ComfortStar CSA12CA(I)-R Service Manual
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ComfortStar CSA12CA(I)-R Service Manual

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SPLIT AIR CONDITIONERS
Indoor Unit: CSA12CD(I)-R CSA12CA(I)-R
CSA18CD(I)-R
CSA24CD(I)-R
Outdoor Unit: CSA12CD(O)-R CSA12CA(O)-R CSA18CD(O)-R
CSA24CD(O)-R

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Summary of Contents for ComfortStar CSA12CA(I)-R

  • Page 1 SPLIT AIR CONDITIONERS Indoor Unit: CSA12CD(I)-R CSA12CA(I)-R CSA18CD(I)-R CSA24CD(I)-R Outdoor Unit: CSA12CD(O)-R CSA12CA(O)-R CSA18CD(O)-R CSA24CD(O)-R...
  • Page 3 Table of Contents §. Safety Precautions Precautions Information servicing(For flammable materials) §. Specifications Model Reference Pipe length and the Drop Height Refrigerant Cycle Diagrams Electrical Wiring Diagrams §. Product Features Display Function Safety Features Basic Features Optional Features §. Maintenance First Time Installation Check Refrigerant Recharge Re-Installation...
  • Page 4 Table of Contents §. Troubleshooting Safety Caution General Troubleshooting Complain Record Form Information Inquiry Error Diagnosis and Troubleshooting Without Error Code Quick Maintenance by Error Code Troubleshooting by Error Code Check Procedures Appendix Temperature Sensor Resistance Value Table for T1,T2,T3 and T4 (°C – K) Temperature Sensor Resistance Value Table for TP(for some units) (°C –...
  • Page 6 Safety Precautions Contents Precautions ......................2 Information servicing(For flammable materials) ..........3...
  • Page 7 1. Precautions CAUTION To prevent personal injury, or property or unit damage, • • While unpacking be careful of sharp edges around adhere to all precautionary measures and instructions the unit as well as the edges of the fins on the con- denser and evaporator.
  • Page 8 2. Information servicing(For • Prior to work taking place, the area around the equipment is to be surveyed to make sure that there are no flammable flammable materials) hazards or ignition risks. • NO SMOKING signs shall be displayed. Checks to the area Ventilated area •...
  • Page 9 • that capacitors are discharged: this shall be done in shall also take into account the effects of aging or a safe manner to avoid possibility of sparking; continual vibration from sources such as compressors or fans. • that there no live electrical components and wiring are exposed while charging, recovering or purging 2.13 Detection of flammable refrigerants the system;...
  • Page 10 • The refrigerant charge shall be recovered into the • Before attempting the procedure ensure that: correct recovery cylinders. The system shall be flushed • mechanical handling equipment is available, if with OFN to render the unit safe. This process may required, for handling refrigerant cylinders;...
  • Page 11 • Empty recovery cylinders are evacuated and, if • The recovered refrigerant shall be returned to the possible, cooled before recovery occurs. refrigerant supplier in the correct recovery cylinder, and the relevant Waste Transfer Note arranged. Do not • The recovery equipment shall be in good working mix refrigerants in recovery units and especially not in order with a set of instructions concerning the cylinders.
  • Page 12 Specifications Contents Model Reference ....................2 Pipe Length and Drop Height ................3 Refrigerant Cycle Diagrams ..................4 Electrical Wiring Diagrams ..................5...

  • Page 13: Model Reference

    1. Model Reference Refer to the following table to determine the specific indoor and outdoor unit model. Indoor Unit Model Outdoor Unit Model Capacity (Btu) Power Supply CSA12CA(I)-R 115V, 60Hz, 1Ph CSA12CA(O)-R CSA12CD(I)-R CSA12CD(O)-R 220-230V, 60Hz, CSA18CD(I)-R CSA18CD(O)-R CSA24CD(I)-R CSA24CD(O)-R ...

  • Page 14: Pipe Length And Drop Height

    2. Pipe Length and Drop Height The length and elevation of connection pipe are shown in the table below. if the pipe length exceeds max pipe length, additional refrigerant should be charged to ensure nominal cooling/heating capacity. Capacity(Btu) Standard Length Max Pipe Length Max Elevation Additional Refrigerant...

  • Page 15: Refrigerant Cycle Diagrams

    3. Refrigerant Cycle Diagrams 12K / 18K Cooling-only 24K Cooling-only  Specifications 4 ...

  • Page 16: Electrical Wiring Diagrams

    4. Electrical Wiring Diagrams Indoor and outdoor unit wiring diagram Indoor Unit Outdoor Unit IDU Model IDU Wiring Diagram ODU Model ODU Wiring Diagram CSA12CA(I)-R CSA12CA(O)-R CSA12CD(O)-R CSA12CD(I)-R 16022000020229 16022000033609 CSA18CD(I)-R CSA18CD(O)-R CSA24CD(I)-R CSA24CD(O)-R Specifications 5  ...
  • Page 17 Indoor unit abbreviations Abbreviation Paraphrase Yellow-Green Conductor Positive and Negative Ion Generator Capacitor PLASMA Electronic Dust Collector LIVE NEUTRAL Heater The Electric Heating Belt of Indoor Unit Indoor Room Temperature Coil Temperature of Indoor Heat Exchanger Outdoor unit abbreviations Abbreviation Paraphrase 4-WAY Gas Valve Assembly/4-WAY VALVE...

  • Page 20: Table Of Contents

    Product Features Contents Display Function ....................2 Safety Features ......................3 Basic Functions .......................4 Table ......................4 Abbreviation ....................5 Fan Mode ......................5 Cooling Mode ....................5 Heating Mode(Heat Pump Units) ..............5 Auto-mode ....................6 Drying Mode ....................7 Forced Operation Function ................7 Sleep Function ....................7 3.10 Auto-Restart Function ..................7 3.11 Refrigerant Leakage Detection ...............7 3.12 Ionizer/Plasma (for some models) ..............7 Optional Functions ....................8...

  • Page 21: Display Function

    1. Display Function Unit display functions fresh defrost run timer fresh defrost run timer fresh defrost run timer Display A Display B Display C Display D Display E Display F Display Function Fresh(available on select units only) fresh or Defrost defrost or When the unit is on run or...

  • Page 22: Safety Features

    2. Safety Features Compressor three-minute delay at restart Compressor functions are delayed for up to one minute upon the first startup of the unit, and are delayed for up to three minutes upon subsequent unit restarts. Zero crossing detection error protection(Except for DC fan units) If AC can not detect zero crossing signal for 4 minutes or the zero crossing signal time interval is not correct, the unit will stop and the LED will display the failure.

  • Page 23: Basic Functions

    3. Basic Functions Table Heating Mode Functions Auto Mode Defrosting Mode A=2°C(3.6°F), Cases Case1:T1 and T2 Case 2:T3 B=-3°C(-5.4°F) 9k~24k cooling only Models 9k~12k heat pump Note: The detailed description of case 1 or case 2 is shown in the following function sections(from 3.5 to 3.6). ...

  • Page 24: Abbreviation

    Abbreviation 3.4.3 Outdoor Fan Control Outdoor units just have one single fan speed. The Unit element abbreviations operation of outdoor fan is consistent with the operation of compressor. Except the following situations: Abbreviation Element • Condenser high temperature protection Indoor room temperature •...

  • Page 25: Auto-Mode

    For above 18K models: heating mode: • Compressor current is over than I and lasts for defrost • The defrosting time has reached the setting value. Setting fan • T2≥2°C(3.6°F) after entering defrosting mode for 3 speed(Turbo) minutes. TE2-6 • After entering defrosting mode for 2 minutes, check the value of T2.

  • Page 26: Drying Mode

    • time on to auto mode; not higher than 30°C(86°F)) every hour. After 2 hours, the temperature stops rising and the indoor • the compressor doesn’t start in 20 minutes when a fan is fixed at low speed. running mode is set in auto. •...
  • Page 27 Maintenance Contents First Time Installation Check .................2 Refrigerant Recharge ....................4 Re-Installation .......................5 Indoor Unit ....................5 Outdoor Unit ....................7...

  • Page 28: First Time Installation Check

    1. First Time Installation Check Air and moisture trapped in the refrigerant system affects To prevent air and moisture from affecting the air the performance of the air conditioner by: conditioner’s performance, the indoor unit, as well as the pipes between the indoor and outdoor unit, must be be •...
  • Page 29 Procedure: • If the pressure successfully reaches -0.1 MPa Tighten the flare nuts of the indoor and outdoor (14.5 Psi), fully close the Handle Lo valve, then units, and confirm that both the 2- and 3-way valves cease vacuum pump operations. are closed.

  • Page 30: Refrigerant Recharge

    2. Refrigerant Recharge mA A Procedure: Close both 2- and 3-way valves. 3-way valves. Slightly connect the Handle Lo charge hose to the Operate the air conditioner in cooling mode to charge 3-way service port. the system with liquid refrigerant. Connect the charge hose to the valve at the bottom When the electronic scale displays the correct of the cylinder.

  • Page 31: Re-Installation

    3. Re-Installation Indoor Unit Collecting the refrigerant into the outdoor unit Procedure: Confirm that the 2- and 3-way valves are opened. Close the 3-way valve so that the gauge rests between 0.3 MPa (43.5 Psi) and 0.5 MPa (72.5 Psi). Connect the charge hose with the push pin of Handle Lo to the 3-way valve’s gas service port.
  • Page 32 Air purging with vacuum pump Procedure: • If the pressure successfully reaches -0.1 MPa Tighten the flare nuts of the indoor and outdoor (14.5 Psi), fully close the Handle Lo valve, then units, and confirm that both the 2- and 3-way valves cease vacuum pump operations.

  • Page 33: Outdoor Unit

    Outdoor Unit Evacuation for the whole system Procedure: Wait for 5 minutes then check whether the gauge Confirm that the 2- and 3-way valves are opened. needle moves after turning off the vacuum pump. If Connect the vacuum pump to the 3-way valve’s the gauge needle moves backward, check whether service port.
  • Page 34 Refrigerant charging mA A Procedure: Close both 2- and 3-way valves. Fully open the Handle Lo manifold valve, 2- and 3-way valves. Slightly connect the Handle Lo charge hose to the 3-way service port. Operate the air conditioner in cooling mode to charge the system with liquid refrigerant.
  • Page 35 Indoor Unit Disassembly Contents Dimension ......................2 Indoor Unit Disassembly ..................3 Front Panel ....................3 Electrical parts ....................8 Evaporator ....................12 Fan motor and fan ..................14 Step motor ....................16 Drain Hose ....................17...

  • Page 36: Dimension

    1. Dimension Capacity Body Code W(mm) D(mm) H(mm) 5K~11K 9K~14K 17K~18K 18K~24K 1040  Indoor Unit Disassembly 2 ...

  • Page 37: Front Panel

    2. Disassembly Indoor unit Front Panel Procedure Illustration 1) Hold the front panel by the tabs on Front Panel the both sides and lift it (see CJ_ AF_001). CJ_AF_001 2) Push up the bottom of an air filter, and then pull it out downwards (see CJ_AF_002).
  • Page 38 Procedure Illustration 3) Open the horizontal louver and push the hook towards left to open it (see CJ_AF_003). Horizontal Louver Hook CJ_AF_003 4) Bend the horizontal louver lightly by both hands to loosen the hooks, then remove the horizontal louver (see CJ_AF_004).
  • Page 39 Procedure Illustration 5) Remove 1 screw and then remove the electrical cover(see CJ_AF_005-1 and CJ_AF_005-2). CJ_AF_005-1 CJ_AF_005-2 6) Disconnect the connector for display board(see CJ_AF_005-3) . CJ_AF_005-3 7) Remove the display board(see CJ_ AF_005-4). CJ_AF_005-4 CJ_AF_005 Note: This section is for reference only. Actual unit appearance may vary. ...
  • Page 40 Procedure Illustration 8) Open the screw caps(2) and the remove the screws(see CJ_AF_006). 9) Release the 4 hooks. CJ_AF_006 10) Release the seven hooks in the back (see CJ_AF_007). Hooks CJ_AF_007 Note: This section is for reference only. Actual unit appearance may vary. ...
  • Page 41 Procedure Illustration 11) Pull out the panel frame while pushing the hook through a clearance between the panel frame and the heat exchanger (see CJ_AF_008). CJ_AF_008 Panel Frame Note: This section is for reference only. Actual unit appearance may vary. ...

  • Page 42: Electrical Parts

    Electrical parts Note: Remove the front panel (refer to 1. Front panel) before disassembling electrical parts. Procedure Illustration 1) Remove the fixing screw and then remove the cover of electronic box and the terminal cover (see CJ_AF_009). Electronic Cover Fixing Screw CJ_AF_009 2) Pull out the room temperature sensor (T1) and the coil temperature sensor...
  • Page 43 Procedure Illustration 4) Remove the fixing screw (see CJ_ AF_011-1). 5) Pull out the Electrical control box along the direction indicated in right image. to remove it (CJ_AF_011-2). Fixing Screw CJ_AF_011-1 Electronic Box CJ_AF_011-2 Swing Motor Applicable to AC Motor Only Indoor Fan Motor 6) Disconnect the wires.
  • Page 44 Procedure Illustration 7) Remove the fixing screw, then remove the capacitor of fan motor (see CJ_ AF_013). Capacitor of Fan Motor CJ_AF_013 Note: This section is for reference only. Actual unit appearance may vary.  Indoor Unit Disassembly 10 ...

  • Page 45: Evaporator

    Evaporator Note: Remove the front panel and electrical parts (refer to 1. Front panel and 2. Electrical parts) before disassembling evaporator. Procedure Illustration 1) Disassemble the pipe holder located at the rear of the unit (see CJ_AF_014). Pipe Holder CJ_AF_014 2) Remove the screws on the evaporator located at the fixed plate (see CJ_AF_015).
  • Page 46 Procedure Illustration 4) Pull out the evaporator (see CJ_AF_017). Evaporator CJ_AF_017 Note: This section is for reference only. Actual unit appearance may vary.  Indoor Unit Disassembly 12 ...

  • Page 47: Fan Motor And Fan

    Fan motor and fan Note: Remove the front panel, electrical parts and evaporator (refer to 1. Front panel, 2. Electrical parts, and 3. Evaporator). before disassembling fan motor and fan. Procedure Illustration 1) Remove the two screws and remove the fixing board of the fan motor (see CJ_ AF_018).

  • Page 48: Step Motor

    Step motor Note: Remove the front panel and electrical parts (refer to 1. Front panel, 2. Electrical parts) before disassembling step motor. Procedure Illustration 1) Remove the two screws, then remove the stepping motor (see CJ_AF_021). Stepping Motor CJ_AF_021 Note: This section is for reference only. Actual unit appearance may vary. ...
  • Page 49 Outdoor Unit Disassembly Contents Outdoor Unit Table ....................2 Dimension ......................3 Outdoor Unit Disassembly ..................16 Panel Plate ....................16 Electrical Parts .....................29 Fan Assembly ....................36 Fan Motor ....................37 Sound blanket .....................38 Four-way valve .....................39 Compressor ....................40...

  • Page 50: Outdoor Unit Table

    1. Outdoor Unit Disassembly Outdoor Unit Table Outdoor Unit Model Panel Plate PCB Board CSA12CA(O)-R X130 PCB Board 1 CSA12CD(O)-R X130 PCB Board 1 CSA18CD(O)-R X230 PCB Board 1 CSA24CD(O)-R X330 PCB Board 1  Outdoor Unit Disassembly 2 ...

  • Page 51: Dimension

    2. Dimension 2.1. X130 Panel Plate  Outdoor Unit Disassembly 3 ...
  • Page 52 For US models:  Outdoor Unit Disassembly 4 ...
  • Page 53 2.2. X230 Panel Plate  Outdoor Unit Disassembly 5 ...
  • Page 54 For US models(Rounded grille):  Outdoor Unit Disassembly 6 ...
  • Page 55 For US models(Square grille):  Outdoor Unit Disassembly 7 ...
  • Page 56 2.3. X330 Panel Plate  Outdoor Unit Disassembly 8 ...
  • Page 57 For US models(Rounded grille):  Outdoor Unit Disassembly 9 ...
  • Page 58 For US models(Square grille):  Outdoor Unit Disassembly 10 ...
  • Page 59 2.4. X430 Panel Plate  Outdoor Unit Disassembly 11 ...
  • Page 60 For US models(Rounded grille):  Outdoor Unit Disassembly 12 ...
  • Page 61 For US models(Square grille):  Outdoor Unit Disassembly 13 ...
  • Page 62 2.5. Panel Plate  Outdoor Unit Disassembly 14 ...
  • Page 63 For US models:  Outdoor Unit Disassembly 15 ...

  • Page 64: Outdoor Unit Disassembly

    3. Outdoor Unit Disassembly Panel Plate 1. D30 Procedure Illustration 1) Turn off the air conditioner and the Big Handle power breaker. 2) Remove the screws of the big handle and then remove the big handle (2 screws) (see CJ_D30_001). CJ_D30_001 Top Cover 3) Remove the screws of the top cover...
  • Page 65 Procedure Illustration 4) Remove the screws of the front right panel and then remove the front right panel (2 screws) (see CJ_D30_003). Front Right Panel CJ_D30_003 5) Remove the screws of the front panel and then remove the front panel (9 screws) (see CJ_D30_004).
  • Page 66 Procedure Illustration 6) Remove the screws of water collecting cover and then remove the water collecting cover (2 screw) (see CJ_ D30_005). Water Collecting Cover CJ_D30_005 7) Remove the screws of the rear net and then remove the rear net (2 screws) CJ_D30_006).
  • Page 67 Procedure Illustration 8) Remove the screws of the right panel and then remove the right panel (8 screws) (see CJ_D30_007). Right Panel CJ_D30_007 Note: This section is for reference only. Actual unit appearance may vary.  Outdoor Unit Disassembly 19 ...
  • Page 68 2. X130 Procedure Illustration 1) Turn off the air conditioner and the power breaker. 2) Remove the screw of the big handle and then remove the big handle (1 screw) (see CJ_X130_001). Big Handle CJ_X130_001 Top Cover 3) Remove the screws of the top cover and then remove the top cover (3 screws).
  • Page 69 Procedure Illustration 4) Remove the screws of water collecting cover and then remove the water collecting cover (2 screws) (see CJ_ X130_003). Water Collecting Cover CJ_X130_003 5) Remove the screws of the front panel and then remove the front panel (6 screws(onoff models) or 8 screws(inverter models) (see CJ_ X130_004).
  • Page 70 Procedure Illustration 6) Remove the screws of the right panel and then remove the right panel (5 screws) (see CJ_X130_005). Right Panel CJ_X130_005 Note: This section is for reference only. Actual unit appearance may vary.  Outdoor Unit Disassembly 22 ...
  • Page 71 3. X230/X330 Procedure Illustration 1) Turn off the air conditioner and the power breaker. 2) Remove the screw of the big handle and then remove the big handle (1 screws) (see CJ_X230_001). Big Handle CJ_X230_001 Top Cover 3) Remove the screws of the top cover and then remove the top cover (4 screws).
  • Page 72 Procedure Illustration 4) Remove the screws of water collecting cover and then remove the water collecting cover (2 screws) (see CJ_ X230_003). Water Collecting Cover CJ_X230_003 5) Remove the screws of the front panel and then remove the front panel (7 screws(onoff models) or 9 screws(inverter models) (see CJ_ X230_004).
  • Page 73 Procedure Illustration 6) Remove the screws of the right panel and then remove the right panel (5 screws) (see CJ_X230_005). Right Panel CJ_X230_005 Note: This section is for reference only. Actual unit appearance may vary.  Outdoor Unit Disassembly 25 ...
  • Page 74 4. X430 Procedure Illustration 1) Turn off the air conditioner and the power breaker. 2) Remove the screw of the big handle and then remove the big handle (1 screw) (see CJ_X430_001). Big Handle CJ_X430_001 Top Cover 3) Remove the screws of the top cover and then remove the top cover (3 screws).
  • Page 75 Procedure Illustration 4) Remove the screws of water collecting cover and then remove the water collecting cover (2 screws) (see CJ_ X430_003). Water Collecting Cover CJ_X430_003 5) Remove the screws of the front panel and then remove the front panel (7 screws(onoff models) or 9 screws(inverter models) (see CJ_ X430_004).
  • Page 76 Procedure Illustration 6) Remove the screws of the right panel and then remove the right panel (6 screws) (see CJ_X430_005). Right Panel CJ_X430_005 Note: This section is for reference only. Actual unit appearance may vary.  Outdoor Unit Disassembly 28 ...

  • Page 77: Electrical Parts

    Electrical parts Antistatic gloves must be worn when you disassemble the electronic box. WARNING: Note: Remove the air outlet grille(refer to 3.1 Panel Plate) before disassembling electrical parts. PCB for ON-OFF Models 1. PCB board 1 Procedure Illustration 1) Remove the two screws fixed the electronic control board (see CJ_ ODU_PCB_001).
  • Page 78 Procedure Illustration 8) For models with subzero refrigeration control board, remove 3 screws of it showed in the figure. CJ_ODU_PCB_001-03 9) The subzero refrigeration control board is in the back of the medal sheet. CJ_ODU_PCB_001-04 Note: This section is for reference only. Actual unit appearance may vary. ...
  • Page 79 2. PCB board 2 Procedure Illustration Capacitor of compressor 1) Remove the fixing screws of the compressor capacitor, then pull it out (see CJ_ODU_PCB_002-1) 2) Remove 2 screws of the transformer and then remove it. (see CJ_ODU_ PCB_002-1) 3) Remove the fixing screws of the fan motor capacitor, then remove it.
  • Page 80 Procedure Illustration Fan Motor 6) Disconnect the wires connected to the compressor. (Red wire connects 4-Way Valve Compressor with PCB board, others connects with terminals) (see CJ_ODU_PCB_002-3) (For some models) 7) Disconnect the connectors for fan motor. (Blue wire, red wire, brown wire and black wire.
  • Page 81 3. PCB board 3 Procedure Illustration Earth wire 1) Disconnect the connectors for fan motor (see CJ_ODU_PCB_003). Fan motor 2) Disconnect the wires connected to the compressor (see CJ_ODU_ PCB_003). 3) Disconnect the wires connected to Pipe temperature sensor (see CJ_ ODU_PCB_003).
  • Page 82 4. PCB board 4 Procedure Illustration 6) Remove the fixing screw of the compressor capacitor, then pull it out (see CJ_ODU_PCB_004-1) 7) Remove 2 screws of the transformer and then remove it. (see CJ_ODU_ PCB_004-1) 8) Remove the fixing screw of the fan motor capacitor, then remove it.
  • Page 83 Procedure Illustration 11) Disconnect the power transformer (see CJ_ODU_004-3) 12) Disconnect the wires connected to terminals. (see CJ_ODU_004-3) 13) Disconnect the wires connected to contactor. (see CJ_ODU_004-3) 14) Disconnect the wires connected to T3/T4 sensor. (see CJ_ODU_004-3) CJ_ODU_PCB_004-3 Note: This section is for reference only. Actual unit appearance may vary. Outdoor Unit Disassembly 35 ...

  • Page 84: Fan Assembly

    Fan Assembly Note: Remove the panel plate (refer to 3.1 Panel Plate) before disassembling fan. Procedure Illustration 1) Remove the nut securing the fan with a spanner (see CJ_ODU_ FAN_001). 2) Remove the fan. CJ_ODU_FAN_001 Note: This section is for reference only. Actual unit appearance may vary. ...

  • Page 85: Fan Motor

    Fan Motor Note: Remove the panel plate and the connection of fan motor on PCB (refer to 3.1 Panel Plate and 3.2 Electrical parts) before disassembling fan motor. Procedure Illustration 3) Remove the fixing screws of the fan motor (4 screws) (see CJ_ODU_MOTOR_001). 4) Remove the fan motor.

  • Page 86: Sound Blanket

    Sound blanket Note: Remove the panel plate (refer to 3.1 Panel plate) before disassembling sound blanket. Procedure Illustration 1) Remove the sound blanket (side and top) (see CJ_ODU_BLANKET_001). Sound Blanket(top) (Applicable to models with blanket) Sound Blanket(side) (Applicable to models with blanket) CJ_ODU_BLANKET_001 Note: This section is for reference only.
  • Page 87 Four-way valve (for heat pump models) WARNING: Evacuate the system and confirm that there is no refrigerant left in the system before removing the four-way valve and the compressor. (For R32 & R290, you should evacuate the system with the vacuum pump; flush the system with nitrogen;...

  • Page 88: Compressor

    Compressor WARNING: Evacuate the system and confirm that there is no refrigerant left in the system before removing the four-way valve and the compressor. (For R32 & R290, you should evacuate the system with the vacuum pump; flush the system with nitrogen; then repeat the two steps before heating up the brazed parts. The operations above should be implemented by professionals.) Note: Remove the panel plate, connection of compressor on PCB (refer to 3.1 Panel plate and 3.2 Electrical parts) before disassembling sound blanket.
  • Page 89 Procedure Illustration 3) Remove the hex nuts and washers securing the compressor, located on the bottom plate (see CJ_ODU_COMP_003). CJ_ODU_COMP_003 Suction Pipe 4) Heat up the brazed parts and then remove the the discharge pipe and the suction pipe (see CJ_ODU_COMP_004). Discharge Pipe 5) Lift the compressor from the base pan assembly with pliers.
  • Page 90 Troubleshooting Contents Safety Caution .......................2 General Troubleshooting ..................3 Complain Record Form ..................4 Information Inquiry ....................6 Error Diagnosis and Troubleshooting Without Error Code .........7 Remote maintenance ..................7 Field maintenance ..................8 Quick Maintenance by Error Code ................9 Troubleshooting by Error Code ................14 EH 00 (EEPROM parameter error diagnosis and solution) ......14 EL 01 (Indoor and outdoor unit communication diagnosis and solution) ..15 EH 02 (Zero-crossing detection error diagnosis and solution) ......17...

  • Page 91: Safety Caution

    1. Safety Caution WARNING Be sure to turn off all power supplies or disconnect all wires to avoid electric shock. While checking indoor/outdoor PCB, please equip oneself with antistatic gloves or wrist strap to avoid damage to the board. WARNING Electricity remains in capacitors even when the power supply is off.

  • Page 92: General Troubleshooting

    2. General Troubleshooting Error Display (Indoor Unit) When the indoor unit encounters a recognized error, the operation lamp will flash in a corresponding series, the timer lamp may turn on or begin flashing, and an error code will be displayed. These error codes are described in the following tables: Operation Timer...

  • Page 93: Complain Record Form

    3. Complain Record Form Complain Record Form Request No.: Date: Installation Date: Service Date: Customer Information Name Telephone No. Home Address Email Product Information Indoor Unit Model Outdoor Unit Model Serial No. of indoor unit Serial No. of outdoor unit Working Mode □Cooling □Heating...
  • Page 94 Parameter Checking information by Remote controller Displaying code Displaying code meaning Display value Display value meaning Room temperature Indoor coil temperature Outdoor coil temperature Approval from Manufacturer □Approved □More Proof needed □Rejected  Troubleshooting 5 ...

  • Page 95: Information Inquiry

    4. Information Inquiry • To enter information inquiry status, complete the following procedure within ten seconds: • Press LED(or DO NOT DISTURB) 3 times. • Press SWING(or AIR DIRECTION) 3 times. • Finish 1 and 2 within 10 seconds, you will hear beeps for two seconds, which means the unit goes into parameter checking mode.

  • Page 96: Error Diagnosis And Troubleshooting Without Error Code

    5. Error Diagnosis and Troubleshooting Without Error Code WARNING Be sure to turn off unit before any maintenance to prevent damage or injury. Remote maintenance SUGGESTION: When troubles occur, please check the following points with customers before field maintenance. Problem Solution Unit will not start TS10 - TS11...

  • Page 97: Field Maintenance

    Field maintenance Problem Solution Unit will not start TS12 - TS13 Compressor will not start but fans run TS12 - TS13 Compressor and condenser (outdoor) fan will not start TS12 - TS13 Evaporator (indoor) fan will not start TS12 - TS13 Condenser (Outdoor) fan will not start TS12 - TS13 Unit runs, but shortly stops...

  • Page 98: Quick Maintenance By Error Code

    6. Quick Maintenance by Error Code If you do not have the time to test which specific parts are faulty, you can directly change the required parts according the error code. You can find the parts to replace by error code in the following table. Error Code Part requiring replacement EH 00...
  • Page 99 1.Remote Maintenance Electrical Circuit Refrigerant Circuit Possible causes of trouble Unit will not start ☆ ☆ ☆ ☆ The power switch is on but fans will not start ☆ ☆ ☆ The temperature on the display board cannot be set ☆...
  • Page 100 1.Remote Maintenance Others Possible causes of trouble Unit will not start The power switch is on but fans will not start ☆ The temperature on the display board cannot be set Unit is on but the wind is not cold(hot) Unit runs, but shortly stops The unit starts up and stops frequently ☆...
  • Page 101 2.Field Maintenance Refrigerant Circuit Others Possible causes of trouble Unit will not start Compressor will not start but fans run ☆ Compressor and condenser (outdoor) fan will not start Evaporator (indoor) fan will not start Condenser (Outdoor) fan will not start Unit runs, but shortly stops ☆...
  • Page 102 2.Field Maintenance Electrical Circuit Possible causes of trouble Unit will not start ☆ ☆ ☆ ☆ ☆ ☆ Compressor will not start but fans run ☆ ☆ ☆ ☆ ☆ Compressor and condenser (outdoor) fan will not start ☆ ☆ ☆...

  • Page 103: Troubleshooting By Error Code

    7. Troubleshooting by Error Code EH 00 (Indoor EEPROM parameter error diagnosis and solution) Description: Indoor PCB main chip does not receive feedback from EEPROM chip. Recommended parts to prepare: • Indoor PCB Troubleshooting and repair: Shut off the power supply and turn it on 2 minutes later.

  • Page 104: El 01 (Indoor And Outdoor Unit Communication Diagnosis And Solution)

    EL 01 (Indoor / outdoor unit communication error diagnosis and solution) Description: The indoor unit has not received feedback from the outdoor unit for 110 seconds, four consecutive times Recommended parts to prepare: • Indoor PCB • Outdoor PCB • Reactor Troubleshooting and repair: Power off, then restart the unit after 2 minutes.
  • Page 105 Remarks: • Use a multimeter to test the DC voltage between 2 port(or S or L2 port) and 3 port(or N or S port) of outdoor unit. The red pin of multimeter connects with 2 port(or S or L2 port) while the black pin is for 3 port(or N or S port) . When AC is normal running, the voltage will move alternately between -25V to 25V.

  • Page 106: Eh 02 (Zero-Crossing Detection Error Diagnosis And Solution)

    EH 02 (Zero crossing detection error diagnosis and solution) Description: When PCB does not receive zero crossing signal feedback for 4 minutes or the zero crossing signal time interval is abnormal. Recommended parts to prepare: • Connection wires • Indoor PCB Troubleshooting and repair: Check the connections and power supply.

  • Page 107: Eh 03/F5/Ec 07 (Fan Speed Is Operating Outside Of The Normal Range Diagnosis And Solution)

    EH 03 /EC 07 (Fan speed is operating outside of the normal range diagnosis and solution) Description: When indoor fan speed keeps too low (300RPM) for certain time, the LED displays the failure code and AC turns off. Recommended parts to prepare: •...
  • Page 108 Index: 1. Indoor or Outdoor DC Fan Motor(control chip is in fan motor) Power on and when the unit is in standby, measure the voltage of pin1-pin3, pin4-pin3 in fan motor connector. If the value of the voltage is not in the range showing in below table, the PCB must has problems and need to be replaced. •...
  • Page 109 3. Indoor AC Fan Motor Power on and set the unit running in fan mode at high fan speed. After running for 15 seconds, measure the voltage of pin1 and pin2. If the value of the voltage is less than 100V(208~240V power supply) or 50V (115V power supply), the PCB must has problems and need to be replaced.

  • Page 110: Eh 60/Eh 61/Ec 52 (Open Circuit Or Short Circuit Of Temperature Sensor Diagnosis And Solution)

    EH 60/EH 61/EC 52 (Open or short circuit of temperature sensor diagnosis and solution) Description: If the sampling voltage is lower than 0.06V or higher than 4.94V, the LED displays the failure code. Recommended parts to prepare: • Connection wires •...

  • Page 111: Eh 0B (Indoor Pcb/Display Board Communication Error Diagnosis And Solution)

    EH 0b (Indoor PCB/display board communication error diagnosis and solution) Description: The display board cannot communicate with the indoor PCB. Recommended parts to prepare: • Communication wire • Indoor PCB • Display board Troubleshooting and repair: Power off, then restart the unit 2 minutes later Is it still displaying the error code? The unit functions normally...

  • Page 112: El 0C (Refrigerant Leakage Detection Diagnosis And Solution)

    EL 0C (Refrigerant leakage detection diagnosis and solution) Description: Define the evaporator coil temperature T2 of the compressor just starts running as Tcool. In the beginning 5 minutes after the compressor starts up, if T2 < Tcool-2°C does not keep continuous 4 seconds and this situation happens 3 times, the LED displays the failure code and AC turns off.

  • Page 113: Pc 03 (High Pressure Protection)

    PC 03 (High pressure protection diagnosis and solution) Description: If the current is less than setting value for 4 seconds, AC shuts off and restarts after 3 minutes in cooling mode or after 4 minutes in heating mode. If this happens 8 times, the LED displays the failure code and AC turns off. Recommended parts to prepare: •...

  • Page 114: Check Procedures

    8. Check Procedures 8.1 Temperature Sensor Check WARNING Be sure to turn off all power supplies or disconnect all wires to avoid electric shock. Operate after compressor and coil have returned to normal temperature in case of injury. 1. Disconnect temperature sensor from PCB (Refer to Chapter 5. Indoor Disassembly and Chapter 6. Outdoor Disassembly). 2.
  • Page 115 8.2 Fan Motor Check 1) Power off and disconnect fan motor power cord from PCB. Measure the resistance value of each winding by using the multi-meter. The normal value show as follows . YKFG-13-4-38L Model YKFG-15-4-28-1 YKFG-20-4-10L YKFG-20-4-5-11 YKFG-13-4-38L-4 Brand Welling Welling Welling...
  • Page 116 Appendix Contents Temperature Sensor Resistance Value Table for T1, T2, T3, and T4 (°C – K) ..2 Temperature Sensor Resistance Value Table for TP (for some units)(°C --K) ..3 iii) Pressure On Service Port ..................4...
  • Page 117 i) Temperature Sensor Resistance Value Table for T1,T2,T3 and T4 (°C – K) °C °F K Ohm °C °F K Ohm °C °F K Ohm °C °F K Ohm 115.266 12.6431 2.35774 0.62973 108.146 12.0561 2.27249 0.61148 101.517 11.5 2.19073 0.59386 96.3423 10.9731...
  • Page 118 ii) Temperature Sensor Resistance Value Table for TP(for some units) (°C --K) °C °F K Ohm °C °F K Ohm °C °F K Ohm °C °F K Ohm °C °F K Ohm °C °F K Ohm °C °F K Ohm °C °F K Ohm...
  • Page 119 iii) Pressure On Service Port Cooling chart(R410A): ODU(DB) °F(°C) 0(-17) 5(-15) 95 (35) (-9.44) (7.22) (23.89) (29.44) (40.56) (46.11) (48.89) IDU(DB/WB) 70/59 (21.11/15) 10.1 10.6 75/63 (23.89/17.22) 10.7 11.2 80/67 (26.67/19.44) 11.2 11.9 90/73 (32.22/22.78) 10.5 10.3 10.0 10.6 12.4 13.0 70/59 (21.11/15) 75/63 (23.89/17.22)
  • Page 120 Heating chart(R410A): ODU(DB/WB) 57/53 47/43 37/33 27/23 17/13 (-8.33/- 0/-2 -17/-18 °F(°C) (13.89/11.67) (8.33/6.11) (2.78/0.56) (-2.78/-5) 10.56) (-17/-19) (-27/-28) IDU(DB) 55(12.78) 30.3 28.5 25.3 22.8 20.8 18.5 16.5 65(18.33) 32.5 30.0 26.6 25.4 23.3 20.5 19.0 75(23.89) 33.8 31.5 27.8 26.3 24.9 21.5...
  • Page 121 Cooling chart(R22): ODU(DB) °F(°C) 0(-17) 5(-15) 95 (35) (-9.44) (7.22) (23.89) (29.44) (40.56) (46.11) (48.89) IDU(DB/WB) 70/59 (21.11/15) 75/63 (23.89/17.22) 80/67 (26.67/19.44) 90/73 (32.22/22.78) 70/59 (21.11/15) 75/63 (23.89/17.22) 80/67 (26.67/19.44) 90/73 (32.22/22.78) 70/59 (21.11/15) 0.40 0.41 0.46 0.50 0.51 0.49 0.51 0.54 0.63...
  • Page 122 Heating chart(R22): ODU(DB/WB) 57/53 47/43 37/33 27/23 17/13 (-8.33/- 0/-2 -17/-18 °F(°C) (13.89/11.67) (8.33/6.11) (2.78/0.56) (-2.78/-5) 10.56) (-17/-19) (-27/-28) IDU(DB) 55(12.78) 18.9 17.8 15.8 14.3 13.0 11.6 10.3 65(18.33) 20.3 18.8 16.6 15.9 14.6 12.8 11.9 75(23.89) 21.1 19.7 17.3 16.4 15.6 13.4...
  • Page 123 Cooling chart(R32): ODU(DB) °F(°C) 0(-17) 5(-15) 95 (35) (-9.44) (7.22) (23.89) (29.44) (40.56) (46.11) (48.89) IDU(DB/WB) 70/59 (21.11/15) 10.3 10.8 75/63 (23.89/17.22) 10.9 11.4 80/67 (26.67/19.44) 11.4 12.1 90/73 (32.22/22.78) 10.7 10.5 10.2 10.8 12.6 13.3 70/59 (21.11/15) 75/63 (23.89/17.22) 80/67 (26.67/19.44) 90/73 (32.22/22.78) 70/59 (21.11/15)
  • Page 124 Heating chart(R32): ODU(DB/WB) 57/53 47/43 37/33 27/23 17/13 (-8.33/- 0/-2 -17/-18 °F(°C) (13.89/11.67) (8.33/6.11) (2.78/0.56) (-2.78/-5) 10.56) (-17/-19) (-27/-28) IDU(DB) 55(12.78) 30.9 29.1 25.8 23.3 21.2 18.9 16.8 65(18.33) 33.2 30.6 27.1 25.9 23.8 20.9 19.4 75(23.89) 34.5 32.1 28.4 26.8 25.4 21.9...
  • Page 125 System Pressure Table-R22 Pressure Temperature Pressure Temperature °C °F °C °F 14.5 -41.091 -41.964 1600 41.748 107.146 21.75 -32.077 -25.739 1650 16.5 239.25 43.029 109.452 -25.177 -13.319 1700 246.5 44.281 111.706 36.25 -19.508 -3.114 1750 17.5 253.75 45.506 113.911 43.5 -14.654 5.623 1800...
  • Page 126 System Pressure Table-R410A Pressure Temperature Pressure Temperature °C °F °C °F 14.5 -51.623 -60.921 2350 23.5 340.75 38.817 101.871 21.75 -43.327 -45.989 2400 39.68 103.424 -36.992 -34.586 2450 24.5 355.25 40.531 104.956 36.25 -31.795 -25.231 2500 362.5 41.368 106.462 43.5 -27.351 -17.232 2550...
  • Page 127 System Pressure Table-R32 Pressure Temperature Pressure Temperature °C °F °C °F 14.5 -51.909 -61.436 1850 18.5 268.25 28.425 83.165 21.75 -43.635 -46.543 1900 275.5 29.447 85.005 -37.323 -35.181 1950 19.5 282.75 30.448 86.806 36.25 -32.15 -25.87 2000 31.431 88.576 43.5 -27.731 -17.916 2050...

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