TECHNICAL DATA & SERVICE MANUAL Indoor Unit MCA201R MCA271R MCA351R Outdoor Unit GR201R GR271R GR351R SPLIT SYSTEM AIR CONDITIONER INDOOR UNIT OUTDOOR UNIT 0.8180.263.1 06/2002
Important! Please Read Before Starting This air conditioning system meets strict safety and operating standards. As the installer or service person, it is an important part of your job to install or service the system so it operates safely and efficiently. For safe installation and trouble-free operation, you must: Carefully read this instruction booklet before beginning. Follow each installation or repair step exactly as shown. Observe all local, state, and national electrical codes. Pay close attention to all warning and caution notices given in this manual. This symbol refers to a hazard or WARNING unsafe practice which can result in severe personal injury or death. This symbol refers to a hazard or CAUTION unsafe practice which can result in personal injury or product or property damage. If Necessary, Get Help These instructions are all you need for most installation sites and maintenance conditions. If you require help for a special problem, contact our sales/service outlet or your certified dealer for additional instructions. In Case of Improper Installation The manufacturer shall in no way be responsible for improper installation or maintenance service, including failure to follow the instructions in this document. Special Precautions WARNING When Wiring ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH. ONLY A QUALIFIED, EXPERIENCED ELECTRICIAN SHOULD ATTEMPT TO WIRE THIS SYSTEM. Do not supply power to the unit until all wiring and tubing are completed or reconnected and checked. Highly dangerous electrical voltages are used in this system. Carefully refer to the wiring diagram and these instructions when wiring. Improper connections and inadequate grounding can cause accidental injury or death. Ground the unit following local electrical codes. Connect all wiring tightly. Loose wiring may cause overheating at connection points and a possible fire hazard. When Transporting Be careful when picking up and moving the indoor and outdoor units. Get a partner to help, and bend your knees when lifting to reduce strain on your back. Sharp edges or thin aluminum fins on the air conditioner can cut your fingers. When Installing In a Ceiling or Wall Make sure the ceiling/wall is strong enough to hold the units weight. It may be necessary to construct a strong wood or metal frame to provide added support. In a Room Properly insulate any tubing run inside a room to prevent sweating that can cause dripping and water damage to walls and floors. In Moist or Uneven Locations Use a raised concrete pad or concrete blocks to provide a solid, level foundation for the outdoor unit. This prevents water damage and abnormal vibration. In an Area with High Winds Securely anchor the outdoor unit down with bolts and a metal frame. Provide a suitable air baffle. In a Snowy Area (for Heat Pump-type Systems) Install the outdoor unit on a raised platform that is higher than drifting snow. Provide snow vents. When Connecting Refrigerant Tubing Use the flare method for connecting tubing. Apply refrigerant lubricant to the matching surfaces of the flare and union tubes before connecting them, then tighten the nut with a torque wrench for a leakfree connection. Check carefully for leaks before starting the test run. When Servicing Turn the power off at the main power box (mains) before opening the unit to check or repair electrical parts and wiring. Keep your fingers and clothing away from any moving parts. Clean up the site after you finish, remembering to check that no metal scraps or bits of wiring have been left inside the unit being serviced. Others CAUTION Ventilate any enclosed areas when installing or testing the refrigeration system. Escaped refrigerant gas, on contact with fire or heat, can produce dangerously toxic gas. Confirm upon completing installation that no refrigerant gas is leaking. If escaped gas comes in contact with a stove, gas water heater, electric room heater or other heat source, it can produce dangerously toxic gas. i ii
Table of Contents Page 1 OPERATING RANGE 1 2 SPECIFICATIONS 2 2-1 Unit Specification 2 2-2 Indoor Unit 3 2-3 Outdoor Unit 4 2-4 Other Component Specifications 5 3 DIMENSIONAL DATA 6 3-1 Indoor Unit 6 3-2 Outdoor Unit 7 4 REFRIGERANT FLOW DIAGRAM 8 5 PERFORMANCE DATA 9 5-1 P Air Throw Distance Chart 9 5-2 Cooling Capacity 10 5-3 Heating Capacity 13 6 ELECTRICAL DATA 14 6-1 Electrical Characteristic 14 6-2 Electric Wiring Diagrams 15 7 FUNCTION 16 7-1 Cool Mode Operation 16 7-2 Heat Mode Operation 17 7-3 Auto Cool/Heat mode operation 18 7-4 Dry Mode Operation 19 7-5 Protection Operation in Cool and Dry Operation Mode 20 7-6 Protection Operation in Heat Mode) 22 7-7 Cool Draft Prevention (Heating 25 7-8 Others Features 26 8 TROUBLESHOOTING 28 8-1 Check before and after troubleshooting 28 8-2 Check Power Supply Wiring 28 8-3 Check Indoor Unit Wiring 28 8-4 Check Power Supply 28 8-5 Check Lead wires and Connector in Indoor and Outdoor Units 28 8-6 Air Conditioner Does not work 29 8-7 Some Parts of Air Conditioner does not operate 32 8-8 Air Conditioner operates, but abnormalities are observed 34 8-9 If a Sensor is defective 35 9 CHECKING ELECTRICAL COMPONENTS 36 9-1 Measure of insulation Resistance 36 9-2 Check Continuity for Electrical Parts 36 9-3 Checking Motor Capacitor 37 iii
1.OPERATING RANGE Cooling Heating Temperature Indoor Air Intake Temp. Outdoor Air Intake Temp. Maximum 32 C D.B. / 23 C W.B. 43 C D.B. Minimum 19 C D.B. / 14 C W.B. 19 C D.B. Maximum 27 C D.B. 24 C D.B. / 18 C W.B. Minimum 16 C D.B. -5 C D.B. / -6 C W.B. DB-Dry Bulb WB-Wet Bulb 1
2.SPECIFICATIONS 2-1 Unit Specification Model Unit Voltage Rating Indoor Unit MCA201R MCA271R MCA351R Outdoor Unit GR201R GR271R GR351R 230 V 50 Hz Performance Capacity Cooling / Heating W 2000 2300 2450 2800 3150 3550 BTU/h 6820 7840 8350 9550 10740 12100 Air Circulation Hi-Me-Low m 3 /hr 280 320 420 280 320 420 300 350 450 Moisture Removal Liters/h 0.5 0.8 1.1 Electrical Rating Running Amperes A 3.2 3.3 4.0 4.0 5.5 5.7 Power Input W 700 720 850 850 1150 1250 Power Factor % 95 95 92 92 90 91 C.O.P W/W 2.86 3.19 2.88 3.29 2.74 2.96 Compressor locked rotor amperes A 20 24 30 Features Controls / Temperature Control Microprocessor / I.C. thermostat Control Units Wireless remote control unit Timer 24 hr ON o OFF Fan Speed Indoor/Outdoor 3-Auto / 1 Air Flow Direction (indoor) Horizontal Manual Vertical Auto Air Filter Washable, Anti-Mold Compressor Rotary ( Hermetic ) Refrigerant/Amount charged at shipment g R22-690 R22-650 R22-690 Refrigerant Control Capillary Operation Sound Indoor: hi / Me / Lo db-a 39 33 28 40 35 31 42 38 34 Outdoor: Cool/Heat db-a 38 40 37 40 37 40 Refrigerant Tubing Connections Flare Max Allowable tubing length at shipment mt 7.5 Refrigerant tube Narrow tube mm (in) 6.35 (1/4 ) diameter Wide tube mm (in) 9.52 (3/8 ) 9.52 (3/8 ) 12.7 (1/2 ) Max allowable tubing Lenght mt 10 10 15 Refrigerant g/m 15 15 15 Dimensional & Weight Indoor Unit Outdoor Unit Height mm 270 540 Unit dimensions Width mm 805 700 Depth mm 181 265 Height mm 343 585 Package dimensions Width mm 855 830 Depth mm 232 360 Weight Net Kg 8 35 36 38 Shipping Kg 10 38 39 41 Shipping volume m 3 0.07 0.18 DATA SUBJECT TO CHANGE WITHOUT NOTICE. Remarks: Rating conditions are: Cooling : Indoor air temperature 27 C D.B. / 19 C W.B. Outdoor air temperature 35 C D.B. / 24 C W.B. Heating : Indoor air temperature 20 C D.B. Outoor air temperature 7 C D.B. / 6 C W.B. 2
2-2 Indoor Unit Model Unit MCA201R MCA271R MCA351R Controller PCB Part No Controls Control circuit fuse WSA-LTR Microprocessor 250 V 3.15 A Remote Control Unit Fan & Fan Motor Type Cross-Flow Q.ty.Dia. and length mm 1- θ 95 / 617 Fan motor model.q.ty KFV4Q-11HP-S-----------1 No of poles rpm (230V,hi) 4-----1160 4-----1160 4------1250 Nominal output W 10 BRN-WHT 561.8 VLT-WHT 197.4 Coil Resistance (Ambient Temp.) VLT-ORG 63.4 YEL-ORG 155.7 YEL-PNK 115.9 Safety device Type Internal Fuse Operating temp. Open C 145 +/-5 Close C - Run capacitor µf 0.6 0.6 0.8 Vac 400 400 400 Flap Motor Type Stepping Motor Model MP24GAI Rating 12 VDC Coil resistance (Ambient temp 25 C) ohm 380 Heat Exch.Coil Coil Aluminium plate fin/ Copper tube Rows 2 Fin pitch mm 1.6 Face area m 2 0.13 DATA SUBJECT TO CHANGE WITHOUT NOTICE 3
2-3 Outdoor Unit Model Unit GR201R GR271R GR351R Compressor Type Rotary (Hermetic) Compressor model mm RH130VHAT RH154VHAT RH189VHAF Nominal output Compressor oil Diamond MS 56.Amount cc 300 300 520 Coil resistance (Ambient temp 25 C)+/- 7% cr Ω 4.26 3.5 2.64 cs Ω 5.87 5.55 4.02 Safety device Type Overload relay Operating temp Open C 150 +/-5 150 +/-5 155 +/-5 Close C 90 +/-10 90 +/-10 90 +/-10 Operating amp(ambient temp 25 C) - Run capacitor µf 25 25 30 VAC 450 450 450 Grank case heater Fan & Fan Motor Type Propeller Q.ty.Dia. and length mm 1------θ 370 Fan motor model.q.ty K35610-M01723-------1 No of poles rpm (230V,hi) 6------820 Nominal output W 22 Ω BRN-WTH 374 +/- 7% Coil Resistance (Ambient Temp.20 C) Ω PNK-BRN 484 +/-7% - Safety device Type Internal protector Operating temp. Open C 150 +-10 Close C Auto Run capacitor µf 1.5 Vac 400 Heat Exch.Coil Coil Aluminium Plate fin / Copper tube Rows 1 Fin pitch mm 1.6 1.6 1.2 Face area m 2 0.35 External Finish Acrylic baked-on enamel finish DATA SUBJECT TO CHANGE WITHOUT NOTICE 4
2-4 Other Component Specifications Indoor unit Transformer (TR) TPN41-0001 Primary 230V 50HZ Rating Secondary 12 V 300mA Capacity Coil resistance Ω (at 21 C) Primary 495 Secondary 2.86 Thermal cut-off temp. 125 C Thermistor (Coil sensor) NTC - TERMISTOR Resistance KΩ 10 at 25 C Thermistor (Room sensor) Resistance KΩ Outdoor Unit 4-Way Valve (Solenoid coil) CHV01A(coil) CHV-0101 (valve) Coil rating 230V-50HZ Coil resistance KΩ 1.430 +/- 7% Thermostat ( Defrost thermo ) NTC - TERMISTOR Operating Temp C 2 / 15 +/-2 ON Resistance KΩ 10 at 25 C 5
3.DIMENSIONAL DATA 3-1 Indoor Unit 6
3-2 Outdoor Unit 7
4.REFRIGERANT FLOW DIAGRAM 8
5.PERFORMANCE 5-1 Air Throw Distance Chart COOLING Room ir temp : 27 C Fan Speed : High Axis Air Velocity (m/s) Vertical distance (m) 1 2 3 4 Horizontal distance (m) 1 2 3 4 5 6 7 8 9 Axis air velocity Flap angle 0 30 HEATING Room ir temp : 20 C Fan Speed : High Axis Air Velocity (m/s) Vertical distance (m) 1 2 3 4 Horizontal distance (m) 1 2 3 4 5 6 7 8 9 Axis air velocity Flap angle 45 60 9
COOLING Room ir temp : 27 C Fan Speed : High Axis Air Velocity (m/s) Vertical distance (m) 1 2 3 4 Horizontal distance (m) 1 2 3 4 5 6 7 8 9 Axis air velocity Flap angle 0 30 HEATING Room ir temp : 20 C Fan Speed : High Axis Air Velocity (m/s) Vertical distance (m) 1 2 3 4 Horizontal distance (m) 1 2 3 4 5 6 7 8 9 Axis air velocity Flap angle 45 60 10
5-2 Cooling Capacity Indoor Unit Otdoor Unit MCA271R GR271R 230 V Single Phase 50 HZ RATING CAPACITY 2.45kW AIR FLOW RATE 420m³/h EVAPORATOR CONDENSER ENT.TEMP. C OUTDOOR AMBIENT TEMP. C W.B. D.B. 25 30 35 40 43 TC 2,32 2,25 2,15 2,01 1,86 CM 0,70 0,75 0,80 0,88 0,96 21 SHC 1,59 1,56 1,51 1,44 1,37 23 SHC 1,80 1,77 1,72 1,65 1,58 15 25 SHC 2,01 1,97 1,92 1,85 1,78 27 SHC 2,22 2,18 2,13 2,01 1,86 29 SHC 2,32 2,25 2,15 2,01 1,86 31 SHC 2,32 2,25 2,15 2,01 1,86 TC 2,51 2,42 2,30 2,16 1,99 CM 0,72 0,77 0,82 0,91 0,98 21 SHC 1,39 1,35 1,30 1,24 1,16 23 SHC 1,60 1,56 1,50 1,44 1,36 17 25 SHC 1,81 1,76 1,71 1,65 1,57 27 SHC 2,02 1,97 1,91 1,85 1,77 29 SHC 2,24 2,17 2,12 2,06 1,98 31 SHC 2,44 2,38 2,30 2,16 1,99 TC 2,66 2,57 #2,45 2,30 2,12 CM 0,75 0,79 0,85 0,93 1,01 21 SHC 1,17 1,13 1,08 1,01 0,94 23 SHC 1,37 1,34 1,28 1,22 1,15 19 25 SHC 1,57 1,54 1,49 1,43 1,35 27 SHC 1,77 1,75 1,69 1,63 1,56 29 SHC 1,97 1,95 1,90 1,84 1,76 31 SHC 2,18 2,16 2,10 2,04 1,97 TC 2,82 2,73 2,60 2,44 2,25 CM 0,77 0,81 0,88 0,96 1,04 23 SHC 1,15 1,11 1,06 1,00 0,92 21 25 SHC 1,35 1,32 1,27 1,20 1,13 27 SHC 1,55 1,52 1,47 1,41 1,33 29 SHC 1,75 1,73 1,68 1,61 1,54 31 SHC 1,96 1,93 1,88 1,82 1,75 TC 3,01 2,89 2,73 2,55 2,38 CM 0,78 0,83 0,90 0,98 1,07 23 25 SHC 1,13 1,08 1,02 0,96 0,89 27 SHC 1,32 1,28 1,23 1,16 1,10 29 SHC 1,52 1,49 1,43 1,37 1,30 31 SHC 1,74 1,70 1,64 1,57 1,51 TC : Total Cooling Capacity KW SHC : Sensible Heat Capacity KW CM : Compressor Input KW Rating Condition (#Mark) are Outdoor Ambient Temperature Indoor Unit Entering Air Temp 11 35 C D.B. 27 C D.B / 19 C W.B.
Indoor Unit Otdoor Unit MCA351R GR351R 230 V Single Phase 50 HZ RATING CAPACITY 3.15 kw AIR FLOW RATE 450 m³/h EVAPORATOR CONDENSER ENT.TEMP. C OUTDOOR AMBIENT TEMP. C W.B. D.B. 25 30 35 40 43 TC 2,99 2,90 2,76 2,59 2,39 CM 0,95 1,01 1,09 1,19 1,30 21 SHC 2,05 2,01 1,94 1,86 1,76 23 SHC 2,32 2,27 2,21 2,12 2,03 15 25 SHC 2,59 2,53 2,47 2,38 2,29 27 SHC 2,86 2,80 2,73 2,59 2,39 29 SHC 2,99 2,90 2,76 2,59 2,39 31 SHC 2,99 2,90 2,76 2,59 2,39 TC 3,23 3,11 2,96 2,78 2,56 CM 0,97 1,04 1,11 1,23 1,33 21 SHC 1,79 1,74 1,67 1,59 1,49 23 SHC 2,06 2,00 1,93 1,85 1,75 17 25 SHC 2,33 2,27 2,20 2,12 2,01 27 SHC 2,60 2,53 2,46 2,38 2,28 29 SHC 2,88 2,79 2,73 2,64 2,54 31 SHC 3,14 3,05 2,96 2,78 2,56 TC 3,42 3,31 #3,15 2,96 2,73 CM 1,02 1,07 1,15 1,26 1,37 21 SHC 1,50 1,45 1,38 1,30 1,21 23 SHC 1,76 1,72 1,65 1,57 1,47 19 25 SHC 2,02 1,98 1,91 1,84 1,73 27 SHC 2,28 2,25 2,18 2,10 2,00 29 SHC 2,53 2,51 2,44 2,36 2,26 31 SHC 2,80 2,77 2,70 2,62 2,53 TC 3,63 3,51 3,34 3,14 2,89 CM 1,04 1,10 1,19 1,30 1,41 23 SHC 1,48 1,43 1,36 1,28 1,18 21 25 SHC 1,73 1,69 1,63 1,55 1,45 27 SHC 2,00 1,96 1,89 1,81 1,71 29 SHC 2,25 2,22 2,16 2,07 1,98 31 SHC 2,52 2,49 2,42 2,34 2,25 TC 3,88 3,71 3,51 3,28 3,05 CM 1,06 1,13 1,21 1,33 1,44 23 25 SHC 1,45 1,39 1,31 1,23 1,15 27 SHC 1,70 1,65 1,58 1,49 1,41 29 SHC 1,96 1,92 1,84 1,76 1,68 31 SHC 2,24 2,18 2,10 2,02 1,94 TC : Total Cooling Capacity KW SHC : Sensible Heat Capacity KW CM : Compressor Input KW Rating Condition (#Mark) are Outdoor Ambient Temperature Indoor Unit Entering Air Temp 35 C D.B. 27 C D.B / 19 C W.B. 12
5-3 Heating Capacity Heating capacity ratio (%) 120 110 100 90 80 70 Point of Rating Condition 60 50 40 30 20 10 0-8 -5 0 5 7 10 15 Outdoor temperature ( C D.B.) NOTE 1) Point of Rating condition Black dot in the chart indicate the following rating condition. Indoor: 20 C D.B. Outdoor: 7 C D.B. / 6 C W.B. 2) Above characteristics indicate instantaneous operation, which does no take into account defrost operation. 3) Fan speed: High 4) Because this air conditioner heats a room by drawing in the heat of the outside air (heat pump system),the heating efficiency will fall when the outdoor temperature is very low. If sufficient heat cannot be obtained with this air conditioner, user another heating appliance in conjunction with it. 13
6.ELECTRICAL DATA 6-1 Electrical Characteristics COOLING MCA201-271-351R Indoor Unit Outdoor Unit Complete Unit Fan Motor Fan Motor Compressor Performance at 230 V 50 Hz Rating Conditions Running Amps. A 0.14 0.14 0.14 0.25 0.25 0.25 0.28 3.6 5.1 3.2 4 5.5 Power Input KW 27 27 29 56 56 56 617 767 1065 700 850 1150 Full Load Conditions Running Amps A 0.14 0.14 0.14 0.25 0.25 0.25 3.3 4.1 5.5 3.7 4.5 5.9 Power Input KW 27 27 29 56 56 56 717 927 1165 800 1010 1250 Rating Condition : Indoor air Temperature 27 C D.B. / 19 C W.B. Outdoor Air Temperature 35 C D.B. Full Load condition : Indoor Air Temperature 32 C D.B. / 23 C W.B. Outdoor Air Temperature 4. C D.B. HEATING MCA20-271-351R Indoor Unit Outdoor Unit Complete Unit Fan Motor Fan Motor Compressor Performance at 230 V 50 Hz Rating Conditions Running Amps. A 0.14 0.14 0.14 0.25 0.25 0.25 2.9 3.6 5.3 3.3 4 5.7 Power Input KW 27 27 29 56 56 56 717 767 1115 720 850 1200 Full Load Conditions Running Amps A 0.14 0.14 0.14 0.25 0.25 0.25 3.3 4.1 5.5 3.7 4.5 5.9 Power Input KW 27 27 29 56 56 56 717 927 1165 800 1010 1250 Rating Condition : Indoor air Temperature 20 C D.B Outdoor Air Temperature 7 C D.B./ 6 C W.B. Full Load condition : Indoor Air Temperature 27 C D.B. Outdoor Air Temperature 24. C D.B. / 18 C W.B. 14
6-2 Electric Wiring Diagrams WARNING To avoid electrical shock hazard, be sure to disconnect power before checking, servicing and/or cleaning any electrical parts Legend CM Compressor Motor C1,C2,C3 Capacitor FLP Louvers Motor FMO Outdoor Fan Motor FMI Indoor Fan Motor REC ASSY Remote Control PCB1 Indoor PC board TH1,TH2 Thermistor TP1,TP2 Terminal Plate 15
7-1 Cool Mode Operation (RT - SPT) [ o c] +3 +2 +1 0-1 over 3 min over 5 min COMP ON OFF OFAN ON OFF H over 30 sec IFAN M L RV ON OFF In Cool Mode, the operation of the Compressor (COMP), Outdoor Fan (OFAN) and Indoor Fan (IFAN) are determined by the difference between the Room Temperature (RT) and the Set Point Temperature (SPT) as in the graph above. Notes: 1. In this graph, the IFAN is operating in the Auto Fan Speed setting. If the user has selected the low, medium or high fan speed, the IFAN will run constantly at that speed only. 2. In addition to the value of (RT-SPT), the operations of the relays are also controlled by protection delays. For example, (a) the minimum On/Off time of the COMP is 5 min and 3 min respectively, and (b) the IFAN can change speed only after it has operated at the same speed for 30 sec. 16
7-2 Heat Mode Operation (RT - SPT) [ o c] +1 0-1 -2-3 COMP ON OFF H 30 sec IFAN M L OFF RV ON OFF Note 1 Note 2 The Heat Mode operation is similar to the Cool Mode operation. The COMP, OFAN and IFAN are mainly controlled by the value of (RT SPT). In the graph above, the IFAN is operating in Auto Fan speed mode. Therefore, the IFAN speed changes automatically according to the (RT - SPT). Note 1: The 30s IFAN operation is for purging the heat from the in-coil after COMP has stopped. Note 2: The IFAN will not be turned on until the in-coil temperature is high enough (as shown in the graph below) to prevent the unit from supplying cool air. IFAN Speed Any Low Stop ICT = Any = Low = In-coil Temperature Hi, Med or Low fan speed which is selected by the user. In Auto Fan Speed Mode, the fan speed is selected by the unit automatically instead. The indoor fan is forced to operate at low speed 30 35 40 ICT [ o c] 17
7-3 Auto (Cool/Heat) Mode Operation (RT - SPT) [ o c] +2 +1 0-1 -2 COMP & OFAN ON OFF ON RV OFF Auto Heat Mode Auto Cool Mode Auto Heat Mode In Auto Mode, the unit switches between the Auto Cooling Mode and Auto Heating Mode automatically to maintain the room temperature (RT) at the set point temperature (SPT). 18
7-4 Dry Mode Operation (RT - SPT) [ o c] +2 +1 0-1 10 20 30 40 50 Time [min] -2 DRY DRY-ON DRY-OFF IFAN COMP & OFAN LOW OFF ON OFF 5 minutes COMP ON time Max 15 minutes 3.5 min Max 15 minutes 6 min (Note 1) (Note 2) In Dry Mode, the unit operates in a mild cool mode to lower the humidity of the room. In order to maintain a high efficiency in the drying operation without over lowering the room temperature excessively, the Dry Mode is different from the Cool Mode in two ways. 1. The IFAN is forced to operate at low speed only. And, the IFAN is turned off with the COMP. 2. The unit operates in either the Dry-on state or the Dry-off state. If RT = SPT, the unit will operate in Dry-off state. The COMP is forced to operate for 6 min after it has stopped working for 15 min. If RT > SPT, the unit will operate in Dry-on state. The COMP is forced off for 3.5 min after it has been working for 15 min. Note 1: COMP is forced off in Dry-on state. Note 2: COMP is forced to operate in Dry-off state. 7-5 Fan Mode Operation In Fan Mode, the indoor fan is turned on to improve the air circulation in the room. COMP and OFAN remain OFF all the time. Note: If the user has selected the Auto Fan Speed setting, the IFAN speed would be selected by the unit automatically according to the difference between RT and SPT, as in Cool Mode. 19
7-6 Protection Operations in Cool and Dry Modes 1. Indoor Coil Defrost Protection The in-coil defrost protection can prevent the ice formation at the in-coil when the ambient temperature is low. ICT [ o c] +5 +2 +1 0-1 t1 t2 t3 OFAN ON OFF COMP ON OFF IFAN ON OFF t1 = 5 min minimum for each COMP starting t2 = OFAN cycling (alternate between ON and OFF every 30 sec) for 20 min maximum t3 = COMP and OFAN stop for 10 min minimum 20 17
2. Outdoor Coil High Pressure Protection The out-coil high pressure protection prevent the build up of high pressure at the out-coil during cooling operation. OCT [ o c] 64 61 55 52 COMP ANY OFF COMP is forced OFF OFAN ANY ON OFAN follow operation of COMP OFAN is forced ON (Note 1) IFAN ANY L IFAN is forced LOW OPER LED ON BLINK Note 1: In some applications, the outdoor fan and the compressor are controlled together by the COMP relay output from the controller. In this case, it will take more time for the out-coil to cool down during the high pressure protection, because the outdoor fan will be turned off with the compressor instead of working as in the graph above. 21
7-7 Protection Operations in Heat Mode 7-7-1 Outdoor Coil Deice Protection The deice process is controlled by an Ice Detection Algorithm (IDA). The IDA is an unique control algorithm incorporated to maintain optimal utilization of the heat pump capacity, especially in below-zero outdoor temperature condition. The out-coil deicing will be activated not only by static temperature detection as normally done, but also while ice forming is detected on the out-coil. COMP to ON DI = 40 (or 10) DT = 5 1 Activate DDt setting Routine Start counting TLD DTF = 0 No OCT < DOC? No TLD > DI & OCT < DST (during last 3 minutes) Yes DDT and DTF information from Deicing Dynamic Threshold setting routine DTF=1 & OCT < DDT No (during last 3 minutes) & ICT < 40 deg Yes Yes Deicer activation (see Notes) Deicer activation (see Notes) LDT > DT + TimeD No LDT < DT-TimeD or LDT < DTmin No Yes Yes DI = TLD - DIT DI = TLD + DIT DI = TLD No DI < DImin Yes DI = DImin No DI > DImax Yes DI = DImax DT = LDT 1 22
1st COMP start, OR deice complete Yes No Reset TLD cnt to 0 DTF = 0 IFAN/OFAN speed change Yes No Reset SCT cnt to 0 DTF = 0 TLD > TST AND SCT > SCD Yes No DDT = OCT - TempD DTF = 1 DDT and DTF information to main algorithm Explanation: The Ice Forming Detection will be done by two algorithms 1. In Dynamic Temp Detection, the ice formation will be detected by (i) Compare the OCT with a Deicing Dynamic Temperature Threshold, and (ii) Detect the drop in ICT which accompany the ice formation. 2. The Static Temp Detection will be done by comparing the OCT with a Deicing Static Temperature Threshold. The Deicing Data Record is used to determine the time delay between two deicing cycles. In general, the time delay will be increased if the last deicing cycle can be completed quickly. 23
7-7-2Indoor Coil High Pressure Protection in Heat Mode The in-coil high pressure protection prevent the build up of high pressure at the in-coil during heating operation. ICT [ o c] 64 A B COMP ANY OFF COMP is forced OFF OFAN ANY OFF Note: The operation temperatures shown as A and B in the chart differ by models. MCA201R MCA271R MCA351R A 50 54 58 B 42 45 50 24
7-8 Cold Draft Prevention (Heating) This function controls indoor fan speed so a strong draft of cold air will not blow out before the indoor heat exchange coil have sufficiently warmed up. When 10 minutes has elapsed, the fan speed is automatically switched to set speed regardless of indoor heat exchange coil temperature. Indoor heat exchange coil temp. ( C) Max.10 minutes Tc Indoor Fan OFF Set Speed NOTE The operation temperature shown as Tc in the chart differ by models. MCA201R MCA271R MCA351R Tc 32 32 34 25
7-9-1 Sleep Function Room temperature is automatically controlled to compensate for body temperature variations while sleeping. This mode of operation is designed for maximal comfort in both COOL and HEAT modes. RT 7-12 Hours Sleep operation Unit is turned to SB after Sleep SPT+3 SPT+2 Cool, Dry modes SPT+1 SPT SPT-1 SPT-2 SPT-3 Heat mode Start Sleep 1 2 3 4 7-12 Time [Hr] 7-9-2 Daily Timer Function Unit can be programmed to be ON and OFF automatically at preset time everyday, by using a remote controller. The resolutions of the ON/OFF timers are 10 min. 7-9-3 IFEEL Function This feature is provided if the unit is used together with a remote controller with the I-FEEL function. When this function is selected, the remote controller sends the room temperature measured by its build-in thermistor to the air con for more accurate temperature control. 7-9-4 Louver Control The airflow louver can be driven by either a 12V DC stepping motor or an AC motor. The louver can be set to operate at auto swing mode or fix position mode. Three additional features are provided if the louver is controlled by a DC stepping motor.? Different swing positions (range) for Heat Mode and Cool Mode operation? Last louver position in fix position mode is stored in the EEPROM, and is restored when the unit is turned on.? The louver is closed automatically when the unit is switched to standby mode. 26
7-9-5 Manual Unit Control and LED indicators The push button switch and the LED indicators on the display panel let the user to control the unit operation without a remote controller. Their operations are provided below. LED indicators: STAND BY INDICATOR OPERATION INDICATOR TIMER INDICATOR 1. Lights up when the Air Conditioner is connected to power and ready to receive the R/C commands 2. Blinks continuously in case of any thermistor failure. 1. Lights up in operation mode (Note: OFF in standby mode). 2. Blinks for 0.5 sec., to announce that a R/C infrared signal has been received and stored. 3. Blinks continuously during? OCT High Pressure Protection Mode? Deicing in Heating Mode 1. Lights up during Timer and Sleep operation. 2. Active On/Off timer setting will become invalid after a power failure. When this happens, the unit is forced to restart in STBY mode, and the Timer Indicator is blinked continuously until (i) the unit is switched to OPER Mode again, or (ii) any message from the R/C is received. Push Button switches: MODE BUTTON (Cool, Heat, SB) Use to cycle the operation mode of the A/C unit among COOL, HEAT and SB modes, without using the R/C. Every time this switch is pressed, the next operation mode is selected, in the order : SB => Cool Mode => Heat Mode => SB =>... 7-9-6 Recovery from Power Failure Last unit settings (SPT, operation mode, louver settings, etc) are saved in the EEPROM in the unit. In case of power failure, these settings are restored automatically. 27
8.TROUBLESHOOTING 8-1 Check before and after troubleshooting WARNING Hazardous voltage can cause ELECTRICAL SCHOCK or DEATH. Disconnect power or turn off circuit breaker before you start checking or servicing. 8-2 Check power supply wiring Check that power supply wires are connected to terminals L and N on the terminal plate in the indoor unit. 8-3 Check indoor unit wiring Check that inter-unit wiring is correctly connected to the outdoor unit from the indoor unit 8-4 Check power supply Check that voltage is in specified range (+/- 10% of the rating) Check that power is being supplied. 8-5 Check lead wires and connectors in indoor and outdoor units Check that coating of lead wires is not damaged Check that lead wires and connectors are firmly connected Check that wiring is correct. 28
8-6 Air Conditioner does not operate 8-6-1 Circuit breaker trips (or fuse blows). A. when the circuit breaker is set to ON, it is tripped soon.(resetting is not possible) There is possibility of ground fault Check insulation resistance If resistance value is 2MΩor less, insulation is defective ( NO ) WARNING 1 Remove inter-unit wires from terminal platea in outdoor unit Mesaure insulation resistance of outdoor unit. NO Insulation of outdoor unit is defective Measure insulation resiatance of electical parts in outdoor unit. 2 Remove inter-unit wires from terminal plate un outdoor unit. Then, pull the power plug out of the wall outlet. Measure insulation resistance of indoor unit NO Insulation of indoor unit is detective. Measure insulation resiatance of electical parts in indoor unit. 29
B. Circuit breaker trips in several minutes after turning the air conditioner on. There is a possibility of short circuit Check capacity of circuit breaker. Capacity of circuit breaker is suitable. Measure resistance of outdoor fan motor winding NO Replace with suitable one (lager capacity) In case of Heating operation: Measure resistance of 4-way valve s winding Measure resisatnce of compressormotor winding 8-6-2 Neither indoor nor outdoor unit runs A. Power is not supplied Check power supply. Power is being supplied to the indoor unit B. Check Push bottom selector in the indoor unit. Circuit breaker i tripped Power failure Reset breaker Wait for recovery or contact power company Push the button switch under the indoor unit pannel. The indoor unit and outdoor unit doesn t runs Indoor PCB Ass y is defective C. Check remote control unit Try to run with another remote control unit. OK First remote control unit is detective. Check for residue buildup on transmitter of remote control unit Clean transmitter.. Check for residue buildup on remote control receiver on front of indoor unit. 30 Clean Receiver.
D. Check fuse on the indoor PCB Ass y Check fuse on indoor PCB Ass y for continuity OK Measure resistance of indoor and outdoor fan motor winding OK Check operation lamp to see if light is ON Measure resistance of compressor motor winding Light is OFF OK Measure resistance of primari and secondary winding of transformer Measure coil resistance of power relay in outdoor unit. Indoor PCB Ass y is detective. Replace the fuse E. Check TIMER on the remote control unit Timer i turned On.Check to see YES if is displayed on remote control Cancel the timer mode push the buttom CLEAR 8-6-3 Only outdoor unit does not run A Check setting temperature COOL HEAT Is room temperature too low? Is room temperature too high? NO Try to lower setting temperature by temperature setting button Outdoor unit still does not run NO Try to raise setting temperature by temperature setting button Outdoor unit still does not run Try to use another remote control unit Try to use another remote control unit OK OK Remote control unit is defective Remote control unit is defective 31
B Check PCB Ass y in either indoor or outdoor unit Indoor PCB Ass y is defective 8-6-4 Only indoor unit does not run Indoor PCB Ass y is defective 8-7 Some part of air conditioner does not operate 8-7-1 Only indoor fan does not run Check fan rotation Turn fan gently once or twice by hand Fan cannot be turned Check fan casing foreign matter on inside Fan motor burnout or foreign matter in bearings Remove foreign matter or repair Repair or replace Measure resistance of indoor fan motor winding OK Check fan motor capacitor 8-7-2 Only flap motor does not run Measure resistance of flap motor winding 32
8-7-3 Only outdoor fan does not run Check fan rotation Turn fan gently once or twice by hand Fan cannot be turned Check fan casing foreign matter on inside Fan motor burnout or foreign matter in bearings Remove foreign matter or repair Repair or replace Measure resistance of outdoor fan motor winding OK Check fan motor capacitor 8-7-4Only compressor does not run Check compressor motor capacitor (C1) Overload Klixon is working YES Measure resistance of compressor motor winding Temperature of compressor is abnormally high. YES Refigerant gas shortage YES Recover refrigerant NO NO Measure power supplì voltage. The voltage is too low Rotor may be locked up Evacuate the air conditioner Measure winding resistance of power relay YES Replacement compressor Charge refrigerant. 33
8-8 Air conditioner operates, but abnormalities are observed 8-8-1 Operation does not switch from HEAT to COOL (or COOL to HEAT). Remote control unit may be detective. Reciver in lamp Ass y may be detective. Measure resistance of 4-way valve s winding COOL HEAT Check voltage between terminals No.1 and N, must be 230 VAC No voltage appears OK Check wiring connection Indoor PCB Ass y is defective HEAT COOL Check voltege between terminals No. 1 and N, must be 0 Volt 34
8-9 If a sensor is defective 8-9-1 ICT (indoor coil sensor) OCT(outdoor coil sensor) RAT (room ambient temperatur) are defetive. Stand by lamp on front side of indoor unit is flashing on and off. (*) YES Thermistor ICT and OCT and RAT are defective YES Repalce thermistor. NOTE Allarm signal (*) Stan by lampoon the front side of the indoor unit will flash on and off when the thermistor is defective. At the same time the outdoor unit will stop. Indoor operate only for ventilation. Temparature sensor Lead wires 35
9.CHECKING ELECTRICAL COMPONENTS 9-1 Measurement of Insulatipon Resisatnce The insulation is good condition if the resistance exceeds 2MΩ 9-1-1Power Supply Wires Clamp the grounding terminal of the power plug with a lead clip of the insulation resistance tester and measure the resistance by placing a probe on either of the two power terminals.(fig 1) Then, also measure resistance between the grounding and other power terminals (Fig 1) NOTE The shape of the power plug may differ from that of the air conditioner which you are servicing. 9-1-2 Indoor Unit Clamp an aluminium plate fin or copper with the lead clip of the insulation resistance tester and measure the resistance by placing a probe on each terminal screw where power supply lines are connected on the terminal plate.(fig 2) 9-1-3 Outdoor Unit Fig. 2 Clamp an aluminium plate fin or copper with the lead clip of the insulation resistance tester and measure the resistance by placing a probe on each terminal screw on the terminal plate.(fig 2). Note that ground line terminal should be skipped 9-2 Measurement of Insulation resistance for electrical Parts Disconnect the lead wires of the desired electric part from terminal plate, capacitor, etc. Similarly disconnect the connector. Then measure the insulation resistance. (Fig 3 and 4) Fig. 3 NOTE Refer to Electric Wiring Diagram If the probe cannot enter the poles because the hole is too narrow the use a probe with a thinner pin Fig. 4 36
9-2-1 Measurement continuity of the Fuse The fuse is situated on Indoor PCB Ass y (Fig 5) Disconnect the fuse from PCB Ass y. Then check if there is continuity on the fuse(fig 6) 9-2-2 Measure the Capacity of the Run Capacitor Disconnect the lead wires of the desired electric part from terminal plate. Similarly disconnect the connector. Then measure the capacity. (Fig 7) Fig. 7 Fig. 5 Fig. 6 37
R.D. 28 Reyrieux BP 131-01601 Trévoux CEDEX France Tél. 04.74.00.92.92 - Fax 04.74.00.42.00 R.C.S. Bourg-en-Bresse B 759 200 728