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Ballu KFR-28GW/BP Series Service Manual

Split type inverter air conditioner
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SPLIT TYPE INVERTER AIR CONDITIONER
SERVICE MANUAL
KFR - 5 701GW/Y2BPE
KFR - 2 601GW/BPE*2
KFR - 2 8
GW /BPE*2
CONTENTS
2.SPECIFICATION...................................
3.OUTLINES AND DIMENSIONS..............
4.WIRING DIAGRAM ...............................
6.PERFORMANCE DATA .........................
7.CONTROL MODE ................................
8.TROUBLESHOOTING ...........................
9.SERVICE FLOW CHART......................
10.SENSOR PARAMETER ......................
12.PARTS LIST ......................................

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Summary of Contents for Ballu KFR-28GW/BP Series

  • Page 1: Table Of Contents

    SPLIT TYPE INVERTER AIR CONDITIONER SERVICE MANUAL KFR - 5 701GW/Y2BPE KFR - 2 601GW/BPE*2 KFR - 2 8 GW /BPE*2 CONTENTS 1.PART NAMES AND FUNCTIONS... 2.SPECIFICATION........3.OUTLINES AND DIMENSIONS....4.WIRING DIAGRAM ....... 5.REFRIGERANT SYSTEM DIAGRAM ..6.PERFORMANCE DATA ......7.CONTROL MODE ........

  • Page 2: Part Names And Functions

    1. PART NAMES AND FUNCTIONS KFR-2601GW/BP*2E Air inlet grille Indoor unit A Indoor unit B Air outlet Air outlet Drain hose Drain hose Front cover Outdoor unit Remote controller Refrigerant tabes Air outlet Air inlet grille: Air from the room is drawn into this section and passes through air flitters that remove dust. Air outlet: Conditioned air is blown out of the air conditioner through it.
  • Page 3 1. PART NAMES AND FUNCTIONS 2. CONTROL PANEL OF INDOOR UNIT Compressor Frequency set indoor outdoor indicator Temperature display Color LCD ON/OFF Remote Temperature control button receiver Remote control receiver Used for receiving the signal from the remote control unit Then the remote control unit is lost or has fault, this button is used to start the air Temporary button conditioner.
  • Page 4 1. PART NAMES AND FUNCTIONS REMOTE CONTROL UNIT Transmitter Sensor Transmitting signals to the indoor unit. Testing the ambient temperature of the remote controller Displaying the running condition. SET TEMP SET TEMP AUTO On/Off Button Turn the appliance on and off by pressing consecutively.
  • Page 5 1. PART NAMES AND FUNCTIONS KFR-2801GW/BP*2E INDOOR UNIT(A) Air freshing filter Air inlet grille Air filter Indoor coil sensor Air inlet Vertical vane Air outlet Horizontal vane INDOOR UNIT(B) air inlet grille air freshing filter air filter indoor coil sensor air inlet impeller (left-right adjustment)
  • Page 6 1. PART NAMES AND FUNCTIONS OUTDOOR UNIT` Air inlet (rear and side) Tubes and cable Drainage hose Air outlet Drainage hole(bottom) Valve cover...
  • Page 7 1. PART NAMES AND FUNCTIONS Remote Control Unit Transmitter Sensor Transmitting signals to the indoor unit Detecting the ambient temperature of the remote controller Indicating the operation SET TEMP AUTO On/Off Button Turn the appliance on and off by 1-hour timer pressing the button consecutively.
  • Page 8 1. PART NAMES AND FUNCTIONS KFR-5701GW/Y2BPE KFR-2501G/Y Air inlet grille Indoor unit Front panel KFR-3201G/Y Air outlet Air inlet grille Front panel Hisense Drainage hose Remote control unit Air outlet Hisense Refrigerant tubes Drainage hose Remote control unit Outdoor unit Air outlet Your air conditioner consists of two indoor units and an outdoor unit.
  • Page 9 1. PART NAMES AND FUNCTIONS KFR-5701GW/Y2BPE CONTROL PANEL OF INDOOR UNIT Compressor Frequency set indoor outdoor indicator Temperature display Color LCD ON/OFF Remote Temperature control button receiver Remote control receiver Used for receiving the signal from the remote control unit When the remote control unit is lost or has fault, this button is used to start the air Temporary button conditioner.
  • Page 10 1. PART NAMES AND FUNCTIONS KFR-5701GW/Y2BPE REMOTE CONTROL UNIT Transmitter Sensor Transmitting signals to the indoor unit. Testing the ambient temperature of the remote controller Displaying the running condition. SET TEMP SET TEMP AUTO On/Off Button Turn the appliance on and off by pressing consecutively.

  • Page 11: Specification

    2.SPECIFICATION Model KFR-28GW/BP*2E Function Cooling(S) Cooling(D) Heating(S) Heating(D) Power supply a.c 220V~ 50Hz Capacity Capacity l /h Dehumidification Air flow 1020 1020 Power outlet Running current 11.0 13.0 Power input 2.05 2.50 Electrical data Auxiliary heater A(KW) Power factor Starting current Compressor motor current INDOOR 0.288/0.206/0.146 Fan motor current...
  • Page 12 2.SPECIFICATION KFR-2601GW/BP*2E Model Function Cooling (S) Cooling(D) Heating(S) Heating(D) Power supply AC220V~ 50Hz Capacity Capacity Dehumidification l /h Air flow Power outlet Running current 12.0 Power input 1870 2400 Electrical data Auxiliary heater A(KW) ---- Power factor Starting current Compressor motor current Fan motor current INDOOR 0.288/0.206/0.146 Coefficient of performance(C.O.P)
  • Page 13 2.SPECIFICATION Model KFR-5701GW/Y2BPE Function Cooling(S) Cooling(D) Heating(S) Heating(D) Power supply a.c 220V~ 50Hz Capacity 2.5/3.2 3.6/4.8 Capacity Dehumidification l /h 1.2/1.5 1.2/2.0 Air flow 360/500 380/550 Power outlet Running current Power input 2.55 3.00 Electrical data Auxiliary heater A(KW) Power factor Starting current Compressor motor current Fan motor current...
  • Page 14 5.REFRIGERANT SYSTEM DIAGRAM 3.OUTLINES AND DIMENSIONS KFR-28G/BPEX2...

  • Page 16: Wiring Diagram

    4.WIRING DIAGRAM KFR-2601GW/BPE*2 INDOOR UNIT £¨ 3 £© Evaporator Terminal board Heat Indoor exchanger temp. temp. Power transformer £¨ 1 £© £¨ 2 £© £¨ 4 £© BLK BLK BLK BLK Magnetic ACIN1(L)ACIN2(N) COIL ROOM coil (WHT) (RED) FLAP Step motor Control board HALL PULSE DISPLAY...
  • Page 17 4.WIRING DIAGRAM KFR-2601GW/BPE*2 OUTDOOR UNIT CONDENSOR SENSOR OUTDOOR SENSOR DISCHARGE SENSOR.
  • Page 18 4.WIRING DIAGRAM KFR-2801GW/BPE*2 INDOOR UNIT TERMINAL PANEL YEW/GRN BLK WHT EVAPORATOR FILTERING LOOP BLK WHT CONTROL BOARD AC IN (BLK) SI YEW VERT FLAP1 WHT MOTOR POWER PANEL DC-CONT DC-CONT HORI FLAP3 BLK MOTOR (LEFT) HORI MOTOR FLAP2 RED (RIGHT) LAMP(BLK) RED WHT BLU POWER...
  • Page 19 4.WIRING DIAGRAM KFR-2801GW/BPE*2 OUTDOOR UNIT CONDENSOR SENSOR OUTDOOR SENSOR DISCHARGE SENSOR.
  • Page 20 4.WIRING DIAGRAM INDOOR UNIT (KFR-2501G/Y BPE) WIRING DIAGRAM £¨ 3 £© Evaporator Terminal plate Heat Indoor exchanger temp. temp. Power transformer £¨ 1 £© £¨ 2 £© £¨ 4 £© BLK BLK BLK BLK Magnetic ACIN1(L)ACIN2(N) COIL ROOM loop (WHT) (RED) FLAP Step motor...
  • Page 21 4.WIRING DIAGRAM INDOOR UNIT (KFR-3201G/Y BPE) WIRING DIAGRAM INDICATOR BOARD ELECTRICAL WIRING DIAGRAM CONTROL BOARD +5V(CN01.1) +5V(CN08.1) TERM.PANEL GND(CN01.2) GND(CN08.2) CS(CN01.3) AC IN1 CS(CN08.3) SO(CN08.4) SO(CN01.4) AC OUT1 SCK(CN08.5) CLK(CN01.5) ACIN2(CN06.2) REMOTE(CN08.6) REMOTE(CN01.6) (SI) SI(CN06.1) BRIGHT(CN02.1) BRIGHT(CN02.1) -27V(CN02.2) -27V(CN02.2) 4.6B(CN02.3) 4.6B(CN02.3) L E N 4.6A(CN02.4)
  • Page 22 4.WIRING DIAGRAM OUTDOOR UNIT(KFR-5701W/Y2BPE) WIRING DIAGRAM CONDENSOR SENSOR OUTDOOR SENSOR DISCHARGE SENSOR.

  • Page 25: Refrigerant System Diagram

    5.REFRIGERANT SYSTEM DIAGRAM EVACUAT ION PROCEDURES Connect the refrigerant pipes (both the liquid and gas pipes ) between the indoor and the outdoor units. Remove the se rvice port cap of the stop valve on the sid e o f the out doo r unit ga s pipe .
  • Page 26 COOLING CAPACITY Indoor Outdoor intake air DB Ñ ° model Intake Air (WB ) Ñ ° KFR-2801GW/BPE 3163 1431 3059 1394 2826 1402 2579 1429 2252 1421 2016 1444 (220V) 3219 1317 3171 1410 3016 1400 2764 1397 2512 1421 2219 1466 3305...
  • Page 27 HEATING CAPACITY Indoor Outdoor intake air WB ° Ñ model Intake Air (DB ) ° Ñ KFR- 2993 1592 3335 1700 3810 1804 4121 1736 4175 1556 4025 1363 2801GW/B 2917 1674 3431 1832 3651 1793 3952 1667 3988 1461 3928 1298 (220V)
  • Page 28 COOLING CAPACITY Outdoor intake air DB 　 Indoor ° Ñ Indoor unit Intake Air model Ñ (WB ) ° 2668 2675 1144 2602 1147 2569 1244 2403 1377 2196 1474 KFR- 3069 1066 2822 1144 2928 1169 2749 1269 2599 1397 2354 1469...
  • Page 29 HEATING CAPACITY Indoor Outdoor intake air WB ° Ñ Indoor unit Intake Air model (DB ) ° Ñ 2781 1531 3037 1609 2780 1531 3774 1652 4143 1663 4055 1401 3375 1136 KFR- 1837 2808 1672 1837 3571 1686 3800 1637 3710 1370...

  • Page 30: Control Mode

    7.CONTROL MODE Section 1 Main Control Features Control features of remote controller (refer to the Use and Installation Manual) Display on the indoor unit (1) Display on the indoor unit KFR-28GW/BPx2/2801 GW/BPx2 “Run ” indicator lamp, green; it is on when the air conditioner is running (Run-mode). “Standby”...
  • Page 31 7.CONTROL MODE LCD Back Lighting When the air conditioner is in run mode, the background of the LCD is lighted up. For different run modes, the background shows different colors as follows: Cooling Heating Dehumidifying Airflowing Automatic green green orange automatic display according to the specific mode.
  • Page 32 7.CONTROL MODE Section 2 Run Mode of Air Conditioner Use the remote controller, and set the air conditioner in the following run modes: automatic, heating, cooling, dehumidifying and air freshening. 1. Automatic (1) When Troom temperature Ttemperature setting, the air conditioner is running in the cooling mode; (2) When Troom temperature Ttemperature setting, the air conditioner is running in the heating mode.
  • Page 33 7.CONTROL MODE b. Model KFR-2601 GW/BPõ2Å Single Double Minimum Maximum Rated Frequency Minimum Maximum Rated Frequency (4) Control of four-way valve The four-way valve is always in the cut-off position. (5) Outdoor fan motor T outdoor temperature 28 , High airflow rate °Ñ...
  • Page 34 7.CONTROL MODE 4. Heating mode (1) If Tindoor coil pipe °Ñ , the indoor fan runs according to the airflow settings on the remote controller. a. Model KFR-28GW/BPx2/2801 GW/BPx2 Low: 900 rpm Medium: 1,100 rpm High: 1,200 rpm High efficiency: 1,300 rpm b.
  • Page 35 7.CONTROL MODE (6) Control of electronic expansion valve Primary valve openness control, overheat control, exhaust control and capacity control. (7) Defrost run The defrost run is carried out by reversing the heating cycle. Conditions for entering the defrost run: The heating run has last for at least 30 minutes; Other conditions (to be added in) C.
  • Page 36 7.CONTROL MODE 6. Perfect protection functions of the air conditioner 1. Abnormal sensor: In case an indoor or outdoor sensor is short circuited or open circuited, the compressor gets stopped. 2. Abnormal IPM (power module) In case IPM gets in trouble such as overheat (100 ), overcurrent (28A), short circuit (51A) and too low °Ñ...

  • Page 37: Troubleshooting

    8. TROUBLESHOOTING In case of occurrence of a trouble during operation, the system stops itself, and then the trouble description is displayed. If you want the trouble description to be reappeared, press the “Sensor Switch” button and set the remote controller to the “Self Temperature Control”...
  • Page 38 8. TROUBLESHOOTING Malfunction of IPM power module Incorrect outdoor PROM data Outdoor air circulation temperature sensor in trouble b. KFR-2601 GW/BPx2E Code Description of Trouble Cause of Trouble Room temperature sensor abnormal Thermistor short-circuited or open circuited Heat exchanger temperature sensor Thermistor short-circuited or open circuited abnormal Heat exchanger frozen...
  • Page 39 ° 8. TROUBLESHOOTING 3.6 Abnormal power supply voltage protection When the supply voltage is above 260V or below 150V, the compressor stops, and the trouble code is displayed. 3.7 Overhot protection for the indoor heat exchanger When the temperature of the indoor coil 70 , the compressor will stop; Ñ...
  • Page 40 6.PERFORMANCE CURVES 9.SERVICE FLOW CHART 5.REFRIGERANT SYSTEM DIAGRAM 5.REFRIGERANT SYSTEM DIAGRAM Switch on the power supply Does it receive Does LED screen Start up self-diagnosis the signal of display function remote controller? Normally? Check the result Is the fuse blown? Remote controller Is remote trouble or replace the...

  • Page 41: Service Flow Chart

    9.SERVICE FLOW CHART 5.REFRIGERANT SYSTEM DIAGRAM Running and standby light flicker(*3) Indoor heat exchanger Is Running light flickers(*4) freezed indoor heat exchanger Is over load Indoor coil Is indoor heat sensor trouble exchanger freezed Is indoor heat Indoor coil exchanger very hot? sensor trouble Is the indoor Fan motor or...
  • Page 42 9.SERVICE FLOW CHART 5.REFRIGERANT SYSTEM DIAGRAM Timer and running indicator flicker(*5) Communication trouble Connect the indoor Indoor control Are all the lead and outdoor unit board trouble and wires connected again according to replace it between indoor and the wiring diagram outdoor unit? Does the power Replace the outdoor...
  • Page 43 9.SERVICE FLOW CHART 5.REFRIGERANT SYSTEM DIAGRAM Indoor fan motor trouble (No trouble display) Set the air conditioner operate in fan mode Does fan motor Is indoor fan stop with the Fan motor trouble and motor running? remote replace it controller Does the socket of Indoor control board indoor control board...
  • Page 44 9.SERVICE FLOW CHART 5.REFRIGERANT SYSTEM DIAGRAM Running and standby indicator light up(#3) Standby and timer Comprssor over hot indicator light up(#6) protection Over current trouble Swich off and Is the operating Normal Is the surface of Normal start up current beyond protection compressor very hot? protection...
  • Page 45 9.SERVICE FLOW CHART 5.REFRIGERANT SYSTEM DIAGRAM High power and timer indicator light up(#12) IPM trouble Does the trouble Is the IPM trouble appear diappear in 3 IPM radiator very frequently? minutes ? hot? Normal protection Assure good ventilation Start up the air of outdoor Is the conditioner in 30...
  • Page 46 5.REFRIGERANT SYSTEM DIAGRAM 6.PERFORMANCE CURVES 5.REFRIGERANT SYSTEM DIAGRAM 9.SERVICE FLOW CHART KFR-28G/BPE*2...
  • Page 47 6.PERFORMANCE CURVES 9.SERVICE FLOW CHART 5.REFRIGERANT SYSTEM DIAGRAM 5.REFRIGERANT SYSTEM DIAGRAM KFR-2601G/BPE*2 KFR-2501G/BPE...
  • Page 48 5.REFRIGERANT SYSTEM DIAGRAM 6.PERFORMANCE CURVES 5.REFRIGERANT SYSTEM DIAGRAM 9.SERVICE FLOW CHART KFR-3201G/BPE...
  • Page 49 6.PERFORMANCE CURVES 9.SERVICE FLOW CHART 5.REFRIGERANT SYSTEM DIAGRAM 5.REFRIGERANT SYSTEM DIAGRAM KFR-5701W/Y2BPE...

  • Page 50: Sensor Parameter

    10.SENSOR PARAMETER THE PARAMETER OF THE INDOOR COIL SENSOR, OUTDOOR SENSOR AND HEAT EXCHANGER SENSOR T('c) R(Ko) V(v) T('c) R(Ko) V(v) T('c) R(Ko) V(v) - 20 39. 58 0. 5307 10. 1 1. 5878 3. 265 2. 9504 - 19 37.
  • Page 51 10.SENSOR PARAMETER THE PARAMETER OF THE DISCHARGE SENSOR T('C) R(O) V(v) T('C) R(O) V(v) T('C) R(O) V(v) - 10 313. 4 0. 3 44. 74 1. 545 9. 659 3. 372 297. 2 0. 315 42. 89 1. 59 9. 331 3.

  • Page 52: Disassembly Instructions

    11. DISASSEMBLY INSTRUCTIONS KFR-2601G/BPE*2 Front Panel 1. Remove the grille 1) Open the screw cover of the grille. 2) Take out the screws of the grille. 3) Hold both sides of the grilleand drag it towards oneself, shown the operation switching board of the indoor unit. Screws 2.
  • Page 53 11. DISASSEMBLY INSTRUCTIONS KFR-2601G/BPE*2 3. Remove the air outlet 1) Take out the screws of the air outlet. 2) Remove the atepper motor. 3) Disconnect the drainage hose and the air outlet. 4) Remove the air outlet. Screws 4. Remove the evaporator 1) Disconnect the evaporator and the other parts, Take out the screws of the evaporator and Screws...
  • Page 54 11. DISASSEMBLY INSTRUCTIONS KFR-28G/BPE*2...
  • Page 55 11. DISASSEMBLY INSTRUCTIONS KFR-28G/BPE*2 4.Remove the evaporator 1) Disconnect the evaporator and the other parts¬take out the screws and remove the evaporator. Screws Air outlet Screws Fan motor Cross-flow fan Screw 5. Remove the cross-flow fan and the fan motor 1)Take out the screws and remove the rubber ring.
  • Page 56 11. DISASSEMBLY INSTRUCTIONS KFR-2601G/BPE OPERATION PROCEDURE PHOTOS Front Panel 1.Remove the grille 1) Open the screw cover of the grille. 2) Take out the screws of the grille. 3) Hold both sides of the grilleand drag it towards oneself, shown the operation switching board of the indoor unit. Screws 2.
  • Page 57 11. DISASSEMBLY INSTRUCTIONS KFR-2601G/BPE R emove the air outlet ．　 1) Take out the screws of the air outlet. 2) Remove the atepper motor. 3) Disconnect the drainage hose and the air outlet. 4) Remove the air outlet. Screws 4. Remove the evaporator 1) Disconnect the evaporator and the other parts,Take out Screws the screws of the evaporator and remove the evaporator.，...
  • Page 58 11. DISASSEMBLY INSTRUCTIONS KFR-3201G/BPE OPERATION PROCEDURE PHOTOS Front Panel 1. Remove the grille 1) Open the front panel. 2) Take out the screws in the grille. 3) Hold the both sides of the grille, dragging towards oneself and then remove it. Screws 2.
  • Page 59 11. DISASSEMBLY INSTRUCTIONS KFR-3201G/BPE 4. Remove the evaporator 1) Disconnect the evaporator and the other parts then remove Screws the screws of the evaporator. 2) Remove the evaporator. Fan Motor Motor Cover 5.Remove the cross-flow fan and the fan motor 1) Take out the screws of the motor cover and remove the cover.
  • Page 60 11. DISASSEMBLY INSTRUCTIONS KFR-5701W/Y2BPE PHOTOS OPERATING PROCEDURE 1.Remove the front panel Front panel Side cover Screws Remove the valve cover. Remove the side cover. Remove the front panel. Valve cover Screws Screws Back guard Screws...
  • Page 61 11. DISASSEMBLY INSTRUCTIONS PHOTOS OPERATING PROCEDURE Electrical control box ass'y Fan motor wire 2. Remove the outside fan 1) Turn the nut which fix the outside Fan in anti-clockwise and remove the outside fan. Outside fan Noise defending cover Fan motor Fan motor wire 3.
  • Page 62 11. DISASSEMBLY INSTRUCTIONS PHOTOS OPERATING PROCEDURE Electrical control box ass'y Screws 4. Remove the electrical control Box ass'y Back guard 1) Remove all the terminals of the electrical control box ass'y. 2) Take out the screws and remove the electrical control box.

  • Page 63: Parts List

    12. PARTS LIST KFR-2501G/BPE KFR-2601G/BPE*2...
  • Page 64 12. PARTS LIST KFR-2801G/BPE*2...
  • Page 65 12. PARTS LIST KFR-2601G/BPX2E KFR-2501G/BPE Key No. Part No. Description Q'ty Q'ty Steppor Motor 529- 0- 0000- 062- 0A- 0 Cross-Flow Fan Ass’y 852- 0- 2509- 206- 00- 0 852- 0- 2510- 128- 00- 1 Bearing Ass’y RZA-0-0000-001-XX-0 Fan Motor RZA-0-5172-155-XX-0 PCB Ass’y Remote Controller...
  • Page 66 12. PARTS LIST KFR-3201G/BPE...
  • Page 67 12. PARTS LIST KFR- 3201G / BPE Key NO. Description Quantity Part NO. Front Panel RZA-2-1601-003-XX-0 Air Filt er RZA-0-2305-005-XX-0 Electrical Control Box cover RZA-2-2369-006-XX-0 Display panel RZA-0-2258-003-XX- Grille Ass’y RZA-0-1501-004-XX-0 Water Plate RZA-0-2326-102-XX-0 Evaporator Supportor RZA-2-2219-014-XX-0 Evaporator Ass’y RZA-0-0055-033-XX-0 Bearing Ass’y RZA-0-2510-100-XX-0 RZA-0-2509-100-XX-0...
  • Page 68 12. PARTS LIST KFR-2601W/BPE*2...
  • Page 69 12. PARTS LIST ATTENTION ! OUTDOOR UNIT To ensure correct parts supply, please let us know followings. When you make service parts order: 1. Part NO. 2.Description 3.Q’ty Part No. Description Q’ty 852-0-4526-119-00-1 Compressor Ass’y 852-0-4509-118-00-2 Solenoid Valve Ass’y 852-0-4206-821-00-2 Tube Ass’y Capillary 852-0-4206-822-00-2 Tube Ass’y Capillary...
  • Page 70 12. PARTS LIST Key No. Part No. Description Q’ty 852-0-4507-344-00-1 Nipple Ass’y 852-2-2309-744-01-0 Mounting Plate 852-0-2506-178-00-0 Fan Support Ass’y 801-2-6194-134-00-2 Cover Terminal 801-2-5303-142-00-2 Gasket Terminal 852-0-5301-427-01-0 ELEC. Component box Ass’y 4-2379-562-22-0 Terminal Base 4-2379-510-10-1 Terminal Base 852-2-5301-290-01-0 Clip Capacitor 852-2-2487-112-01-0 Mounting 852-2-5304-179-01-0 Clip Wire...

This manual is also suitable for:

Kfr-2601gw/bp seriesKfr-5701gw/y2bpeKfr-28g/bpex2Kfr-2501g/y2bpeKfr-3201g/y2bpeKfr-3001gw/bpe

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