1. Manuals
  2. Brands
  3. Technibel Manuals
  4. Air Conditioner
  5. CA250R5TAA
  6. Technical & service manual

Technibel CA250R5TAA Technical & Service Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
TECHNICAL & SERVICE MANUAL
CA250R5TAA - GR250R5TAA
CA250R5TAA - GR250R7TAA
CA360R5TAA - GR360R7TAA
CA480R5TAA - GR480R7TAA
SPLIT SYSTEM AIR CONDITIONER
SPLIT SYSTEM AIR CONDITIONER
0.8180.113.1
05/01

Advertisement

Table of Contents
loading

Related Manuals for Technibel CA250R5TAA

Summary of Contents for Technibel CA250R5TAA

  • Page 1 TECHNICAL & SERVICE MANUAL CA250R5TAA - GR250R5TAA CA250R5TAA - GR250R7TAA CA360R5TAA - GR360R7TAA CA480R5TAA - GR480R7TAA SPLIT SYSTEM AIR CONDITIONER SPLIT SYSTEM AIR CONDITIONER 0.8180.113.1 05/01...

  • Page 2: Table Of Contents

    Table of Contents 1.SPECIFICATIONS…………………………………………………………………………… Unit Specifications…………………………………………………………………….. Major Component Specifications……………………………………………………. (A) Indoor Unit………………………………………………………………………..(B) Outdoor Unit………………………………………………………………………. 10 Other Component Specifications……………………………………………………. 13 Dimensional Data……………………………………………………………………... 15 (A) Indoor Unit………………………………………………………………………..15 (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 CA250R5TAA 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 1-1 Unit Specifications MODEL No. Indoor Unit CA250R5TAA 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. SPECIF¡ICATIONS 1-1 Unit Specifications MODEL No. Indoor Unit CA360R5TAA 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 1,920/1,680/1,320 Moisture removal(High)
  • Page 7 1. SPECIFICATIONS 1-1 Unit Specifications MODEL No. Indoor Unit CA480R5TAA 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 1,920/1,680/1,320 Moisture removal(High) Liters/ h...

  • Page 8: Major Component Specifications

    1. SPECIFICATIONS 1-2 Major Component Specifications (A) Indoor Unit MODEL No. CA250R5TAA Source 220 - 230 - 240 V / 1 phase / 50Hz Controller P.C.B. Ass’y CR-X253GH (Microprocessor) Fan (Number…diameter) Turbo (1...ø490) Fan Motor Model…Nominal output SFG6X – 41A5P...40 W...
  • Page 9 1. SPECIFICATIONS (A) Indoor Unit MODEL No. CA360R5TAA CA480R5TAA Source 220 - 230 - 240 V / 1 phase / 50Hz Controller P.C.B. Ass’y CR-X253GH (Microprocessor) Fan (Number…diameter) Turbo (1...ø490) Fan Motor Model…Nominal output SFG6X – 61A3P...60 W Source 220 - 230 - 240 V / 1 phase / 50Hz No.
  • Page 10 1. SPECIFICATIONS 1-2 Major Component Specifications (B) Outdoor Unit Unit Model No. GR250R5TAA Source 220 - 240 - 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 ..
  • Page 11 1. SPECIFICATIONS (B) 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 250V, 3.15 A Compressor Rotary (Hermetic) Model ..number C-R224H8U Source 380 - 400 - 415 V / 3 phase / 50 Hz Nominal output...
  • Page 12 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 13: (B) Outdoor Unit

    1. SPECIFICATIONS 1-3 Other Component Specifications Unit model No. Indoor Unit Outdoor Unit CA250R5TAA GR250R5TAA, GR250R7TAA Power Transformer ATR - II215TA ATR - I65B Rated Primary V. Hz AC 230 V, 50 Hz AC 230, 50 Hz Secondary 10.2V , 1.4 A 14 V , 0.4 A...
  • Page 14 1. SPECIFICATIONS 1-3 Other Component Specifications Unit model No. Indoor Unit Outdoor Unit CA360R5TAA CA480R5TAA GR360R7TAA GR480R7TAA Power Transformer ATR - II215TA ATR - I65B Rated Primary V. Hz AC 230 V, 50 Hz AC 230, 50 Hz Secondary 10.2V , 1.4 A 14 V , 0.4 A 14 V , 0.5 A —...

  • Page 15: Dimensional Data

    1. SPECIFICATIONS 1-4 Dimentional Data (A) Indoor Unit : CA250R5TAA 820 (Ceiling opening) 590 (Suspention bolt pitch) Air intake grille Air outlet Refrigerant liquid line (ø 6.35) Refrigerant gas line (ø 15.88) Drain connection Power supply entry For discharge duct...
  • Page 16 1. SPECIFICATIONS (A) Indoor Unit : CA360R5TAA, CA480R5TAA 820 (Ceiling opening) 590 (Suspention bolt pitch) Air intake grille Air outlet Refrigerant liquid line (ø9.52) Refrigerant gas line (ø19.05) Drain connection Power supply entry For discharge duct Suspention bolt mounting 0183_X_I –...
  • Page 17 1. SPECIFICATIONS 1-4 Dimentional Data (B) Outdoor Unit : GR250R5TAA GR250R7TAA 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 (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: (A) Indoor Unit

    1. SPECIFICATIONS 1-5 Refrigerant Flow Diagram Outdoor Unit : GR250R5TAA Indoor Unit : CA250R5TAA : 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...
  • Page 20 1. SPECIFICATIONS Outdoor Unit : GR360R7TAA Indoor Unit : CA360R5TAA : GR480R7TAA : CA480R5TAA 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 Distributor ref.control valve...

  • 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 43°C DB Cooling Minimum 18°C DB / 14°C WB – 5°C DB Maximum 27°C DB 21°C DB / 15,5°C WB Heating Minimum 15°C DB...

  • Page 22: Cooling Capacity

    1. SPECIFICATIONS 1-7 Cooling Capacity Indoor Unit : CA250R5TAA 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 2.82...
  • Page 23 1. SPECIFICATIONS Indoor Unit :CA250R5TAA 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 2.44 6.67 6.26 5.81 7.37 7.03...
  • Page 24 1. SPECIFICATIONS Indoor Unit :CA360R5TAA Outdoor Unit : GR360R7TAA RATING CAPACITY : 10.6 kW AIR FLOW RATE : 1920 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 2.57 2.68 10.1 9.08 8.44 10.7 10.21...
  • Page 25 1. SPECIFICATIONS Indoor Unit :CA480R5TAA 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 4.17 4.09 10.1 10.6 10.2 11.9 11.6 11.2...

  • 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 : CA250R5TAA MODEL : GR250R5TAA, GR250R7TAA SOUND LEVEL : HIGH 37 dB(A), NC 30 SOUND LEVEL : 52 dB(A), NC 44 31 dB(A), NC 22 CONDITION : Distance 1m, Height 1m CONDITION : Distance 1m, Under the unit 1.5m...
  • Page 28 1. SPECIFICATIONS MODEL : CA480R5TAA MODEL : GR480R7TAA SOUND LEVEL : HIGH 43 dB(A), NC 36 SOUND LEVEL : 55 dB(A), NC 47 36 dB(A), NC 24 CONDITION : Distance 1m, Height 1m CONDITION : Distance 1m, Under the unit 1.5m SOURCE : 380 - 400 - 415V, 3 Phase, 50 Hz SOURCE...

  • Page 29: 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 30: (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 31: 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 32: 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 33: 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 34: 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 35: 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 36: 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 37: 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 38 2. PROCESSES AND FUNCTIONS 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 39: 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 40: 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 41: (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 42: 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 43: 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 44: 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 45: Auto-Flap Control

    2. PROCESSES AND FUNCTIONS 2-17 Auto-flap Control Auto flap can control the air flow in 5 steps. Auto-flap 20° 40° F4 F5 0450_M_S Fig. 21 Flap position Operation mode Automatic setting Optional setting Cooling/dehumidifying F1 • F2 • F3 • Swing F1 •...

  • Page 46: Electronic Refrigerant Control Valve Control

    2. PROCESSES AND FUNCTIONS 2-19 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 47: Voltage Detection Control

    2. PROCESSES AND FUNCTIONS 2-20 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 48: Electrical Characteristics

    3. ELECTRICAL DATA 3-1 Electrical characteristics Indoor model : CA250R5TAA / 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 0.60 / 0.63...
  • Page 49 3. ELECTRICAL DATA Indoor model : CA250R5TAA / 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 0.60 / 0.63...
  • Page 50 3. ELECTRICAL DATA Indoor model : CA360R5TAA / 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 0.92 / 0.93 1.24 / 1.31 4.58 / 4.32...
  • Page 51 3. ELECTRICAL DATA Indoor model : CA480R5TAA / Outdoor model : GR480R7TAA 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 0.92 / 0.93 1.24 / 1.31 7.76 / 8.12...

  • Page 52: Electric Wiring Diagrams / Schematic Diagrams

    3. ELECTRICAL DATA 3-2 Electric Wiring Diagrams / Schematic Diagrams Indoor Unit CA250R5TAA, CA360R5TAA, CA480R5TAA – 52 –...
  • Page 53 3. ELECTRICAL DATA CA250R5TAA, CA360R5TAA, CA480R5TAA • 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 54: (B) Outdoor Unit

    3. ELECTRICAL DATA 3-2 Electric Wiring Diagrams / Schematic Diagrams (B) Outdoor Unit 1 1 1 GR250R5TAA – 54 –...
  • Page 55 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 56 3. ELECTRICAL DATA 2 2 2 GR250R7TAA – 56 –...
  • Page 57 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 58 3. ELECTRICAL DATA 3 3 3 GR360R7TAA – 58–...
  • Page 59 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 L3 N F2(3.15A) Symbols Description Symbols...
  • Page 60 3. ELECTRICAL DATA GR480R7TAA 4 4 4 – 60 –...
  • Page 61 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 62: Troubleshooting

    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 63 4. SERVICE PROCEDURES (1)-1 Check before and after Troubleshooting (GR250R5) 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 64 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 65 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 66 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 67 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 68 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 69 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 70 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 71 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 72 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 73 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 PCB inappropriate ? Is there a cut line or contact Correct wiring.
  • Page 74 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 75 4. SERVICE PROCEDURES 11) 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 76 4. SERVICE PROCEDURES 12) 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 13) Symptom: LCD on the remote controller displays “CHECK P04”.
  • Page 77 4. SERVICE PROCEDURES 14) 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 78 4. SERVICE PROCEDURES 16) 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 79 4. SERVICE PROCEDURES 18) 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 80 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 81 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 82 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 83 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 84 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 85 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 86 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 87 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 88 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 89 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 90 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 91 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 92 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 93 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 94 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 95 (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 96: 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 97 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 98 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 99 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 100 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 101 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 102 4. SERVICE PROCEDURES Sensor and Solenoid Layout Diagram Indoor Unit • CA250R5TAA • CA360R5TAA • CA480R5TAA Electronic refrigerant control valve (ERCV) Electronic refrigerant control valve (ERCV) (E1), (RED) TH3 (E2), (BLK) TH3 (E2), (BLK) TH2 (E1), (RED) (E3), (BRN) TH4 (E3), (BRN)
  • Page 103 4. SERVICE PROCEDURES • GR360R7TAA TH6, 7, 8 TH7 (C2), (RED) 63PH TH8 (GRN) ( Discharge gas) TH6 (C1), (BLK) 0585_C_S 0584_C_S • GR480R7TAA TH6, 7, 8 TH7 (C2), (RED) 63PH TH8 (GRN) ( Discharge gas) TH6 (C1), (BLK) 0585_C_S 0586_C_S –...
  • Page 104 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 105 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 for twin, triple or quartet types (2, 3 or 4 indoor units).
  • Page 106 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 107 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 108 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 109 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. Check the indoor and outdoor unit combination (wiring) Single type? Group control (One indoor unit and one for multiple remote controller for one...

This manual is also suitable for:

Gr250r5taaGr250r7taaCa360r5taaGr360r7taaCa480r5taaGr480r7taa

Table of Contents