET Chassis is the only one that requires this option part. All other chassis

shown has this control ability already on the circuit board inside indoor unit, These units

do not need above optional kit.

Additional Features


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External input

Pump down function

Low noise mode

Peak cut function

Suppresses night time operating sound.

Suppresses maximum capacity and performs

energy-saving operation and can prevent

breaker tripping.

Refrigerant recovery is performed with one

button when moving, etc.

Valve close timing can also be easily

confirmed by LED display and outdoor unit

damage can be prevented.

External output

ON/OFF

ERROR

This output indicates the outdoor unitoperation status's On / Off.

This output indicates the outdoor unit and

connected indoor unit's Normal / Error.

Blue fin heat exchanger

Corrosion-resistance of the heat exchanger

even in coastal areas has been improved by

blue fin treatment of the outdoor unit heat

exchanger.

Blue fin heat exchanger

Cobalt Blue protection

Standard chromate protection

Aluminium base material

Hydrophilic coating


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Documents

Inverter Training 08-BASIC.ppt