ComfortStar CSA36CD Service Manual

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Split-Type Air Conditioner

On/Off

NO.

MODEL

NO.

MODEL

CSA36CD

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Summary of Contents for ComfortStar CSA36CD

Page 1 Split-Type Air Conditioner On/Off MODEL MODEL CSA36CD...
Page 2 This manual is for professional maintenance personnel only...
Page 3: Table Of Contents
CONTENTS Part I : Technical Information ........Error! Bookmark not defined. 1. Summary ......................4 1-1 Appearance .........................4 1-2 Model List ..........................7 2. Outline Dimension Diagram ................2-1 Indoor Unit...........................8 2-2 Outdoor Unit ........................10 3. Specification sheet ....................4. Function and Control ..................4-1 L-Style ..........................
Page 4: Appearance
1. Summary 1-1 Appearance  Indoor Unit  Outdoor Unit Note: The outdoor grille can be replaced.
Page 5: Outline Dimension Diagram
2. Outline Dimension Diagram The following data is for reference only and the actual size may vary. 2-1 Indoor Unit（Unit：mm） 2-2 Outdoor Unit（Unit: mm）...
Page 6 4. Function and Control 4-1 H-Style 1) Remote Controller Introduction  Introduction for Buttons on Remote Controller Note： All the figures above are the displays after being initially electrified or re-electrified after power off. In actual operations, the remote controller screen displays related items only.
Page 7 * Press this button to set the temperature display to Fahrenheit, which is displayed by default in Celsius. The “℃” will not be displayed on the LCD. * Press this button again to restore the temperature display to Celsius. Note: Temperature display in Fahrenheit is not available for some models. When temperature is displayed in Fahrenheit on the remote controller, it might be in Celsius on the unit, the function and operation of which will not be affected.
Page 8 c. Some area don't have the YKR-H/132E.Local regulation and actual object shall prevail. Note: The temperature cannot be set in AUTO or Fan mode, thus these two buttons are not functional. 9. TURBO * Press this button only in COOL or HEAT mode to set TURBO on or off to speedy the cooling or heating.
Page 9 b. ECO (Optional) * If this button is pressed in COOL mode, the unit will enter the ECO mode which has the lowest electricity consumption, and exit it automatically 8 hours after. * Changing modes or turning off the remote controller will automatically cancel the ECO function.
Page 10: Refrigerant System Diagram
• Ensure the remote controller is pointed to the signal receiving Window and that there is no obstruction in between and the distance is 8m at the maximum. • Do not let the remote controller drop or fling it at will. Do not let any liquid in the remote controller.
Page 11: Electrical Part
Indoor heat exchanger Compressor (Evaporation) (Compression) Liquid of low Gas of high pressure & pressure temperature (also a little gas) Super cooled liquid of high pressure Capillary Outdoor heat exchanger (Throttling) (Condensation) 6. Electrical Part 6.1 Wiring Diagram  Indoor Unit CSA36CD(I)
Page 12  Outdoor Unit CSA36CD(O)
Page 13: Part Ii : Installation And Maintenance
Part II : Installation and Maintenance 7. Main Tools for Installation and Maintenance...
Page 14: Installation
8. Installation 8-1 Notes for Installation Important Notices  Before installation, please contact with local authorized maintenance center, if unit is not installed by the authorized maintenance center, the malfunction may not solved, due to discommodious contact.  The air conditioner must be installed by professionals according to the national wiring rules and this manual.
Page 15: Installation Of Indoor Unit
 The power cable enables communication between the indoor and outdoor units. You must first choose the right cable size before preparing it for connection. Grounding Requirements  The air conditioner is the type I electrical appliance and must ensure a reliable grounding.
Page 16 1. The wall for installation of the indoor unit shall be hard and firm, so as to prevent vibration. 2. Use the "+" type screw to fasten the peg board, horizontally mount the peg board on the wall, and ensure the lateral horizontal and longitudinal vertical. 3.
Page 17 Tightening torque table The size of pipe(mm) Torque(N·m) Φ6/Φ6.35 15～25 Φ9 /Φ9.5 2 35～40 Φ12/Φ12.7 45～60 Φ15.88 73～78 Φ19.05 75～80  Wrap the Piping 1. Use the insulation sleeve to wrap the joint part the indoor unit and the connection pipe, and then use insulating material to pack and seal insulation pipe, to prevent generation of condensate water on the joint part.
Page 18: Installation Of Outdoor Unit
● Fix the cable reliably with fasteners (Pressing board). ● Put the E-parts cover back in its original place and fasten it with screws. Wiring Diagram NOTE: ※ This manual usually includes the wiring mode for the different kind of A/C. We cannot exclude the possibility that some special type of wiring diagrams are not included.
Page 19  Install the connection pipe Connect the Outdoor Unit with Connecting Pipe: Aim the counter-bore of the connecting pipe at the stop valve, and tighten the Taper nut with fingers. Then tighten the Taper nut with a torque wrench. ★When prolonging the piping, extra amount of refrigerant must be added so that the operation and performance of the air conditioner will not be compromised.
Page 20 Wiring Diagram NOTE: ※ This manual is usually includes the wiring mode for the different kind of A/C. We cannot exclude the possibility that some special type of wiring diagrams are not included. ※ The diagram are for reference only. If the entity is difference with this wiring diagram, please refer to the detailed wiring diagram adhered on the unit which you purchased.
Page 21: Check After Installation And Test Operation
vacuum pumping method) Before working on the air conditioner, remove the cover of the stop valve(gas and liquid valves)and be sure to retighten it afterward.(to prevent the potential air leakage) 1. To prevent air leakage and spilling tighten all connecting nut of all flare tubes. 2.
Page 22 ④ Check that no foreign matter or tools are left inside the unit. ★ Leak test of the refrigerant Depending on the installation method, the following methods may be used to check for suspect leak, on areas such as the four connections of the outdoor unit and the cores of the cut-off valves and t-valves: ①...
Page 23: Maintenance
9. Maintenance 9-1 Troubleshooting Guide Many error codes many appears on this air conditionor, and this troubleshooting guide is prepared for the maintenance personnel to detect the error position and the parts to be replaced during the troubleshooting process. In this Guide, the Troubleshooting Method is guided by the Error Name, and the Reference Code under the General Index is the error code of the Indoor Unit unit of the mainstream model supplied by the Company.
Page 24 Example: Cause: explain the principle of the specific error. Explanation Inspection path: The basic order of troubleshooting. Related key of error position Tools that should be carried for such troubleshooting, and Tools required for inspection replacing parts that may be necessary for such error. Frequent Any possibly broken part related to the error may be the parts that problematic...
Page 25 （1）E0 - Overcurrent Protection of Indoor Unit Cause: The main PCB detects that the working current of the system exceeds the upper limit of protection, and will indicate "indoor unit overcurrent protectin:. The air conditioner stopps running for protection and displays the failure code E0. Explanation of error Inspection path: current transformer →...
Page 26 （2）E1- Indoor Unit temperature sensor error Cause: The detection of short circuit or open circuit of Indoor Unit temperature sensor during the inspection of main PCB in the Indoor Explanation of Unit machine, indicated by “Indoor Unit temperature sensor error”. error Inspection path: Sensor→Sensor wire→Connectors→Indoor Unit main PCB...
Page 27 Most Indoor Unit temperature sensors have a resistance value of 15KΩ. Do not use improper sensor during repairing and maintenance, or it may led to the wrong temperature sensing of the machine, the start error or shutdown error. You can switch the air conditioner to the “Blowing”...
Page 28 Most Indoor Unit temperature sensors have a resistance value of 20KΩ. Do not use improper sensor during repairing and maintenance, or it may led to the start of protection mode due to wrong temperature sensing of the machine, or the protection error. In case a sensor with the resistance value over 20KΩ...
Page 29 Most Indoor Unit temperature sensors have a resistance value of 20KΩ. Do not use improper sensor during repairing and maintenance, or it may led to the start of anti-frosting or overheat protection mode due to wrong temperature sensing of the machine. In case a sensor with the resistance value over 20KΩ...
Page 30 （ 5） E4 -Indoor Unit motor error of wall mounted air conditioner （ PG motor） Cause: PG motor is equipped with speed feedback signal line. When the feedback signal of speed is not received by the Indoor Unit main PCB, it has no way to recognize the rotating speed of motor, which will be indicated as “Indoor Unit motor error”.
Page 31 (6) E4- Indoor Unit motor error of wall mounted air conditioner (DC motor) Cause: The Indoor Unit motor of some highly energy efficient models is DC motor using a green plug through which the Indoor Unit main PCB can drive the motor and sense the current rotational speed feedback.
Page 32 Five lead wires division: Count from the outermost side of the four wires of the DC motor terminal, the first blue wire is the speed feedback wire with a voltage of 0.5-5V when the motor rotates; the second yellow wire is the motor driving wire with a voltage of 2.0-7.5V when the motor rotates;...
Page 33 (8) P2- High-pressure protection Cause: In standby state or when the equipment is running, the high-pressure switch is disconnected three times (within 20 minutes) and reported as " High-pressure protection"; Explanation of Inspection path: high-pressure switch cable → connector → error high-pressure switch →...
Page 34 The reason why high-pressure switches are often disconnected is the leakage of equipment. When the high voltage switch is off, first check whether the air conditioner's pressure is normal. If it is normal but the Special attention failure is still displayed aftere replacing the Outdoor Unit main PCB, it is possible that the connecting pipe may be too long or the Outdoor Unit ambinet temperature is too low (9) P3- Liquid Deficiency Protection...
Page 35: Troubleshooting For Normal Malfunction
9-2 Troubleshooting for Normal Malfunction  The Foremost Inspecting Items ① The input voltage must be within +10% tolerance of the rated Voltage. If it is not the case, the air-conditioner will probably not work normally. ② Check the connecting cord between indoor unit and outdoor unit to see if it is properly connected.
Page 36 The compressor stops running but If you turn off the air-conditioner and the indoor motor keeps working restart it immediately, it will return to when it is at cooling mode with the normal in 3 minutes, after that, the indoor temperature higher than set air-conditioner will automatically adjust temperature.
Page 37 ②The Indoor Motor Does Not Work (1) Items a) Check if the indoor Motor is connected correctly to the connector (CN8)? b) Check if the AC input voltage is correct? c) Check if the IC of indoor Motor is connected correctly to the connector (CN2)? d) Check if the capacity of indoor Motor is connected correctly to the connector (CN8)? (2) Trouble shooting procedure...
Page 38 ③The Outdoor Unit Does Not Work (1) Items a) Check if the input voltage is correct? b) Check if the wire connection of the outdoor connecting terminal is correct? (2) Trouble shooting procedure...
Page 39 ④The Step Motor Does Not Work (1) Items a) Check if the input voltage is correct? b) Check if the step motor controlling the up-down movement firmly connected to Cn2? (2) Trouble shooting procedure...
Page 40 ⑤Heating Mode Can Work, But No Hot Air Blow (1) Check if the set temperature is lower than the indoor temperature? (2) Check if the indoor PCB is connected to the terminal correctly?
Page 41 ⑥ Remote Control Can Not Work Trouble shooting procedure...
Page 43: Exploded Views And Parts List
10. Exploded Views and Parts List 10-1 Indoor Unit Part List Part Name Quantity Part Name Quantity Evaporator assembly panel Evaporator left side Display board 13.1 carriage Evaporator part A Air louver 13.2 Evaporator part B Filter 13.3 Medium frame Motor cover decorative strip Left side panel...
Page 44: Outdoor Unit
Air louver Terminal board 19.7 Chassis Control box cover Drain jam Remote controller Medium frame Shaft sleeve wiring cover Step motor Screw cover 9.10 Bearing assembly Outlet pipe assembly Bearing fixed Drain hose chassis Cross flow motor 10-2 Outdoor Unit Part List Part Name Quantity...
Page 45: Removal Procedure
assembly Compressor Motor capacitor footing bolt Base footing Capacitor clamp Compressor Partition board capacitor Panel grille Terminal board Panel Cable clamp Axial flow motor Cable clamp Motor E-parts bracket Motor support Accessories Hanging ear of Putty 26.1 condenser Rear grille Plastic tie Left side board 11.
Page 46 Remove front Panel Remove air louver Remove air filter...
Page 47 Remove article decoration Remove medium frame cover Remove medium frame...
Page 48 Remove Control the lid Remove Electric box Remove high pressure dust removal generator...
Page 49 Remove evaporator Remove motor press plate Remove the blade Remove motor...
Page 50 Remove Stepper motor Remove protect fingers of strainer Remove volute tongue, guide vane, connecting rod...
Page 51: Outdoor Unit
11-2 Outdoor Unit Part Procedure Diagram Turn off the power , remove connection screws among top cover plate, front panel and right side panel, then remove the top cover. Remove the control box cover Remove connection screws between the front grille and the front panel .Then remove the front grille.
Page 52 Remove connection screws connecting the front panel with the chassis and the motor support , and remove the front pannal. Remove connection screws Connecting the right side panel, then remove the E-part cover. Remove connection screws connecting the right side panel with the valve support and electric box, then remove the right side panel.
Page 53 Remove the nut fixing the blade and then remove the axial flow blade. Remove the tapping screws fixing the motor, pull out the lead-out wire and remove the motor. Loosen the wire and disconnect the terminal.Lift to remove electrical rack...
Page 54 Remove the tapping screws fixing the motor support . Lift motor support to remove it. Remove 2 connection screws Connecting the partition board, remove the reactor. Loosen the screws of the partition board， then lift and pull the partition board to remove .
Page 55 Remove connection screws connecting the left side support plate with the valve support, then remove the left side support plate. After the unit is discharged, Unscrew the fastening nut of the 4-way Valve Assy coil and remove the pipeline assembly. Remove the screws fixing the gas valve.
Page 56 Loosen 1 footing screws of valve plate, remove the valve plate. Loosen 3 footing screws of compressor, Remove and remove the compressor. Loosen 2 fixing screws Connecting chassis, and remove the condenser. Last remaining chassis.
Page 57: Appendix
Appendix Common Sensor R-T Analysis Table Temperature sensor R-T analysis table （15K ） Sensor standard resistance：15KΩ±3% B:B(25/50)=3950K±2％Reference temperature：25（℃） MCU_A/D exchange ±3LSB（at10bit） Series (sampling) resistor：10（KΩ）±1％ (except disk sensor) Single chip (A/D reference voltage) supply voltage：5V Temp Resistance（KΩ） MCU Input voltage（V） A/D Exchange value （℃）...
Page 58 31.50 32.99 34.52 1.114 1.163 1.214 30.03 31.42 32.84 1.158 1.207 1.258 10.0 28.64 29.94 31.26 1.203 1.252 1.304 11.0 27.32 28.53 29.77 1.248 1.298 1.350 12.0 26.07 27.20 28.35 1.294 1.344 1.396 13.0 24.89 25.94 27.01 1.341 1.391 1.443 14.0 23.76 24.74...
Page 59 53.0 4.553 4.802 5.060 3.309 3.378 3.446 54.0 4.382 4.625 4.877 3.350 3.419 3.487 55.0 4.219 4.457 4.703 3.390 3.459 3.527 56.0 4.061 4.293 4.534 3.429 3.498 3.566 57.0 3.911 4.137 4.373 3.468 3.537 3.604 58.0 3.767 3.988 4.218 3.506 3.574 3.642 59.0...
Page 60 98.0 0.9826 1.068 1.160 4.476 4.518 4.557 99.0 0.9535 1.037 1.127 4.489 4.530 4.569 100.0 0.9252 1.007 1.095 4.502 4.543 4.580 101.0 0.8981 0.9778 1.064 4.515 4.555 4.592 102.0 0.8717 0.9497 1.034 4.527 4.566 4.603 103.0 0.8463 0.9225 1.005 4.539 4.578 4.613 104.0...
Page 61 Temperature sensor R-T analysis table (20K) Sensor standard resistance：20KΩ±3% B:B(25/50)=3950K±2％ reference temperature：25（℃） MCU_A/D exchange ±3LSB（at10bit） Series（sampling）resistor：10（KΩ）±1％ Single chip (A/D reference voltage) supply voltage：5V Temp Resistance（KΩ） MCU Input voltage（V） A/D Exchange value ℃ 318.3 347.0 377.6 0.128 0.140 0.154 299.6 326.2 354.6 0.136 0.149...
Page 62 39.95 41.85 43.78 0.922 0.964 1.009 38.11 39.88 41.68 0.960 1.002 1.047 36.37 38.02 39.69 0.998 1.041 1.087 34.71 36.25 37.81 1.038 1.081 1.127 33.14 34.57 36.03 1.078 1.122 1.168 31.65 32.98 34.34 1.119 1.163 1.210 30.23 31.47 32.74 1.161 1.206 1.252 28.88...
Page 63 5.216 5.519 5.831 3.147 3.222 3.297 5.025 5.321 5.625 3.188 3.263 3.339 4.842 5.131 5.428 3.229 3.304 3.380 4.667 4.948 5.238 3.270 3.345 3.420 4.499 4.773 5.055 3.310 3.385 3.459 4.338 4.605 4.880 3.349 3.423 3.498 4.183 4.444 4.712 3.388 3.462 3.536 4.035...
Page 64 1.070 1.164 1.258 4.436 4.479 4.521...
Page 65 Temperature sensor R-T analysis table (50K) Sensor standard resistance：50KΩ±2％ B:B(25/50)=3950K±2％ reference temperature：25（℃） MCU_A/D exchange ±2LSB（at8bit） Series（sampling）resistor：5.1（KΩ）±1％ Single chip (A/D reference voltage) supply voltage：5V Temp Resistance（KΩ） MCU Input voltage（V） A/D Exchange value ℃ 465.7 486.2 507.3 0.049 0.052 0.055 439.7 458.7 478.3 0.052 0.055...
Page 66 63.88 65.36 66.85 0.351 0.362 0.373 61.08 62.47 63.86 0.366 0.377 0.389 58.42 59.72 61.02 0.382 0.393 0.405 55.88 57.1 58.32 0.398 0.410 0.422 53.47 54.61 55.76 0.415 0.427 0.439 51.18 52.25 53.32 0.433 0.445 0.457 0.450 0.463 0.476 46.88 47.86 48.84 0.468...
Page 67 9.24 9.585 9.94 1.684 1.736 1.790 8.916 9.253 9.599 1.723 1.777 1.831 8.605 8.934 9.271 1.763 1.817 1.872 8.307 8.627 8.955 1.803 1.858 1.914 8.02 8.331 8.652 1.843 1.899 1.955 7.744 8.048 8.36 1.883 1.939 1.997 7.479 7.775 8.079 1.923 1.981 2.039 7.224...
Page 68 1.961 2.066 2.176 3.494 3.558 3.621 1.905 2.007 2.114 3.524 3.588 3.650 1.85 1.95 2.055 3.554 3.617 3.679 1.797 1.895 1.997 3.583 3.645 3.707 1.746 1.841 1.941 3.612 3.674 3.734 1.696 1.789 1.887 3.640 3.702 3.762 1.648 1.739 1.834 3.668 3.729 3.788 1.602...

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