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Technibel SPA250R5TAA Technical & Service Manual

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TECHNICAL & SERVICE MANUAL
SPA250R5TAA - GR250R5TAA
SPA250R5TAA - GR250R7TAA
SPA360R5TAA - GR360R7TAA
SPA480R5TAA - GR480R7TAA
SPLIT SYSTEM AIR CONDITIONER
SPLIT SYSTEM AIR CONDITIONER
0.8180.111.1
05/01

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  • Page 1 TECHNICAL & SERVICE MANUAL SPA250R5TAA - GR250R5TAA SPA250R5TAA - GR250R7TAA SPA360R5TAA - GR360R7TAA SPA480R5TAA - GR480R7TAA SPLIT SYSTEM AIR CONDITIONER SPLIT SYSTEM AIR CONDITIONER 0.8180.111.1 05/01...

  • Page 2: Table Of Contents

    Table of Contents 1.SPECIFICATIONS…………………………………………………………………………… Unit Specifications…………………………………………………………………….. Major Component Specifications……………………………………………………. (A) Indoor Unit………………………………………………………………………..(B) Outdoor Unit………………………………………………………………………. 11 Other Component Specifications……………………………………………………. 16 Dimensional Data……………………………………………………………………... 16 (A) Indoor Unit………………………………………………………………………..16 (B) Outdoor Unit………………………………………………………………………. 17 Refrigerant Flow Diagram……………………………………………………………. 19 Operating Range……………………………………………………………………… 21 Cooling Capacity………………………………………………………………………. 22 Heating Capacity………………………………………………………………………...
  • Page 3 3. ELECTRICAL DATA………………………………………………………………………... 49 Electrical Characteristics……………………………………………………………... 49 Electric Wiring Diagrams / Schematic Diagrams…………………………………... 53 (A) Indoor Unit………………………………………………………………………..53 (B) Outdoor Unit………………………………………………………………………. 55 4. SERVICE PROCEDURES………………………………………………………………….. 63 Troubleshooting……………………………………………………………………….. 63 Checking the Electrical Components……………………………………………….. 97 − −...

  • Page 4: Specifications

    1. SPECIFICATIONS 1-1 Unit Specifications MODEL No. Indoor Unit SPA250R5TAA Outdoor Unit GR250R5TAA POWER SOURCE 220 - 230 - 240 V / 1 Phase / 50 Hz PERFORMANCE Cooling Heating Capacity BTU / h 25,000 27,000 Air circulation (Hi/Me/Lo) m3 / h...
  • Page 5 1 . SPECIFICATIONS Unit Specifications MODEL No. Indoor Unit SPA250R5TAA Outdoor Unit GR250R7TAA POWER SOURCE 380 - 400 - 415 V / 3N / 50 Hz PERFORMANCE Cooling Heating Capacity BTU / h 25,000 27,000 Air circulation (Hi/Me/Lo) m3 / h...
  • Page 6 1 . SPECIFICATIONS 1-1 Unit Specifications MODEL No. Indoor Unit SPA360R5TAA Outdoor Unit GR360R7TAA POWER SOURCE 380 - 400 - 415 V / 3N / 50 Hz PERFORMANCE Cooling Heating Capacity 10.6 11.4 BTU / h 36,000 39,000 Air circulation (Hi/Me/Lo) m3 / h 1,680/1,410/1,200 Moisture removal(High)
  • Page 7 1 . SPECIFICATIONS Unit Specifications MODEL No. Indoor Unit SPA480R5TAA Outdoor Unit GR480R7TAA POWER SOURCE 380 - 400 - 415 V / 3N / 50 Hz PERFORMANCE Cooling Heating Capacity BTU / h 47,800 54,600 Air circulation (Hi/Me/Lo) m3 / h 1,920/1,610/1,320 Moisture removal(High) Liters/h...

  • Page 8: Major Component Specifications

    1. SPECIFICATIONS 1-2 Major Component Specifications (A) Indoor Unit MODEL No. SPA250R5TAA Source 220 - 230 - 240 V / 1 phase / 50Hz Remote Controller (option) Wired : K70D026ZAA / Wireless : K70D027ZAA Controller P.C.B. Ass’y CR-X253GH (Microprocessor) Fan (Number…diameter) Centrifugal (4...ø130)
  • Page 9 1. SPECIFICATIONS (A) Indoor Unit MODEL No. SPA360R5TAA Source 220 - 230 - 240 V / 1 phase / 50Hz Remote Controller (option) Wired : K70D026ZAA / Wireless : K70D027ZAA Controller P.C.B. Ass’y CR-X253GH (Microprocessor) Fan (Number…diameter) Centrifugal (4...ø150) Fan Motor Model…Nominal output KFG4Q–101D5P...100 W Source...
  • Page 10 1. SPECIFICATIONS (A) Indoor Unit MODEL No. SPA480R5TAA Source 220 - 230 - 240 V / 1 phase / 50Hz Remote Controller (option) Wired : K70D026ZAA / Wireless : K70D027ZAA Controller P.C.B. Ass’y CR-X253GH (Microprocessor) Fan (Number…diameter) Centrifugal (4...ø150) Fan Motor Model…Nominal output KFG4Q–101D5P...100 W Source...

  • Page 11: (B) Outdoor Unit

    1. SPECIFICATIONS 1-2 Major Component Specifications Outdoor Unit Unit Model No. GR250R5TAA Source 220 - 240 V / 1 phase / 50 Hz Controller P.C.B. Ass'y CR-C253GH5 (Microprocessor) Control circuit fuse 250 V, 3.15 A Compressor Rotary (Hermetic) Model...number C-R221H5W Source 220 - 240 V / 1 phase / 50 Hz Nominal output...
  • Page 12 1. SPECIFICATIONS Outdoor Unit Unit Model No. GR250R7TAA Source 380 - 400 - 415 V / 3 phase / 50 Hz Controller P.C.B. Ass'y CR-C253GH (Microprocessor) Control circuit fuse 250 V, 3.15 A Compressor Rotary (Hermetic) Model...number C-R224H8U Source 380 - 400 - 415 V / 3 phase / 50 Hz Nominal output 2400 Compressor oil...
  • Page 13 1. SPECIFICATIONS (B) Outdoor Unit Unit Model No. GR360R7TAA GR480R7TAA Source 380 - 400 - 415 V / 3 phase / 50 Hz Controller P.C.B. Ass'y CR-C253GH (Microprocessor) Control circuit fuse 250 V, 3.15 A Compressor Rotary (Hermetic) Scroll (Hermetic) Model ..

  • Page 14: Other Component Specifications

    1. SPECIFICATIONS 1-3 Other Component Specifications Unit model No. Indoor Unit Outdoor Unit SPA250R5TAA GR250R5TAA, GR250R7TAA Power Transformer ATR - II215TB ATR - I65B Rated Primary V. Hz AC 230 V, 50 Hz AC 230 V, 50 Hz Secondary 10.2V , 1.4 A 14 V , 0.4 A...
  • Page 15 1. SPECIFICATIONS 1-3 Other Component Specifications Unit model No. Indoor Unit Outdoor Unit SPA360R5TAA SPA480R5TAA GR360R7TAA GR480R7TAA Power Transformer ATR - II215TB ATR - I65B Rated Primary V. Hz AC 230 V, 50 Hz AC 230 V, 50 Hz Secondary 10.2V , 1.4 A 14 V , 0.4 A 14 V , 0.5 A...

  • Page 16: Dimensional Data

    1. SPECIFICATIONS 1-4 Dimentional Data (A) Indoor Unit : 250, 360, 480 Type 25 type 36, 48 type 1270 1570 1048 1190 1490 Ref.gas line ø 15.88 ø 19.05 Ref. liquid line ø 6.35 ø 9.52 Refrigerant gas line (Wide tube) Refrigerant liquid line (Narrow tube) Drain connection...

  • Page 17: (B) Outdoor Unit

    1. SPECIFICATIONS 1-4 Dimentional Data (B) Outdoor Unit : GR250R5TAA GR360R7TAA Dimension : mm Hole for anchor bolt (4-ø13) Refrigerant tube joint (narrow tube) Flare connection 1/4 in (6.35 mm) Refrigerant tube joint (wide tube) Flare connection 5/8 in (15.88 mm) Refrigerant tubing inlet Power supply inlet 0411_C_S...
  • Page 18 1. SPECIFICATIONS 1-4 Dimentional Data (B) Outdoor Unit : GR360R7TAA GR480R7TAA Dimension : mm Hole for anchor bolt (4-ø13) Refrigerant tube joint (narrow tube) Flare connection 3/8 in (9.52 mm) Refrigerant tube joint (wide tube) Flare connection 3/4 in (19.05 mm) Refrigerant tubing inlet Power supply inlet 0412_C_S...

  • Page 19: Refrigerant Flow Diagram

    1. SPECIFICATIONS 1-5 Refrigerant Flow Diagram Outdoor Unit : GR250R5TAA Indoor Unit: SPA250R5TAA : GR250R7TAA Compressor Accumulator Accumulator Gas line service valve Gas line O.D. nipple ø15.88mm (5/8") High Muffler pressure switch 4-way valve Heat exchanger Heat exchanger Distributor Strainer...
  • Page 20 1. SPECIFICATIONS 1-5 Refrigerant Flow Diagram Outdoor Unit : GR360R7TAA Indoor Unit: SPA360R5TAA : GR480R7TAA : SPA480R5TAA Compressor *Accumulator Accumulator Gas line service valve Gas line High pressure O.D. nipple switch ø19.05mm (3/4") Muffler 4-way valve Heat exchanger Heat exchanger Distributor Strainer Electronic...

  • Page 21: Operating Range

    1. SPECIFICATIONS 1-6 Operating Range Temperature Indoor air intake temp. Outdoor air intake temp. Maximum 35°C DB / 25°C WB 45°C DB Cooling Minimum 17°C DB / 14°C WB – 5°C DB Maximum 27°C DB / — WB 21°C DB / 15.5°C WB Heating Minimum 15°C DB / —...

  • Page 22: Cooling Capacity

    1. SPECIFICATIONS 1-7 Cooling Capacity Indoor Unit : SPA250R5TAA Outdoor Unit : GR250R5TAA RATING CAPACITY : 7.3 kW AIR FLOW RATE : 1140 m EVAPORATOR CONDENSER ENT. TEMP. °C °C AMBIENT TEMP. 7.37 7.03 6.67 6.26 5.81 2.43 2.59 2.78 2.86...
  • Page 23 1. SPECIFICATIONS Indoor Unit : SPA250R5TAA Outdoor Unit : GR250R7TAA RATING CAPACITY : 7.3 kW AIR FLOW RATE : 1140 m EVAPORATOR CONDENSER ENT. TEMP. °C °C AMBIENT TEMP. 7.37 7.03 6.67 6.26 5.81 2.07 2.22 2.38 2.43 2.49 5.81 7.03...
  • Page 24 1. SPECIFICATIONS Indoor Unit : SPA360R5TAA Outdoor Unit : GR360R7TAA RATING CAPACITY : 10.6 kW AIR FLOW RATE : 1680 m EVAPORATOR CONDENSER ENT. TEMP. °C °C AMBIENT TEMP. 10.7 10.21 9.69 9.08 8.44 2.15 2.29 2.46 2.63 2.82 9.08 8.44 10.7 10.21...
  • Page 25 1. SPECIFICATIONS Indoor Unit : SPA480R5TAA Outdoor Unit : GR480R7TAA RATING CAPACITY : 14 kW AIR FLOW RATE : 1920 m EVAPORATOR CONDENSER ENT. TEMP. °C °C AMBIENT TEMP. 14.13 13.48 12.8 11.14 3.72 3.97 4.27 4.15 4.05 10.3 11.3 10.9 10.6 10.2...

  • Page 26: Heating Capacity

    1. SPECIFICATIONS 1-8 Heating Capacity 15˚C 20˚C 25˚C 25˚C 20˚C 15˚C –15 –10 –5 Outdoor temperature ˚C WB 0413_M_S NOTE Above characteristics are based on: 1) Tubing length is 7 meters. 2) Air flow speed is high speed. Minimum outdoor ambient temperature: –15°C WB Above characteristics indicate instantaneous capacity.

  • Page 27: Noise Criterion Curves

    1. SPECIFICATIONS 1-9 Noise Criterion Curves MODEL : SPA250R5TAA MODEL : GR250R5TAA, GR250R7TAA SOUND LEVEL : HIGH 45 dB(A), NC 43 SOUND LEVEL : 52 dB(A), NC 44 37 dB(A), NC 34 CONDITION : Distance 1m, Height 1m CONDITION : Distance 1m, Under the unit 1m...
  • Page 28 1. SPECIFICATIONS MODEL : SPA480R5TAA MODEL : GR480R7TAA SOUND LEVEL : HIGH 48 dB(A), NC 46 SOUND LEVEL : 55 dB(A), NC 47 40 dB(A), NC 36 CONDITION : Distance 1m, Height 1m CONDITION : Distance 1m, Under the unit 1m SOURCE : 380 - 400 - 415V, 3 Phase, 50 Hz SOURCE...

  • Page 29: Air Throw Distance Chart

    1. SPECIFICATIONS 1-10 Air Throw Distance Chart Model: 250 Type HORIZONTAL DISTANCE (m) 30˚ 50˚ 70˚ 0˚ 30˚ 15˚ Model: 360 Type HORIZONTAL DISTANCE (m) 30˚ 50˚ 70˚ 15˚ 0˚ 30˚ Model: 480 Type HORIZONTAL DISTANCE (m) 30˚ 50˚ 70˚ 15˚...

  • Page 30: Processes And Functions

    2. PROCESSES AND FUNCTIONS 2-1 Room Temperature Control The unit adjusts room temperature by turning the outdoor unit’s compressor ON and OFF. This process is controlled by the thermostat located in the indoor unit. The figures on this and the next page show how each part of the system performs as the room temperature changes and the thermostat activates the compressor to start (thermo ON) or stop (thermo OFF).

  • Page 31: (B) Heating

    2. PROCESSES AND FUNCTIONS (B) Heating THERMO. ON THERMO. ON REMOTE CONTROL THERMO. OFF THERMO. OFF SENSOR (Only for wireless THERMO. ON remote controller) SET. +1°C SETTING TEMP. SET. –1°C THERMO. OFF THERMO. OFF BODY SENSOR THERMO. ON THERMO. ON THERMO.

  • Page 32: Cold Draft Prevention (Heating Cycle)

    2. PROCESSES AND FUNCTIONS 2-2 Cold Draft Prevention (Heating Cycle) The cold draft prevention function controls indoor fan speed so a strong draft of cold air will not blow out before the indoor heat exchange coils have warmed up. STANDBY shows on the remote controller when the indoor fan speed is LL (very low) or OFF.

  • Page 33: Automatic Fan Speed (Indoor Unit)

    2. PROCESSES AND FUNCTIONS 2-3 Automatic Fan Speed (Indoor Unit) By pressing the FAN SPEED button on the remote controller, the fan speed can be set at one of four steps: AUTO., HI., MED., or LO. When set at AUTO. the indoor unit fan speed will be automatically adjusted to the room temperature as the two charts shown below.

  • Page 34: Outdoor Fan Speed Control

    2. PROCESSES AND FUNCTIONS 2-4 Outdoor Fan Speed Control To optimize the performance of air conditioner, the outdoor fan speed is selected automatically according to the outdoor temperature. Note that in both Cooling and Heating modes, the fan comes on at first at high speed (H mode) for 5 seconds.

  • Page 35: Freeze Prevention (Cooling)

    2. PROCESSES AND FUNCTIONS 2-5 Freeze Prevention (Cooling) Freeze Prevention keeps the indoor heat exchange coil from freezing. Freezing reduces the efficiency of the unit, and frost buildup on the coil blocks cool air circulation from the indoor unit's fan. MIN.

  • Page 36: Condensing Temperature Control (Cooling)

    2. PROCESSES AND FUNCTIONS 2-6 Condensing Temperature Control (Cooling) Condensing temperature is controlled by the outdoor heat exchanger coil temperature as sensed by sensor C2. OUTDOOR UNIT COIL TEMP. C2 (°C) OUTDOOR FAN FORCED SPEED H, M H, M ELECTRONIC REF. CONTROL VALVE OPEN 0436_M_S...

  • Page 37: Overload Protection (Heating)

    2. PROCESSES AND FUNCTIONS 2-7 Overload Protection (Heating) This function prevents the air conditioner from overloading. (°C) INDOOR UNIT COIL TEMP. (E2) OVERLOAD PROTECTION OVERLOAD PROTECTION FUZZY CONTROL FUZZY CONTROL ELECTRONIC REF. CONTROL VALVE OPEN OPEN START UP OUTDOOR FM COMPENSATION H OR M H OR M...

  • Page 38: Discharge Temperature Control (Cooling And Heating)

    2. PROCESSES AND FUNCTIONS 2-8 Discharge Temperature Control (Cooling and Heating) This function prevents the compressor motor from burnout by overheating. (135) 115 (125) 105 (115) 95 (113) 93 DISCHARGE GAS TEMP. (°C) (110) 90 (105) 85 THE TEMPERATURES IN THE PARENTHESIS IS FOR 48 TYPE.
  • Page 39 2. PROCESSES AND FUNCTIONS 2-9 Auto. Mode for Automatic Heating/Cooling Switching COOLING SELECTION TEMP. +2.5 deg SHIFT SET TEMP. +2 deg REMOTE CONTROLLED SET TEMP. SHIFT SET TEMP. –2 deg HEATING SELECTION TEMP. –3 deg HEATING COOLING HEATING 0440_M_S Fig. 12 Chart summary and Explanations This chart shows how the Operation Mode (COOLING or HEATING) is determined by the microprocessor taking the room temperature into consideration.

  • Page 40: Defrosting Control, Outdoor Heat Exchanger Coil (Heating)

    2. PROCESSES AND FUNCTIONS 2-10 Defrosting Control, Outdoor Heat Exchanger Coil (Heating) When the outdoor temperature is low, frost may form on the outdoor heat exchanger coil. When this occurred, the defrosting system operates. The microprocessor in the outdoor unit monitors the relationship between the temperature of the outdoor heat exchanger coil and the outdoor temperature so it can defrost when necessary.

  • Page 41: 4-Way Valve, Solenoid Control

    2. PROCESSES AND FUNCTIONS 2-11 4-Way Valve, Solenoid Control The basic function of the 4-way valve is to direct the refrigerant in the correct direction according to the Operation Mode (COOLING or HEATING) selected. The following two charts show conditions of the controls and functions listed in the left hand column when the solenoid is ON or OFF.

  • Page 42: (B) Auto Control Mode

    2. PROCESSES AND FUNCTIONS (B) AUTO Control Mode POWER SOURCE OPERATION BUTTON MORE THAN 10 MINUTES MORE THAN 10 MINUTES (THERMO. OFF) (THERMO. OFF) AUTO COOL COOL MODE CONTROL HEAT HEAT HEAT THERMO. OFF THERMO. ON 3 MINUTES MORE THAN 3 MINUTES COMPRESSOR MORE THAN...

  • Page 43: Electronic Refrigerant Control Valve

    2. PROCESSES AND FUNCTIONS 2-13 Electronic Refrigerant Control Valve This valve allows very precise and smooth control of the amount of refrigerant flow in the system. Since the valve is operated by a step motor, the control circuits can open or close it in very exact amounts, so the degree of heating or cooling can be changed by just a little, or changed very quickly or slowly.

  • Page 44: Compressor Current Detection Circuit

    2. PROCESSES AND FUNCTIONS 2-15 Compressor Current Detection Circuit The Compressor Current Detection Circuit detects the compressor current and, depending on the current range, can stop the compressor motor so it will not be damaged by overcurrent. Overcurrent can be caused by several factors, particularly mechanical seizing of the compressor or liquid backflow.

  • Page 45: Dehumidifying Operation

    2. PROCESSES AND FUNCTIONS 2-16 Dehumidifying Operation Dehumidifying operation uses the cooling cycle to remove moisture from the air, but by running an indoor fan at a low speed, to dehumidify without greatly lowering room temperature. In this mode, the microprocessor automatically controls the ON-OFF operation between +2 deg.

  • Page 46: Auto-Flap Control

    2. PROCESSES AND FUNCTIONS 2-17 Auto-flap Control Auto flap can control the air flow in 5 steps. Cooling Heating 0677_M_I Fig. 21 Flap position Operation mode Automatic setting Optional setting Cooling/dehumidifying F1 • F2 • F3 • Swing F1 • F2 • F3 • F4 • F5 • Swing Heating F1 •...

  • Page 47: Electronic Refrigerant Control Valve Control

    2. PROCESSES AND FUNCTIONS 2-18 Electronic Refrigerant Control Valve Control The circulation volume of the refrigerant is controlled by a pulse type electronic control valve. When the power is switched ON, the opening degree of the electronic control valve is controlled between 90 and 480 steps after setting the initial step at the time when the thermostat is ON.

  • Page 48: Voltage Detection Control

    2. PROCESSES AND FUNCTIONS 2-19 Voltage Detection Control When the power voltage falls below 160 V (voltage between N phase and each phase) or rises above 260 V, the “P2” alarm is issued to protect the compressor and electrical components. –...

  • Page 49: Electrical Characteristics

    3. ELECTRICAL DATA 3-1 Electrical characteristics Indoor model : SPA250R5TAA / Outdoor model : GR250R5TAA Cooling Indoor Unit Outdoor Unit Complete Unit Fan Motor Fan Motor Compressor Performance at 220 - 240 V / 1 phase / 50 Hz 220 – 240 V / 1 phase / 50 Hz 0.43 / 0.43...
  • Page 50 3. ELECTRICAL DATA 3-1 Electrical characteristics Indoor model : SPA250R5TAA / Outdoor model : GR250R7TAA Cooling Indoor Unit Outdoor Unit Complete Unit Fan Motor Fan Motor Compressor Performance at 220 - 240 V / 1 phase / 50 Hz 380 – 415 V / 3 phase / 50 Hz 0.43 / 0.43...
  • Page 51 3. ELECTRICAL DATA 3-1 Electrical characteristics Indoor model : SPA360R5TAA / Outdoor model : GR360R7TAA Cooling Indoor Unit Outdoor Unit Complete Unit Fan Motor Fan Motor Compressor Performance at 220 - 240 V / 1 phase / 50 Hz 380 - 415 V / 3 phase / 50 Hz 0.95 / 0.98 1.24 / 1.31 4.58 / 4.32...
  • Page 52 3. ELECTRICAL DATA 3-1 Electrical characteristics Indoor model : SPA480R5TAA / Outdoor model : GR480R7TAA Cooling Indoor Unit Outdoor Unit Complete Unit Fan Motor Fan Motor Compressor Performance at 220 - 240V / 1 phase / 50 Hz 380 - 415V / 3 phase / 50 Hz 0.95 / 0.98 1.24 / 1.31 7.76 / 8.12...

  • Page 53: Electric Wiring Diagrams / Schematic Diagrams

    3. ELECTRICAL DATA 3-2 Electric Wiring Diagrams / Schematic Diagrams Indoor Unit 1 1 1 SPA250R5TAA, SPA360R5TAA, SPA480R5TAA – 53 –...
  • Page 54 3. ELECTRICAL DATA SPA250R5TAA, SPA360R5TAA, SPA480R5TAA • Schematic Diagram CR-X253GH Controller 8P-R1 F1(5A) 8P-1(L) 8P-R2 RC12V 8P-R3 230V 8P-2(N) 49FI Room Thermistor Indoor Coil Indoor Coil DP.DPH Indoor Coil DC12V To Outdoor Unit Symbols Description Symbols Description Indoor Fan Motor...

  • Page 55: (B) Outdoor Unit

    3. ELECTRICAL DATA 3-2 Electric Wiring Diagrams / Schematic Diagrams Outdoor Unit 1 1 1 GR250R5TAA – 55 –...
  • Page 56 3. ELECTRICAL DATA GR250R5TAA • Schematic Diagram Terminal CR-C253GH5 Plate (6P) Controller 63PH 2P-1 2P-2 L1 F1(3.15A) 63PH AC 230V AC 14V 49FO Outdoor Coil C1 Outdoor Coil C2 Discharge DC12V Symbols Description Symbols Description Compressor Motor CR-C253GH5 Outdoor Controller Outdoor Fan Motor RY1~4 Auxiliary Relay...
  • Page 57 3. ELECTRICAL DATA 2 2 2 GR250R7TAA – 57 –...
  • Page 58 3. ELECTRICAL DATA GR250R7TAA • Schematic Diagram Terminal CR-C253GH Plate (8P) Controller 63PH 2P-1 2P-2 L1 F1(3.15A) 63PH AC 230V 49FO AC 14V Outdoor Coil C1 Outdoor Coil C2 Discharge DC12V N L3 L2 F2(3.15A) L3 N Symbols Description Symbols Description Compressor Motor CR-C253GH...
  • Page 59 3. ELECTRICAL DATA 3 3 3 GR360R7TAA – 59 –...
  • Page 60 3. ELECTRICAL DATA GR360R7TAA • Schematic Diagram Terminal CR-C253GH Plate (8P) Controller 63PH 2P-1 2P-2 L1 F1(3.15A) 63PH AC 230V 49FO1 AC 14V Outdoor Coil C1 49FO2 Outdoor Coil C2 FMO1 FMO2 Discharge DC12V N L3 L2 F2(3.15A) L3 N Symbols Description Symbols...
  • Page 61 3. ELECTRICAL DATA 4 4 4 GR480R7TAA – 61 –...
  • Page 62 3. ELECTRICAL DATA GR480R7TAA • Schematic Diagram Terminal CR-C253GH Plate (8P) Controller 63PH 2P-1 2P-2 L1 F1(3.15A) 63PH AC 230V 49FO1 AC 14V Outdoor Coil C1 49FO2 Outdoor Coil C2 FMO1 FMO2 Discharge DC12V N L3 L2 F2(3.15A) L3 N Symbols Description Symbols...

  • Page 63: Service Procedures

    4. SERVICE PROCEDURES 4-1 Troubleshooting This section explains: What the LED codes mean What the remote control unit display screen messages mean How to use the flow charts to find and solve problems How to use the self-diagnostic tests to find parts that aren’t working right This unit is made to be trouble free, and not need much service.
  • Page 64 4. SERVICE PROCEDURES (1)-1 Check before and after Troubleshooting (GR250R5TAA) Many problems may happen because of wiring or power supply problems, so you should check these areas first. Problems here can cause false results in some of the other tests, and so should be corrected first.
  • Page 65 4. SERVICE PROCEDURES (1)-2 Check before and after Troubleshooting (GR250R7, GR360R7, GR480R7) Many problems may happen because of wiring or power supply problems, so you should check these areas first. Problems here can cause false results in some of the other tests, and so should be corrected first.
  • Page 66 4. SERVICE PROCEDURES (2) General Troubleshooting Flow Chart: Diagnosis and Remedy When you have found a major problem, such as refrigerant not flowing in the system or reduced air circulation, come to this section and find the box listing the problem. Connected to the box are the main causes of the problem and their remedies.
  • Page 67 4. SERVICE PROCEDURES (B) Heating b. Heating Poor heating Is setting temp. Change the setting temp. suitable ? Is heating load Review heating load too large ? estimate. Refrigerant flow 4-way valve is Replace the valve. failure defective. Refrigerant Charge with shortage refrigerant.
  • Page 68 4. SERVICE PROCEDURES Meanings of alarm messages If an error occurred in the air conditioner, the error condition is presented by indicating the error code in the wired remote controller display or by the combination of lamp statuses for operation, timer and heat stand-by (OFF status and flashing status). Wired remote Wireless remote Possible causes of troubles...
  • Page 69 4. SERVICE PROCEDURES Wired remote Wireless remote Possible causes of troubles controller controller display display Operation lamp Indoor thermistor is either Indoor coil temp. (E1 = TH2) cannot be detected. and heat stand-by open or short. Indoor coil temp. (E2 = TH3) cannot be detected. lamp flash Indoor room temperature cannot be detected.
  • Page 70 4. SERVICE PROCEDURES (4) LED Indication on the Outdoor Unit’s P.C.B. Ass’y If something goes wrong with the outdoor unit, LED lamps on the outdoor P.C.B. Ass’y light up to show the cause of the trouble, in addition to the Alarm message on the remote controller.
  • Page 71 4. SERVICE PROCEDURES Symptoms and parts to inspect Symptom: LCD on the remote controller does not display and remote controller does not operate. Start Is the LED (D80) on the indoor unit PCB lit? Is there 12 V DC Is there 12 V DC Repair the between R2 and R3 between 2 and 3...
  • Page 72 4. SERVICE PROCEDURES 2) Symptom: LCD on the remote controller displays “CHECK E01”. (Unusual communication between remote controller and indoor unit.) Start Remote controller judges itself Replace the remote controller. with self-diagnostic functions Is there an open or a contact defect in the No.
  • Page 73 4. SERVICE PROCEDURES Symptom: LCD on the remote controller is displaying “CHECK E04”. (Unusual communication between the indoor and outdoor units.) Start Cut the breaker and remove the Is the contact good at the 2P Correct the connections. indoor/outdoor unit control lines connector for indoor serial connected to U1 and U2 of the communications on the outdoor...
  • Page 74 4. SERVICE PROCEDURES Symptom: LCD on the remote controller is displaying “CHECK E06”. (Unusual communication between the indoor and outdoor units) Start Correct the setting. Is the indoor address setting for the non-volatile memory IC on the indoor unit inappropriate ? Is there a cut line or contact Correct wiring.
  • Page 75 4. SERVICE PROCEDURES Symptom: LCD on the remote controller displays “CHECK P01”. (Indoor fan protection thermostat operation warning) Start Is there 220-240 V AC between S4 and T20-3 on the indoor unit PCB? Correct the connection Is there 220-240 V AC between Is the indoor fan wire winding T20-3 and S4 after T20-1 and T20-3 protection thermostat (49FI) off?
  • Page 76 4. SERVICE PROCEDURES 10) Symptom: LCD on the remote controller displays “CHECK P02”. (Compressor / outdoor fan protection thermostat operation warning / power supply voltage abnormality) Start Is the power supply to the outdoor Check the power breaker etc. unit normal? and repair.
  • Page 77 4. SERVICE PROCEDURES 11) Symptoms: LCD on the remote controller displays “CHECK P03”. (Alarm for unusual discharge temp. of compressor) Start Unusual discharge gas temperature • Refrigerant shortage • Clogged refrigerant circuit • Electronic refrigerant control valve defect (indoor unit) 0343_M_I 12) Symptom: LCD on the remote controller displays “CHECK P04”.
  • Page 78 4. SERVICE PROCEDURES 13) Symptom: LCD on the remote controller displays “CHECK P05”. (Negative phase detection operation warning) Start Is the power supply to the outdoor Check the power breaker etc. unit normal? and repair (Voltage defective phase?) Does the outdoor unit operate when No problem two of the three phases are changed? (Actuation of negative phase protector)
  • Page 79 4. SERVICE PROCEDURES 15) Symptom: LCD on the remote controller displays “CHECK E16”. Start When the group of the units are Repair the wiring. installed, is there any mis-cross between inter unit control wiring and refrigerant tubing? Are the total capacities of indoor units Select indoor units which match with to that of outdoor units more than 107%? the outdoor capacity.
  • Page 80 4. SERVICE PROCEDURES 17) Symptom: LCD on the remote controller displays “CHECK H01, H02, H03”. (PC compressor current detection) * Please check the related part described in the following chart after confirming the code setting (S4) of the outdoor unit’s capacity on the PCB in the outdoor unit. Start “CHECK H01”...
  • Page 81 4. SERVICE PROCEDURES Procedures When a Specific Component Does Not Work Indoor fan does not operate. Is fan motor capacitor Replace the capacitor. normal ? Is there voltage output Replace the P.C.B. Ass'y of P.C.B. Ass'y for fan in the indoor unit. motor ? •...
  • Page 82 4. SERVICE PROCEDURES Compressor motor does not operate. Does compressor motor magnetic Replace the compressor contactor (52C) actuate ? motor magnetic contactor. Check resistance of compressor motor winding. Replace the compressor. 0461_M_I Outdoor fan does not operate. Are auxiliary relays (1Y, 2Y) Replace the relays.
  • Page 83 4. SERVICE PROCEDURES Service Functions of Remote Controller From the remote controller you can control both the operation and settings of the unit as well as perform several useful service checks. This section explains how to use the remote controller on the following items from (A) to (J). (A) Set service check switches.
  • Page 84 4. SERVICE PROCEDURES (B) Use the test run procedure The purpose of the test run function is to let you control the operation of the unit directly without turning the unit on or off by thermostat. As indicated in the following procedure, be sure to stop test run operation when you finish the procedure, or the air conditioner may be damaged.
  • Page 85 4. SERVICE PROCEDURES (C) Check the sensor temperature readings The air conditioner has thermo sensors which are used to control the unit. Each sensor has an address which is made up of the indoor unit address, and the sensor address. The indoor unit address is used only when several units are hooked up to one remote controller (group control).
  • Page 86 4. SERVICE PROCEDURES Refer to the table below for the relationship between the sensor address and the location of the sensor. Relationship between the sensor address and the location of sensor Sensor Address Location of Sensor (Themistor) (CODE No.) Indoor Unit —...
  • Page 87 4. SERVICE PROCEDURES This picture shows the service check display. UNIT No. UNIT No. 1–1 R.C. CODE Refrigerant Circuit No. CODE No. CHECK Alarm message SERVICE 0358_M_I c. A maximum of 4 alarm messages can be accessed by pressing either SET TEMP button as follows.
  • Page 88 4. SERVICE PROCEDURES Important Never press CL (clear) button unless you want to erase the accessed data in memory. Follow the procedure below only when erasing is necessary. To erase accessed data, press the CL button. When erasing is finished,“----” mark appears on the controller’s display. CAUTION After checking the alarm messages, be sure to press the TEST / CHK button.
  • Page 89 4. SERVICE PROCEDURES (F) Execute the auto. address operation Auto. address operation is executed by pressing the A. ADD (S1) button of outdoor unit’s PCB usually. For your convenience it can be executed by remote controller also. a Press the TEST / CHK and ) buttons at the same time for more than 4 seconds.
  • Page 90 4. SERVICE PROCEDURES (G) Confirm and change the indoor unit address The purpose of the above function is to let you confirm the indoor unit address after the auto. address operation, and change the indoor unit address if it is needed.
  • Page 91 4. SERVICE PROCEDURES e Set the required new indoor unit’s No. by pressing the ) button. AIR FLOW UNIT MODE Ex: UNIT No. 3-6: currently registered indoor unit address R.C. FLAP SET TEMP. CODE TIMER SET FAN SPEED SETTING DATA Required new indoor No.8: SET DATA In this case, UNIT No.
  • Page 92 4. SERVICE PROCEDURES (H) Change the shift temperature in heating mode If the indoor unit is installed at high location (ex. ceiling level), the thermostat tends to turn off at heating mode because of the hot air temperature around ceiling level. In order to solve the problem, the shift temp.
  • Page 93 4. SERVICE PROCEDURES ( I ) Set the indoor unit address This function is usable if the auto. address operation is not available. Indoor unit address can be set one by one by remote controller in such case. NOTE 1) In case of group control, branch wiring for group control should be removed temporarily.
  • Page 94 4. SERVICE PROCEDURES d Set the No. of R. C. which you want to set with ) button. Ex. No. of R. C. will be set 2. AIR FLOW UNIT MODE UNIT No. R.C. FLAP SET TEMP. CODE TIMER SET FAN SPEED SETTING DATA...
  • Page 95 4. SERVICE PROCEDURES i Select the code No. 14 to set group setting with the (SET TEMP) button. j Set the No. of group setting as shown below with the ) button. Nos. of group setting. AIR FLOW 0 : Standard system (except group UNIT MODE UNIT No.
  • Page 96 4. SERVICE PROCEDURES (J) Change the period of the filter timer If the period of filter timer is not suitable (for example in case of dirty environment), the period can be shortened to half as follows: a Press the TEST / CHK button for more than 4 seconds. AIR FLOW UNIT MODE...

  • Page 97: Checking The Electrical Components

    4. SERVICE PROCEDURES 4-2 Checking the Electrical Components Measurement of Insulation Resistance • The insulation is in good condition if the resistance exceeds 1 MΩ. Power Supply Wires Clamp the earthed wire of the Power Supply wires with a lead clip of the insulation resis- Earthed wire tance tester and measure the resistance by placing a probe on either of the power wires.
  • Page 98 4. SERVICE PROCEDURES Measurement of Insulation Resistance for Electrical parts Probe • Disconnect the connector of the desired electric part from terminal plate, P.C.B. Ass’y, etc. (Fig. 42) • Similary, disconnect the lead wires from Clip compressor, capacitor, etc. (Fig. 43) Copper tube or •...
  • Page 99 4. SERVICE PROCEDURES Checking the Protective Devices • Disconnect the connector, which consists of P (plug) and S (socket) when you want to check the protective device. • Then check continuity among plug’s (and/or socket’s) terminal as in Fig. 44. •...
  • Page 100 4. SERVICE PROCEDURES Checking the Electrical Parts Power transformer (TR1) ....Indoor unit *Measure the coil resistance. • Primary ; Measure the resistance between No.1 and No.3 (WHT lead wires) terminals of 3P (WHT) socket connected to power transformer. • Secondary 14V ;...
  • Page 101 4. SERVICE PROCEDURES Solenoid coil of the electronic refrigerant *Measure the coil resistance. control valve (ERCV) ………… Indoor unit • Measure the resistance between No. 5 (GRY lead wire) and other terminals (another color of lead wires) of 5P (WHT) plug connected to the solenoid coil. Refer to “1-2-(A) Major component specifications”.
  • Page 102 4. SERVICE PROCEDURES Fuse on indoor and outdoor P.C.B. Ass’y …. Both in indoor and outdoor unit *Check the continuity. • Remove the P.C.B. Ass’y from the electrical component box. Then pull out the fuse from the P.C.B. Ass’y. (Fig. 46) Fuses Fuses Indoor P.C.B.
  • Page 103 (ERCV) Electronic refrigerant control valve (ERCV) TH4 (E3), (BRN) TH2 (E1), (RED) TH4 (E3), (BRN) ERCV 0472_T_I ERCV E1, E3 0471_T_I E1, E3 • SPA360R5TAA • SPA250R5TAA • SPA480R5TAA TH3 (E2), (BLK) TH3 (E2), (BLK) 0474_T_I 0475_T_I – –...
  • Page 104 4. SERVICE PROCEDURES Outdoor Unit • GR250R5TAA, GR250R7TAA TH6, 7, 8 20S, 63PH TH8 (GRN) TH7 (C2), (RED) ( Discharge gas) TH6 (C1), (BLK) 0582_C_S 0583_C_S • GR360R7TAA TH6, 7, 8 TH7 (C2), (RED) 63PH TH8 (GRN) ( Discharge gas) TH6 (C1), (BLK) 0585_C_S 0584_C_S...
  • Page 105 4. SERVICE PROCEDURES • GR480R7TAA TH6, 7, 8 TH7 (C2), (RED) 63PH TH8 (GRN) ( Discharge gas) TH6 (C1), (BLK) 0585_C_S 0586_C_S – –...
  • Page 106 4. SERVICE PROCEDURES (5) Thermistor Characteristic Curve (1) Room temp. sensor : TH1 (KTEC-35) (2) Indoor heat exch. coil sensor : TH2(E1), TH3(E2), TH4(E3) Outdoor heat exch. coil sensor : TH6(C1), TH7(C2) ( PBC-41E) ( PB3M-41E) –20 –15 –10 –5 Temperature (°C) 0375_M_I Temperature (°C)
  • Page 107 4. SERVICE PROCEDURES (6) PCB Setting Setting of outdoor control PCB (A) Standard control (single outdoor unit) In case of single outdoor unit installation, no indoor unit’s setting is necessary. Keep R.C. address setting at “0” as factory shipment state. In this case, auto.
  • Page 108 4. SERVICE PROCEDURES (7) R.C. Address Setting Method Outdoor unit R.C. address setting method In case of group control or central control, set the R.C. address to 1, 2, 3, ... according to the No. of outdoor units. Outdoor control PCB CN4 (2P Black) Refrigerant circuit address (factory setting = 0)
  • Page 109 4. SERVICE PROCEDURES (8) Automatic Address Setting Method Displaying Indoor / Outdoor Unit Combination Numbers — For group control and central control with multiple outdoor units — Display the indoor / outdoor unit address after automatic address setting. Carry out automatic address setting with 1) When installing multiple units, match the remote controller.
  • Page 110 4. SERVICE PROCEDURES (10) Items to Check Prior to Test Run 1) Turn on the power supply switch more than 5 hours before in order to charge the crank case heater. 2) Fully open the outdoor service valve after making the leak inspection of field connected tubing, vacuuming, and gas charging if necessary.
  • Page 111 4. SERVICE PROCEDURES (11) Test Run Procedure Start Turn on RCU address SW Multiple remote of sub remote control unit control? Recheck the test items before test operation. (See 4-2-(10)) Check the indoor and outdoor unit combination (wiring). Single type? Multiple indoor (One indoor unit and one units for one outdoor...

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