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International comfort products DLF4A6 User Manual

International comfort products DLF4A6
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421 08 9205 00 2/21/14
SERVICE MANUAL
R410A Ductless Split System
Air Conditioner and Heat Pump
MODELS: DLC4(A/H)6Outdoor, DLF4(A/H)6Indoor
SIZES: 9K, 12K, 18K, and 24K
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........................
MODEL / SERIAL NUMBER NOMENCLATURE 2........
STANDARD FEATURES AND ACCESSORIES 3.........
PHYSICAL DATA 47.................................
AHRI CAPACITY RATINGS 8..........................
AIRTHROW DATA 8..................................
SOUND RATINGS 9..................................
DIMENSIONS INDOOR 10...........................
DIMENSIONS OUTDOOR 11........................
CLEARANCES 13....................................
SYSTEM OPERATING ENVELOPE 14.................
ELECTRICAL DATA 17...............................
CONNECTION DIAGRAMS 18.........................
WIRING DIAGRAMS 19...............................
REFRIGERATION SYSTEM DIAGRAM 23...............
SYSTEM EVACUATION AND CHARGING 25............
REMOTE CONTROL AND FUNCTIONS 2627...........
FUNCTION AND CONTROLS 2831....................
TROUBLESHOOTING 3259..........................
APPENDIX TABLES 6062...........................
UNIT REMOVAL PROCEDURES 63....................
Indoor 9k 12k 115v 64.................................
Outdoor 9k 12k 115v 75...............................
Indoor 12k 18k 230v 79................................
Outdoor 12k 230v 85...................................
Outdoor 18k 230v 90...................................
Indoor 24k 230v 96.....................................
Outdoor 24k 230v 102..................................
EXPLOSION HAZARD
Failure to follow this warning could
result in death, serious personal
injury, and/or property damage.
Never use air or gases containing
oxygen for leak testing or
operating refrigerant compressors.
Pressurized mixtures of air or
gases containing oxygen can lead
to an explosion.
!
WARNING
SAFETY CONSIDERATIONS
Improper installation, adjustment, alteration, service,
maintenance, or use can cause explosion, fire, electrical
shock, or other conditions which may cause death, personal
injury, or property damage. Consult a qualified installer,
service agency, or your distributor or branch for information
or assistance. The qualified installer or agency must use
factoryauthorized kits or accessories when modifying this
product. Refer to the individual instructions packaged with
the kits or accessories when installing.
Follow all safety codes. Wear safety glasses, protective
clothing, and work gloves. Use quenching cloth for brazing
operations. Have fire extinguisher available. 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.
Recognize safety information. This is the safetyalert
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 safetyalert
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 startup.
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International comfort products DLF4A6 Specifications

General IconGeneral
BrandInternational Comfort Products
ModelDLF4A6
TypeAir Conditioner
SEER RatingUp to 16 SEER
Refrigerant TypeR-410A
Voltage208/230V
Phase1
Dimensions (Outdoor Unit)Varies by model
Weight (Outdoor Unit)Varies by model

Summary

INTRODUCTION

SAFETY CONSIDERATIONS

MODEL / SERIAL NUMBER NOMENCLATURE

STANDARD FEATURES AND ACCESSORIES

PHYSICAL DATA

AHRI* CAPACITY RATINGS

AIR THROW DATA

SOUND RATINGS

DIMENSIONS - INDOOR

DIMENSIONS - OUTDOOR

CLEARANCES

SYSTEM OPERATING ENVELOPE

ELECTRICAL DATA

WIRING

CONNECTION DIAGRAMS

WIRING DIAGRAMS

REFRIGERATION SYSTEM DIAGRAMS

SYSTEM EVACUATION AND CHARGING

Vacuum Pump Evacuation Method

Procedure for evacuating the system using a vacuum pump.

Deep Vacuum Method

Method using a vacuum pump capable of pulling 500 microns.

Triple Evacuation Method

Alternate method for systems not containing liquid water.

REMOTE CONTROL AND FUNCTIONS

Basic Operation Buttons

ON/OFF, MODE, TEMP, FAN controls for basic operation.

Advanced Function Buttons

Horizontal Swing, X-FAN, TIMER, TURBO, SLEEP, LIGHT functions.

Remote Control Display

Indicator Symbols on Display

Explains Transmission, Mode, Fan Speed, and Sleep indicators.

Displayed Information Elements

Covers Temperature, HEALTH/SAVE, and Battery status displays.

FUNCTION AND CONTROLS

Cooling Mode Operations

Describes working conditions and cooling process.

Heating Mode Operations

Describes working conditions and heating process.

Defrost Mode Process

Conditions and process for entering defrost mode.

FUNCTION AND CONTROLS

Protection Mechanisms Overview

Details overload, exhaust temp, communication, module protections.

Mode-Specific Functions

Covers Cold Air prevention, Fan Mode, and AUTO Mode operations.

FUNCTION AND CONTROLS

Protection and Sensor Faults

Covers overload, sensor malfunctions, and failure displays.

Remote Control Operations

Details ON/OFF, Mode, Temp, Fan, Sleep, Buzzer, Auto, Swing, Display.

FUNCTION AND CONTROLS

Advanced Controls & Protection

Covers Memory, Sensor Detection, Frequency, Discharge Pipe, Input Current controls.

System Protection Features

Details Freeze-up, Heating Peak-cut, Defrost, Fan, and Speed controls.

TROUBLESHOOTING

General Precautions and Procedures

Safety precautions, static/dynamic maintenance, and diagnosis steps.

Electrical Shock Hazard Warning

Warning about electrical shock during servicing.

TROUBLESHOOTING - ERROR CODE INTERPRETATION

Display and Error Code Explanation

Explains error codes displayed on indoor/outdoor units.

Diagnostic Codes List

Lists malfunction codes and repair methods for 9k/12k, 115v.

TROUBLESHOOTING - DIAGNOSTIC CODES

Diagnostic Codes for 12K, 230v

Lists malfunction codes and repair methods for 12K, 230v units.

TROUBLESHOOTING - DIAGNOSTIC CODES

Diagnostic Codes for 18k-24k, 230v

Lists malfunction codes and repair methods for 18k-24k, 230v units.

TROUBLESHOOTING - MALFUNCTION ANALYSIS

Common Malfunction Causes and Analysis

Analysis of common malfunctions and their causes.

TROUBLESHOOTING - REFRIGERANT FLOW ISSUES

Refrigerant Flow Malfunctions

Analysis of malfunctions related to refrigerant flow.

Air Circulation Insufficiency

Troubleshooting steps for insufficient air circulation.

TROUBLESHOOTING - FAN & COMPRESSOR ISSUES

Fan and Compressor Operation Problems

Troubleshooting for fan and compressor not running.

TROUBLESHOOTING - MISCELLANEOUS MALFUNCTIONS

Swing Fan, Water Leakage, and Noise Issues

Troubleshooting for swing fan, water leakage, and abnormal sound.

TROUBLESHOOTING - COMPONENT PROTECTION

Compressor Discharge & Overload Protection

Details on compressor discharge, overload, and IPM module protections.

System & Voltage Protection

Troubleshooting for system overload and voltage-related issues.

TROUBLESHOOTING - SYSTEM CHECKS

Basic System Check Procedure

Diagnostic process for 09 & 12K models.

General Fault Diagnosis Flowchart

Flowchart for troubleshooting system faults.

TROUBLESHOOTING - COMPRESSOR & IPM FAULTS

Compressor and IPM Fault Diagnosis

Main check points for compressor and IPM faults.

Fault Diagnosis Process for Compressor/IPM

Flowchart for IPM, out-of-step, and over-current faults.

TROUBLESHOOTING - DETAILED FAULT FLOWCHARTS

Detailed Fault Diagnosis Flowchart

Detailed flowchart for troubleshooting specific faults.

TROUBLESHOOTING - TEMPERATURE PROTECTION

High Temperature & Overload Protection Diagnosis

Troubleshooting for high temp/overload protection.

Temperature Protection Diagnosis Flowchart

Flowchart for diagnosing high temp/overload issues.

TROUBLESHOOTING - START-UP FAILURES

Outdoor Unit Start-up Failure Diagnosis

Diagnosis for outdoor unit start-up failures.

Start-up Failure Diagnosis Flowchart

Flowchart for diagnosing start-up failures.

TROUBLESHOOTING - COMPRESSOR SYNCHRONIZATION

Compressor Out-of-Step Diagnosis

Diagnosis for compressor out-of-step issues.

Compressor Synchronization Diagnosis Flowchart

Flowchart for compressor synchronization diagnosis.

TROUBLESHOOTING - OVERLOAD & DISCHARGE MALFUNCTIONS

Overload & Discharge Malfunction Diagnosis

Diagnosing overload and discharge malfunctions.

Overload/Discharge Malfunction Diagnosis Flowchart

Flowchart for overload/discharge malfunction diagnosis.

TROUBLESHOOTING - COMMUNICATION MALFUNCTIONS

Power Factor Correction (PFC) Fault Diagnosis

Diagnosis for PFC faults in the outdoor unit.

PFC Fault Diagnosis Flowchart

Flowchart for diagnosing PFC faults.

TROUBLESHOOTING - COMMUNICATION MALFUNCTIONS

Communication Malfunction Diagnosis

Diagnosis for communication malfunctions.

Communication Malfunction Diagnosis Flowchart

Flowchart for diagnosing communication issues.

TROUBLESHOOTING - MODEL-SPECIFIC APPLICATIONS

Application Notes for 18 & 24K Models

Instructions for 18 & 24K models regarding malfunctions.

TROUBLESHOOTING - CAPACITOR FAULTS

Capacitor Charging Malfunction Diagnosis

Diagnosis for capacitor charging malfunctions.

Capacitor Fault Diagnosis Flowchart

Flowchart for capacitor charging fault diagnosis.

TROUBLESHOOTING - COMPRESSOR PROTECTION

IPM, De-sync, Over-current Protection Status

Outdoor unit malfunction indicator status and detection.

TROUBLESHOOTING - COMPRESSOR FAULT DIAGNOSIS

Compressor Fault Diagnosis Process

Detailed flowchart for IPM, compressor faults.

TROUBLESHOOTING - TEMPERATURE PROTECTION

High Temperature & Overload Protection Diagnosis

Checks outdoor unit in cooling and indoor in heating mode.

Temperature Protection Diagnosis Flowchart

Flowchart for diagnosing high temp/overload issues.

TROUBLESHOOTING - START-UP FAILURES

Outdoor Unit Start-up Failure Diagnosis

Diagnosis for outdoor unit start-up failures.

Start-up Failure Diagnosis Flowchart

Flowchart for diagnosing start-up failures.

TROUBLESHOOTING - COMPRESSOR SYNCHRONIZATION

Compressor Synchronization Diagnosis

Diagnosing compressor synchronization issues.

Synchronization Diagnosis Flowchart

Flowchart for compressor synchronization diagnosis.

TROUBLESHOOTING - OVERLOAD & DISCHARGE MALFUNCTIONS

Overload & Discharge Malfunction Diagnosis

Diagnosing overload and discharge malfunctions.

Overload/Discharge Malfunction Diagnosis Flowchart

Flowchart for overload/discharge malfunction diagnosis.

TROUBLESHOOTING - COMMUNICATION MALFUNCTIONS

Communication Malfunction Diagnosis

Diagnosis for communication malfunctions.

Communication Malfunction Diagnosis Flowchart

Flowchart for diagnosing communication issues.

TROUBLESHOOTING - OUTDOOR COMMUNICATION CIRCUIT

Outdoor Communication Circuit Diagnosis Process

Key detection points for outdoor communication circuit.

APPENDIX 1

APPENDIX 2

APPENDIX 3

UNIT REMOVAL PROCEDURES

REMOVAL PROCEDURE OF INDOOR UNIT - 9K - 12K 115V

1. External features

Overview of external features.

2. Removing air filters

Procedure for removing indoor unit air filters.

3. Remove front panel

Procedure for removing the front panel of the indoor unit.

4. Remove electric box cover

Procedure for removing the electric box cover.

5. Remove front case assembly

Procedure for removing the front case assembly.

6. Remove the Vertical blade

Procedure for removing the vertical louver.

7. Remove electric box

Procedure for removing the electrical box.

Remove fan motor signal wire

Procedure for removing the fan motor signal wire.

8. Remove the refrigerant piping.

Procedure for disconnecting refrigerant piping.

9. Remove the heat exchanger.

Procedure for removing the heat exchanger.

Heat Exchanger Removal Steps

Loosen screws, widen piping, pull heat exchanger.

Fan and Motor Component Removal

Remove cross flow blade, fan motor, and bearings.

Motor Sub-Assembly Removal

Procedure to remove the motor sub-assembly and fan motor.

REMOVAL PROCEDURE OF OUTDOOR UNIT - 9K - 12K 115V

Unit Features and Top Panel Removal

Overview of features and procedure for removing the top panel.

Grille, Panel, and Side Plate Removal

Steps to remove grille, front panel, and side plates.

Fan Motor and Electrical Box Removal

Remove fan motor, electrical box, and partition plate.

Compressor Removal

Procedure for removing the compressor.

REMOVAL PROCEDURE OF INDOOR UNIT - 12K - 18K 230V

Unit Features and Air Filter Removal

Overview of features and procedure for removing air filters.

Front Panel and Service Cover Removal

Steps for opening/closing front panel and service cover.

Front Grille and Electrical Box Removal

Procedure for removing front grille and electrical box.

Piping Fixture and Motor Pressure Plate Removal

Remove piping fixture, motor pressure plate, and shaft cushion.

REMOVAL PROCEDURE OF OUTDOOR UNIT - 12K 230V

Top Cover, Handle, and Panel Removal

Procedure to remove top cover, handle, damper, and valve cover.

Grille, Side Plate, and Fan Motor Removal

Remove grille, front panel, right side plate, fan motor.

Electrical Box and Partition Plate Removal

Remove electric box and partition plate.

Sound Blanket and Valve Coil Removal

Remove sound blanket and four-way valve coil.

Compressor and Condenser Sub-Assembly Removal

Procedure for removing compressor and condenser sub-assemblies.

REMOVAL PROCEDURE OF INDOOR UNIT - 24K 230V

Unit Features and Air Filter Removal

Overview of features and procedure for removing air filters.

Front Panel and Service Cover Removal

Steps for removing front panel and service cover.

Front Grille and Electrical Box Removal

Procedure for removing front grille and electrical box.

Piping Fixture and Motor Component Removal

Remove piping fixture, guard grille, pressure plate, and shaft cushion.

REMOVAL PROCEDURE OF OUTDOOR UNIT - 24K 230V

Top Cover and Panel Removal

Procedure to remove top cover, handle, damper, and valve cover.

Grille, Side Plate, and Electric Box Removal

Remove grille, front panel, right side plate, and electric box.

Fan Motor and Reactor/Capacitor Removal

Remove axial flow blade, fan motor, reactor, and capacitor.

Pipe and Compressor Removal

Remove suction/discharge pipes, capillary/expansion valve, and compressor.

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