Analysis Report & Solutions For Capacitor Failure V7

Analysis Report & Solutions
For Capacitor Failure

By:
TCL Air Conditioner (Zhongshan) Co., Ltd.
1 Failure Description
2 Solutions for the Failure
CONTENT 3 Reasons for the Failure
4
Control Measure of Follow-on
Production
PART 1
Failure description
PART 1 : Failure Description
Failure Occurred Analysis
Capacitor
Date: May 27th, 2019 After analysis, it was found that the outdoor PCB
Project: Starting-up Test at Super Low Temperature applied one wrong brand capacitor by mistake, which
(Inverter) had different parameter ESR and does not meet with
our requirements. Thus, the AC unit can not turn on
Description: During the testing, when outside when temperature is lower than -5℃ ， and showed
temperature reached -25℃ ， the air conditioner error code E0. It is 40% possibility which may happen
displayed error code E0. in this batch.
PART 2
Solutions for the Failure
PART 2 : Solutions for the Failure
1. For Units Installed

We suggest a returning visit to the end-users from area where the
temperature is lower than -5℃.
1 If you can do the returning visit:

Pls proceed the wiring adjustment as shown in the video on
the left.
2 If you can not do the return visit:

a) After receiving the complain from users about the AC can
not turn on in winter below -5℃, when you repairing,
please proceed the wiring adjustment as shown in the
video on the left.
b) If it is not effective, then you should replace the outdoor
PCB.
Wiring Adjustment Instruction Video
PART 2: Solutions for the Failure
2. For Units Not Been Installed
1 The risk units must be sold to the area where the

temperature is higher than -5℃ in the whole year.
If selling to area where the temperature is lower than

2 -5℃, the units must be rechecked/reworked, which can
be done by TCL’s delegated engineers.
The reworking is to add and solder one electrolytic
capacitor with the value 470uf/35V on the back of PCB,
as shown on the left picture.
3 Discuss for other solutions with TCL sales team.

PART 3
Analysis for the Failure
PART 3: Analysis for the Failure
Failure Description
• Since using the wrong brand capacitor, its ESR is much more bigger, and causes the big power ripple
voltage.
• Its power voltage is lower than the chip’s working voltage, finally causes that the outdoor PCB can’t work,
and the AC can not turn on.
Analysis 1
• The capacitor parameter fluctuation is the major reason.
• If we compare these two brand capacitors, difference are as following:
Specified Brand: ESR of the capacitor E11: 0.15Ω;
Wrong Brand Applied: ESR of the capacitor: high to 0.97 Ω
Analysis 2
• The relation between ripple voltage () and ESR ()
1
∆ 𝑈 𝑜 =∆ 𝐼 𝑜 ( 𝑅 𝐸𝑆𝑅 + )
8 𝑓 𝐶𝑜
• Therefore, as above, the bigger ESR, the bigger ripple voltage.
PART 3: Analysis for the Failure
Failure Description
• Since using the wrong brand capacitor, its ESR is much more bigger, and causes the big power ripple
voltage.
• Its power voltage is lower than the chip’s working voltage, finally causes that the outdoor PCB can’t work,
and the AC can not turn on.
Analysis 3
• The parameter difference between these two brand capacitors causes the abnormal power working
• ESR affects electrolytic capacitor to charge

and discharge power.
Power supply
• The bigger ESR, the bigger ripple voltage. voltage
• When it is at the temperature -5℃, its voltage
is lowest to 4.28V (as right diagram), which is
lower than the power chip working voltage,
Power supply
and causes the main chip to reset. Reset signal
• Thus the outdoor PCB can’t work and AC can
not turn on, then the indoor unit shows error
code E0
PART 4
Control Measure of
Follow-on Production
PART4 : Control Measure of Follow-on Production
The main cause to the failure is the wrong usage of the brand not specified in the
production, but the same material code.
Control Measures
Keep Same Capacitor Features Checklist System of Production

Material
For those different brand capacitors Checklist system of the material code,
but with the same material codes,
brand and key parameter before
keep the same feature performance,
in order to prevent problems caused production.
by using wrong material.
Checklist System of PCB Inspection and Test of PCB

production Before Delivery
For the specified brand material, the
For the specified brand material, the
brand checklist must be applied and
brand checklist must be applied and
recorded before PCB delivery.
recorded on PCB production.
THANK YOU FOR YOUR
UNDERTANDING
TCL AIR CONDITIONER

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Analysis Report & Solutions

For Capacitor Failure

2 Solutions for the Failure

CONTENT 3 Reasons for the Failure

Failure Occurred Analysis

1. For Units Installed

1 If you can do the returning visit:

2 If you can not do the return visit:

2. For Units Not Been Installed

1 The risk units must be sold to the area where the

If selling to area where the temperature is lower than

3 Discuss for other solutions with TCL sales team.

• ESR affects electrolytic capacitor to charge

Keep Same Capacitor Features Checklist System of Production

Checklist System of PCB Inspection and Test of PCB

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