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Zanussi ZS12V70CCHI Service Manual

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Service Manual
Split Type Air Conditioner

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Summary of Contents for Zanussi ZS12V70CCHI

  • Page 1 Service Manual Split Type Air Conditioner...

  • Page 2: Table Of Contents

    2.2 INDOOR UNITS 12K & 18K & 24K 2.3 OUTDOOR UNITS 2.4 PRINTED CIRCUIT BOARD 2.5 INDOOR UNITS 12K (ZS12V70CCHI - ZS12V80CCHI - ZS12V71CCHI - ZS12V81CCHI - ZS12V91C- 2.6 INDOOR UNITS 18K & 24K 2.7 OUTDOOR UNITS 3. REFRIGERANT SYSTEM DIAGRAM 3.1 COOLING AND HEATING MODELS...
  • Page 3 7.4 CLEANING THE AIR OUTLET AND THE PANEL 7.5 PREPARATION FOR EXTENDED NON OPERATION 8. TROUBLESHOOTING 8.1 IMPORTANT INFORMATION ON MALFUNCTION PROCEDURES 8.2 ERROR CODES 8.3 PROTECTION CODES 8.4 TROUBLESHOOTING FLOW CHARTS 8.5 PROTECTION CODES 8.6 WARNING CODES 8.7 PROTECTION FUNCTIONS 8.8 NOISY OPERATION SOLUTION FLOW CHART 8.9 GAS PRESSURE MEASUREMENT IN INVERTER PRODUCTS TABLE 9.

  • Page 4: Construction Views

    1. CONSTRUCTION VIEWS 1.1 Indoor View INDOOR UNIT 1053 1053 1053 150mm or more to ceiling Indoor unit outline 150mm or 150mm or more to wall more to wall Left rear side Right rear side refrigerant refrigerant pipe pipe hole hole Ø...

  • Page 5: Outdoor View

    1.2 Outdoor View 815 725 622 300 261 909 816 567 364 336 1009 916 668 364 334 2. SCHEMATIC DIAGRAMS 2.1 Indoor Units 12K FAN MOTOR ONLY MODELS WITH WI-FI STEPPING MOTOR WI-FI PCB DATA PULSE GEN. GENERATOR 1 2 3 4 1 2 3 1 2 3 4 5 1 2 3 4...

  • Page 6: Indoor Units 12K & 18K & 24K

    2.2 Indoor Units 12K & 18K & 24K ONLY MODELS WITH WI-FI BLDC STEPPING MOTOR WI-FI PCB MOTOR DATA GENERATOR 1 2 3 1 2 3 4 1 2 3 4 5 1 2 3 1 2 3 4 1 2 3 4 5 Signal Empty INDOOR UNIT MAIN CONTROL BOARD...

  • Page 7: Outdoor Units

    2.3 Outdoor Units...

  • Page 8: Printed Circuit Board

    2.4 PRINTED CIRCUIT BOARD 2.5 Indoor Units 12K (ZS12V70CCHI - ZS12V80CCHI - ZS12V71CCHI - ZS12V81CCHI - ZS12V91CCHI SOCKET DESCRIPTION SOCKET DESCRIPTION Indoor unit fan cable CN10 NTC sensor cable CN11 Phase neutral communication cable Display cable CN15 Ioniser cable Software installation cable...

  • Page 9: Indoor Units 18K & 24K

    2.6 Indoor Units 18K & 24K SOCKET DESCRIPTION SOCKET DESCRIPTION CN102 Indoor unit fan cable CN101 Horizontal blade step motor cable CN15 Ioniser cable CN10 NTC sensor cable Wifi module card cable Software installation cable CN100 Display cable CN11 Line-Neutral information cable...

  • Page 10: Outdoor Units

    2.7 Outdoor Units SOCKET DESCRIPTION SOCKET DESCRIPTION CN10 Compressor cable (blue) Earth cable (yellow+green) Compressor cable (red) Information cable (white) Compressor cable (black) CN11 4 way valve cable 1 (blue) Reactor cable CN13 4 way valve cable 2 (blue) Reactor cable NTC temperature sensor cable CN27 BLDC fan cable...

  • Page 11: Refrigerant System Diagram

    3. REFRIGERANT SYSTEM DIAGRAM 3.1 Cooling And Heating Models GAS SIDE 3-WAY VALVE 4-Way valve Di s charge HEAT EXCHANGE (EVAPORATOR) Suction Accumulator COMPRESSOR HEAT EXCHANGE (CONDENSER) LIQUID SIDE Capillar COOLING HEATING Refrigerant pipe diameters for all models; Liquid Inch...

  • Page 12: Precautions

    4. PRECAUTIONS The installation and maintenance must be accordant with the installation manual and instructions. Incorrect operation due to ignoring instruction will cause harm or damage. Wiring should be done by an expert electric technician according to national regulations on electrical wiring. All installation and maintenance shall be performed by qualified person.

  • Page 13: Product Description

    4.4 Product Description Space to the ceiling 15cm above Space to the wall Air outlet side Space to obstruction Air inlet side Space to the wall 30cm above Space to the wall 50cm above Air outlet side NOTE All the pictures in this manual are for explanation purposes only. The actual shape of the indoor unit you purchased may be slight different on front panel and display window.
  • Page 14 Number Name of Accessories Quantity Indoor unit mounting plate Clip anchor Self-tapping screw Remote control Remote control holder Battery (AAA 1.5V) Flare nut (for liquid pipe) Flare nut (for gas pipe) Decorative tape Connection piping assembly Insulation hose for refrigerant piping External power cable Drain hose Interconnection cable...

  • Page 15: Before Installation

    5. BEFORE INSTALLATION 5.1 Tools needs for installation 15. Pipe cutter 16. Measuring tape 1. Level gauge 17. Screw driver ( Phillips and slotted ) 2. Electric drill 18. Pliers and flash cutter 3. Hole core drill (ø55mm / ø70mm) 19.
  • Page 16 5.3.2 Connecting the cables Capacity System Voltage/ Power Cord Cable Connecting Cable Fuse Circuit Watts / Btu/h Frequency Gauge (mm²) Gauge (mm²) Type (A) Breaker (A) 0,75 3517/12000 220-240V/50Hz. 0,75 5280/18000 220-240V/50Hz 0,75 7034/24000 220-240V/50Hz 5.3.3 Electrical wires 12K Heat Pump Type Outdoor blue brown yellow/green...

  • Page 17: Installation Summary

    • Considering the wall structure, the outdoor unit should be installed on a flat surface to avoid raspy noise, echo and vibration. • Choose a place that will not take direct sunlight. If the selected place is exposed to direct sunlight, the outdoor unit should be shaded.

  • Page 18: Piping Connection Summary

    5.5.1 Flaring Work Main cause for refrigerant leakage is due to defect in the flaring work. Carry out correct flaring work using the following procedure: • Cut the pipes and the cable. • Use the piping kit accessory or pipes purchased locally. •...

  • Page 19: Installation Of Electrical Wires Summary

    5.6.4 Checking the Drainage • Open and lift the indoor unit front panel. • Check the drainage – Carefully pour a glass of water on the evaporator. – Ensure the water flows through the drain hose of the indoor unit without any leakage and goes out the drain exit. •...

  • Page 20: Typical Applications

    R-410A is an azeotropic mixture of HFC-32 and HFC-125. It has been developed as a long-term replacement for R-22 in a variety of new air conditioning and cooling equipment. R-22 is an HCFC, or hydro chlorofluorocarbon, which means that it contains chlorine, an element that is depleting to the ozone layer.

  • Page 21: R410A Charging Instruction

    R-410A expands significantly when heated. Exposure of a container to direct sunlight or other heat source can cause it to burst, resulting in serious injury. Allied Signal recommends that its cylinders not be allowed to exceed 52°C. Care also should be taken to avoid damage to containers that could cause them to leak or rupture.

  • Page 22: R410A Pressure Temperature Chart

    The charging process should be finished after the required amount is charged in to the system and remove the manifold and refrigerant hose. 2. Refrigerant Leakage on the System First of all the leakage point should be repaired on the system. For example that there is a leakage on the service valve at piping connection.
  • Page 23 2,49 1,47 21,38 2,48 1,47 21,25 2,70 1,69 24,51 2,69 1,68 24,37 2,93 1,92 27,84 2,92 1,91 27,69 3,18 2,16 31,38 3,17 2,15 31,22 3,44 2,42 35,16 3,43 2,41 34,98 3,71 2,70 39,16 3,70 2,69 38,98 4,01 2,99 43,41 3,99 2,98 43,21 4,32...

  • Page 24: Vacuuming And Refrigerant Charging & Discharging Process

    6.5 Vacuuming and Refrigerant Charging & Discharging Process Vacuuming of the system is very important in terms of performance in cooling systems. During the installation process or if the system is switched on, it must be vacuumed. Air and moisture in the refrigeration system have undesirable effects as indicated below: •...

  • Page 25: Cleaning And Maintenance

    • Check the pressure indicated by the pressure gauge. (low pressure side) • Standard pressure should be 7.5-10.5 kg/cm2 in a regular, high operation mode. • Open the refrigerant tank and fill with refrigerant until the rated pressure is reached. •...

  • Page 26: Cleaning The Air Outlet And The Panel

    1. Lift the indoor unit front panel up to an angle until it stops with a full support from the bracket. Dust filter handle 2. Hold the dust filter handle and lift it up slightly to take it out from the filter holder. 3.

  • Page 27: Troubleshooting

    8. TROUBLESHOOTING Important Notes For Zanussi Inverter Products TEST FUNCTIONS (All products with a VEL board) There is only one test function on Vestel electronic boards. With this control unit, robustness of the components on the indoor unit can be checked. The process is as follows: 1.

  • Page 28: Important Information On Malfunction Procedures

    8.1 Important Information On Malfunction Procedures • Boards should not be replaced due to ER-05, ER-07, ER-03, ER-15, ER-16, AE error codes. • Please make sure that you do not replace the sensor without seeing an error code. Sensors on inverter products rarely break down.

  • Page 29: Protection Codes

    8.3 Protection Codes Indoor Unit CODE Outdoor Unit LED Display Compressor speed limited due to outdoor temperature No display Blinking 1 time - stopping for 3 sec. Compressor speed limited due to outdoor pipe (condenser) temperature No display Blinking 2 times - stopping for 3 sec. Compressor speed limited due to compressor pressing temperature No display Blinking 3 times - stopping for 3 sec.
  • Page 30 Check the compressor cable connections on the main board. Replace the outdoor unit control board. Are there errors in connections? Are there any disconnections, ruptures, looseness etc. in the sockets? Error Code (7 Segment) Outdoor unit led Indoor unit pipe sensor error ER 03 Display shows ER 03 error when the air conditioner is switched on via the...
  • Page 31 Error Code (7 Segment) Outdoor unit led Indoor unit setting not performed/deleted ER 05 Manually do setting via the remote Air conditioner gives ER 05 error. control after getting support from the Type code of the air conditioner is product support unit about the setting deleted.
  • Page 32 Error Code (7 Segment) Outdoor unit led Cooling system error ER 07 Blinking 7 times - stopping for 3 sec. Gives ER 07 error (cooling system Outdoor unit LED signal 7 times. error) Connect the manifold to the outdoor unit service Capillary group blocked.
  • Page 33 Remove the sensor from its place in the condenser and restart the product. Is Replace the outdoor unit control board. the error gone? Out-of-limit heat drop is occurring in the place of the sensor (-40°C) Such a thing only occurs when there is a gas leakage at very cold weather conditions (below -15°C) Repair the leakage point, apply the procedure and give gas to the device at label value.
  • Page 34 Error Code (7 Segment) Outdoor unit led Compressor could not take off error ER 11 Blinking 11 times - stopping for 3 sec. Outdoor unit gives ER 11 error after operating (the error is given when the Outdoor unit LED signals 11 times compressor cannot take off) Measure the network voltage, is it Voltage is too low, try again when it is...
  • Page 35 Error Code (7 Segment) Outdoor unit led Compressor excessive current protection ER 13 Blinking 13 times - stopping for 3 sec. (if t occurs during operation) Outdoor unit gives ER 13 error after operating (Compressor current Outdoor unit LED signals 13 times protection) Check the indoor unit dust filters.
  • Page 36 Error Code (7- Segment) Outdoor unit led Compressor excessive current protection ER 14 Blinking 8/13 times - stopping for 3 sec. (if it occurs during first start) The product gives ER 14 error when Outdoor unit LED signals first 8 times, it is first given energy (Compressor then 13 times current protection)

  • Page 37: Protection Codes

    Error Code (7 Segment) Outdoor unit led Wi-fi module communication error ER 19 ER 19 Error is a communication error between the wi-fi module and the main Reinstall the module and operate. board. Does the problem go away when the wi-fi module is replaced? Replace the indoor unit main board.

  • Page 38: Warning Codes

    8.6 Warning Codes Warning Code (7 Segment) Outdoor unit led Warning Description Compressor speed limited due Limits or decreases the compressor frequency when Blinking 2 times - to outdoor pipe (condenser) No display the temperature on the condenser goes out of limits stopping for 3 sec.
  • Page 39 8.7.3 Protection according to indoor unit evaporator temperature This protection is a function that can occur in cooling and heating modes. Cooling mode indoor unit Evap Temperature Description icing temperature limits Indoor unit pipe sensor If the indoor unit pipe sensor temperature is below this value in 1 °C cooling mode, compressor and outdoor unit fan motor stops.

  • Page 40: Noisy Operation Solution Flow Chart

    8.8 Noisy Operation Solution Flow Chart • Noisy operation may vary, independently from the product, depending on the environmental conditions, mounting conditions or the Therefore, the first and most important thing to do in noisy operation complaints is to exactly noise perception of the consumer.

  • Page 41: Gas Pressure Measurement In Inverter Products Table

    Compressor Noise Indoor Unit Pipes Outdoor Unit Check if there are Check if there is section Check if there is blocking problems such as section narrowing in the evap inlet- or section narrowing in the narrowing, blocking, etc. in outlet. capillaries.
  • Page 42 Factory Gas Pressure Measurement Values Of 18K Products ( Indoor tempera- Outdoor tem- Compressor Id sensor (°C) Current (A) Suction line Discharge line ture (°C) perature (°C) frequency (Hz) pressure (Bar) pressure (Bar) 10.08 5.79 7.81 24.46 10.22 5.93 7.91 25.58 10.62 6.11...

  • Page 43: Components

    9. COMPONENTS 9.1 Compressors Compressor Type Model Winding Resistance (25 °C) 1.99 +/- 7% Ω GS089MAA 1.99 +/- 7% Ω GSG102MKA 1.45 +/- 7% Ω GAT156MBA IMPORTANT NOTE: Attention must be paid to environment and material temperature in compressor measurements. Resistance values between coils should be equal or very close to each other.
  • Page 44 9.2.1 Indoor unit sensors (indoor environment sensor, evaporator pipe sensor) 1. Evaporator defrost sensor 2. Indoor unit sensor. Functions They Help Environment sensor: Regulating the operating functions of the air conditioner (auto, cooling, heating, dehumidification and sleep modes). Evaporator sensor: Regulates the operation of the protection modes of the air conditioner (e.g. anti-frost in indoor unit, remaining hot in heating, operating order of the indoor unit fan motor etc.) 9.2.2 Outdoor unit sensors (ntc) 1.

  • Page 45: Fan Motors

    Compressor discharge line sensor: measures the temperature value of the gas which the compressor discharges. Its duty in the system is to help decrease the cycle of the compressor when the compressor discharge gas temperature goes above the critical level. Condenser pipe sensor: Measures the temperature of the gas at the condenser outlet.
  • Page 46 Ceramic Aluminium Motor inner structure Aluminium body vs AC Ceramic Body Measurement Control Ac voltage of the yellow and grey cable sockets of the tacho socket on the indoor unit board should be measured (Voltage should be 7-10V) Resistances between the blue-red, blue-yellow and yellow-red cables in the supply socket should be separately measured. If a value is seen in all measurements, it means robust;...
  • Page 47 Heating 12K Outdoor Unit ≤ 3 > 3 ~ ≤ 5 > 5 ~ ≤ 8 > 8 ~ ≤ 12 Condenser input temperature (°C) > 12 Outdoor unit fan motor cycle (rpm) 1100 980 BLDC Outdoor Unit Fan Motor Control •...
  • Page 48 3. If a value is read at the motor supply ends, whether the motor circuit of the main board is robust should be controlled. – Attach the motor socket to its place, give energy to the air conditioner and turn it on. In this case, a voltage between 210 Vdc and 340 Vdc at the red and black ends of the motor should be measured.

  • Page 49: Setting With Remote Control

    RC standard use mode. ) 4. You will see 6 zero icon on the screen. 5. Start entering the setting codes by pressing the buttons shown in the tables. Indoor Unit Set Code ZS12V70CCHI 053843*112450 ZS12V71CCHI 053843*112450 ZS12V80CCHI...

  • Page 50: Disassembly And Reassembly Instructions

    10. DISASSEMBLY AND REASSEMBLY INSTRUCTIONS 10.1 Indoor Unit Steps Procedure Visual before disassembly Removal of filter and horizontal louver Open the front panel. Push the filter inward and then draw it upward to remove it. Remove the center pin of horizontal louver from its slot. Remove the horizontal louver pin that connected with step motor shaft by pulling the left side.
  • Page 51 Steps Procedure If you want to disjoint the front panel, remove the panel by waggling toward left and right the two tabs located on the backside from their slots. Screw off the electric box cover located under the front pane Remove the display cable socket located on the indoor unit electron- ic card.
  • Page 52 Steps Procedure Removal of electric box assy Firstly, remove the front case properly. Then screw off the electric box cover. Remove the pipe sensor and ambient sensor located on evaporator from their housing and screw off the earthing cable. Control panel ( electric ) box is fixed to the indoor unit with screws. Remove this screws with a proper tool.
  • Page 53 Steps Procedure 18/24K Evaporator is fixed to the body with 3 screws and 2 pawls. Remove the 2 screws located on evaporator plastic on the left side the prod- uct and other screw located on right rear side. Remove the 2 pawls located on left rear side and right front side. Move the evaporator pipes towards the right side.

  • Page 54: Outdoor Unit

    10.2 Outdoor Unit Steps Procedure Big Holder Screw off the one screw located in big holder. Valve Cover In order to reach the valves, you should screw off the one screw located on valve cover and remove the cover. Top Panel You should screw off the all screws located on the top panel in order to remove the top panel.
  • Page 55 Steps Procedure Front Panel You should screw off the 3 screws located on the upper, 3 screws located on the bottom, 2 screws in left side and 2 screws in the right side on the front panel in order to remove the front panel and reach the compressor and 4 way valve.
  • Page 56 Steps Procedure Reactor Remove the reactor by loosen the 2 screws on the interconnection plate. Axial Fan Loosen the screw fixing the blade. Remove the axial flow blade. Motor Bracket and Fan Motor Loosen the one tapping screw fixing the motor support. Raise the support to remove it.
  • Page 57 Steps Procedure Refrigerant components (4 way valve, capillary, etc.) Remove the 3 screws fixing the isolation sheet and then remove the isolation sheet. Recover the refrigerant at first. Loosen fixing screw on condenser connection. Disassemble the pipes in both inlet and outlet with welding torch.
  • Page 58 Steps Procedure Condenser Recover the refrigerant at first. Loosen fixing screw on condenser connection. Disassemble the pipes in both inlet and outlet with welding torch. Detach the condenser. After remove all condenser connection screws, pull the condenser upwards to remove it.

  • Page 59: Exploded View Indoor Unit

    11. EXPLODED VIEW INDOOR UNIT Description 1 FRONT PANEL 2 DISPLAY BOX WITH PCB 3 DUST FILTER 4 TERMINAL COVER 5 HORIZONTAL BLADE 6 STEP MOTOR 7 VERTICAL 4 BLADES 8 CROSS FAN 9 FAN MOTOR 10 MOTOR COVER 11 WIFI ANTENNA 12 TERMINAL BLOCK 13 CABLE HOLDER 14 CONTROL BOX COVER...

  • Page 60: Exploded View Outdoor Unit

    12. EXPLODED VIEW OUTDOOR UNIT Description 1 FRONT PANEL NOZZLE 2 FRONT PANEL 3 TOP PANEL 4 FAN PROPELLER 5 FAN MOTOR 6 FAN MOTOR BRACKET 7 BASE PLATE Accessories (Optional) 8 COMPRESSOR RUBBER No Description 9 COMPRESSOR BOLT 10 COMPRESSOR 30 DECORATIVE TAPE 11 CHECK VALVE GROUP 31 SCREW GROUP...

This manual is also suitable for:

Zs12v71cchiZs12v80cchiZs12v81cchiZs12v91cchiZs18v70cchiZs18v80cchi ... Show all

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