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ICP DLC4HV18K1A User Manual

ICP DLC4HV18K1A
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421 01 9204 00 1/03/13
SERVICE MANUAL
R−410A Ductless Split System
Air Conditioner and Heat Pump
MODELS: DLC4(A/H)−Outdoor, DLF4(A/H)−Indoor
SIZES: 9K, 12K, 18K, 24K, 30K, and 36K
INTRODUCTION
This Service Manual provides the necessary information to
service, repair, and maintain the DLF4(A,H), DLC4(A/H)
TABLE OF CONTENTS
PAGE
SAFETY CONSIDERATIONS 1........................
SPECIFICATIONS 2..................................
MODEL / SERIAL NUMBER NOMENCLATURE 16.......
STANDARD FEATURES AND ACCESSORIES 17........
DIMENSIONS 18.....................................
CLEARANCES 22....................................
SYSTEM OPERATING ENVELOPE 23..................
ELECTRICAL DATA 25...............................
CONNECTION DIAGRAMS 26.........................
WIRING DIAGRAMS 27...............................
REFRIGERATION SYSTEM DIAGRAM 36...............
REFRIGERANT LINES 38.............................
SYSTEM EVACUATION AND CHARGING 39............
CONTROL SYSTEM 40...............................
MODES OF OPERATION 44...........................
TROUBLESHOOTING 47.............................
DIAGNOSTIC CHARTS 48............................
MALFUNCTION ANALYSIS 55.........................
APPENDIX 79.......................................
SAFETY CONSIDERATIONS
Installing, starting up, and servicing air−conditioning
equipment can be hazardous due to system pressures,
electrical components, and equipment location (roofs,
elevated structures, etc.).
Only trained, qualified installers and service mechanics
should install, start−up, and service this equipment.
Untrained personnel can perform basic maintenance
functions such as cleaning coils. All other operations should
be performed by trained service personnel.
When working on the equipment, observe precautions in the
literature and on tags, stickers, and labels attached to the
equipment.
Follow all safety codes. Wear safety glasses and work
gloves. Keep quenching cloth and fire extinguisher nearby
when brazing. Use care in handling, rigging, and setting
bulky equipment.
Read these instructions thoroughly and follow all warnings
or cautions included in literature and attached to the unit.
Consult local building codes and National Electrical Code
(NEC) for special requirements. In Canada, refer to current
editions of the Canadian Electrical Code, CSA 22.1.
Recognize safety information. This is the safety−alert
symbol
!
!
. When you see this symbol on the unit and in
instructions or manuals, be alert to the potential for personal
injury.Understand these signal words: DANGER,
WARNING, and CAUTION. These words are used with the
safety−alert symbol. DANGER identifies the most serious
hazards which will result in severe personal injury or death.
WARNING signifies hazards which could result in personal
injury or death. CAUTION is used to identify unsafe
practices which may result in minor personal injury or
product and property damage. NOTE is used to highlight
suggestions which will result in enhanced installation,
reliability, or operation.
!
WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
Before installing, modifying, or servicing system, main
electrical disconnect switch must be in the OFF
position. There may be more than 1 disconnect switch.
Lock out and tag switch with a suitable warning label.
CAUTION
!
EQUIPMENT DAMAGE HAZARD
Failure to follow this caution may result in equipment
damage or improper operation.
Do not bury more than 36 in. (914 mm) of refrigerant
pipe in the ground. If any section of pipe is buried, there
must be a 6 in. (152 mm) vertical rise to the valve
connections on the outdoor units. If more than the
recommended length is buried, refrigerant may migrate
to the cooler buried section during extended periods of
system shutdown. This causes refrigerant slugging and
could possibly damage the compressor at start−up.

Table of Contents

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ICP DLC4HV18K1A Specifications

General IconGeneral
BrandICP
ModelDLC4HV18K1A
CategoryAir Conditioner
LanguageEnglish

Summary

Introduction to Service Manual

Introduction

Provides necessary information for servicing, repair, and maintenance of the DLF4(A,H) and DLC4(A/H) units.

Safety Considerations

Details essential safety precautions for installing, servicing, and operating HVAC equipment.

Electrical Shock Hazard Warning

Warning about severe injury or death from electrical shock.

Equipment Damage Hazard Caution

Caution to prevent equipment damage or improper operation from unsafe practices.

Product Specifications Overview

Indoor Unit Electrical and Performance Data

Covers voltage, capacity, air volume, and efficiency ratings for indoor units.

Outdoor Unit Component and Environmental Data

Details compressor, heat exchanger, fan, refrigerant, and operating parameters for outdoor units.

Model and Serial Number Nomenclature

Model Nomenclature Breakdown

Explains the meaning of each position in the model number for unit identification.

Serial Number Nomenclature Breakdown

Details the structure and meaning of serial number positions for unit identification.

Standard Features and Accessories

Standard Unit Features

Lists standard features like ease of operation, comfort, safety, and reliability functions.

Optional Accessories and Warranties

Details optional accessories, warranty periods, and extended warranty information.

Unit Dimensions

Indoor Unit Dimensions

Provides detailed width, height, and depth measurements for indoor units.

Outdoor Unit Dimensions by Size

Details dimensions for outdoor units across various sizes (09K to 36K).

Installation Clearances

Indoor Unit Clearance Requirements

Specifies minimum clearance distances around the indoor unit for proper installation.

Outdoor Unit Clearance Requirements

Details required clearances around the outdoor unit for proper operation and maintenance.

System Operating Envelopes

Operating Range Charts (115V & 230V)

Illustrates cooling and heating operating limits based on indoor and outdoor temperatures.

Operating Envelopes for Various Models

Provides charts defining operating limits for different unit sizes and voltages.

Electrical Data and Wiring Guidelines

Electrical Data Tables

Presents detailed electrical specifications for outdoor and indoor units, including voltage, current, and power.

Field Wiring Recommendations

Offers guidelines for connecting power and communication wires, including AWG size and length.

Electrical Connection Diagrams

115-1-60 Connection Diagrams

Illustrates wiring connections for 115V units, showing terminal blocks and power supply.

208/230-1-60 Connection Diagrams

Depicts wiring for 208/230V units, detailing connections between indoor and outdoor units.

Detailed Wiring Diagrams

Indoor Unit Wiring Schematics

Shows electrical wiring schematics for various indoor unit models and voltages.

Outdoor Unit Wiring Schematics

Provides detailed wiring diagrams for outdoor units across different models and power supplies.

Refrigerant System Diagrams

Cooling-Only System Flow

Illustrates the refrigerant path for cooling-only models, showing key components and valves.

Cooling and Heating System Flow

Depicts the refrigerant flow for cooling and heating models, including 4-way valve operation.

Refrigerant Line Installation and Charging

Refrigerant Line Routing and Sizing

Details pipe routing options, hole sizes, and general installation guidelines for refrigerant lines.

Refrigerant Charge and Length Limits

Specifies refrigerant charge amounts and maximum allowable piping lengths for different unit sizes.

System Vacuum and Refrigerant Charging

Deep Vacuum and Triple Evacuation Methods

Explains recommended methods for evacuating the system to remove air and moisture.

Vacuum Measurement and Final Checks

Details vacuum depth measurement and final checks for tubing integrity and connections.

Remote Control Operation and Features

Remote Control Button Functions

Identifies and explains the function of each button on the remote control for different unit sizes.

Remote Control Display Indicators

Describes the various symbols and indicators displayed on the remote control screen.

Battery Installation and Notes

Provides instructions for installing batteries and important notes regarding remote control maintenance.

Unit Operation Modes and Controls

Operating Modes and Basic Functions

Explains temperature parameters, basic operational functions, and cooling mode processes.

Protection Functions and Fault Codes

Details various protection mechanisms and error codes displayed for malfunctions.

Advanced Control Features and Sensor Malfunctions

Covers drying function, memory, sensor error detection, and compressor protection features.

Troubleshooting and Error Code Interpretation

General Troubleshooting Precautions

Provides essential safety precautions and general checks before performing troubleshooting.

Error Code Reference Tables

Lists error codes, their corresponding symptoms, and potential causes for various unit models.

Malfunction Diagnosis Flowcharts

Initial System Start-up Malfunctions

Guides through troubleshooting common issues like no power or controller malfunctions.

Performance and Airflow Malfunctions

Addresses problems related to poor cooling/heating, insufficient airflow, and heat exchanger issues.

Component Operation Malfunctions

Diagnoses issues with fan motors, compressors, and their related components.

Operational and Noise Related Malfunctions

Covers troubleshooting for swing fan issues, abnormal sounds, and water leakage.

Advanced Malfunction Analysis and Diagnosis

Protection Circuit Analysis

Analyzes common protection circuits like compressor overload, IPM, and voltage issues.

Specific Fault Diagnosis Flowcharts

Provides step-by-step diagnostic flowcharts for common malfunctions like high temperature and start-up failures.

Specific Fault Diagnosis Procedures

Power Factor (PFC) and Communication Fault Diagnosis

Provides diagnostic steps for PFC faults and communication issues between units.

Capacitor, IPM, and Start-up Failure Diagnosis

Details diagnostic procedures for capacitor charging, IPM protection, and start-up malfunctions.

Synchronization, Overload, and Temperature Sensor Diagnosis

Covers troubleshooting for compressor synchronization, overload, and temperature sensor faults.

Appendices: Sensor Resistance Tables

Ambient Temperature Sensor Resistance

Provides resistance values for ambient temperature sensors at various temperatures.

Tube Temperature Sensor Resistance

Lists resistance values for indoor/outdoor tube temperature sensors across a range of temperatures.

Outdoor Discharge Temperature Sensor Resistance

Offers resistance data for the outdoor discharge temperature sensor at different temperature points.

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