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14 Troubleshooting Guide

14.1. Refrigeration Cycle System

In order to diagnose malfunctions, make sure that there are no
electrical problems before inspecting the refrigeration cycle.
Such problems include insufficient insulation, problem with the
power source, malfunction of a compressor and a fan.
The normal outlet air temperature and pressure of the
refrigeration cycle depends on various conditions, the standard
values for them are shown in the table on the right.

Summary of Contents for CS-PC18GKF

Page 1: ...2 2 CS PC24GKF CU PC24GKF 6 3 Features 8 4 Location of Controls and Components 9 4 1 Product Overview 9 5 Dimensions 10 5 1 Indoor Unit 10 5 2 Outdoor Unit 11 6 Refrigeration Cycle Diagram 13 7 Block Diagram 14 8 Wiring Connection Diagram 15 9 Electronic Circuit Diagram 17 10 Printed Circuit Board 18 10 1 Main Printed Circuit Board 18 10 2 Power Printed Circuit Board 20 10 3 Indicator panel 21 11 ...

Page 2: ...vicing Then explain to user the operation care and maintenance as stated in instructions Please remind the customer to keep the operating instructions for future reference This indication shows the possibility of causing death or serious injury This indication shows the possibility of causing injury or damage to properties This symbol denotes item that is PROHIBITTED from doing 1 Engage dealer or ...

Page 3: ... set it to 700 20 F 370 10 C Pb free solder will tend to splash when heated too high about 1100 F 600 C 1 Selection of the installation location Select an installation location which is rigid and strong enough to support or hold the unit and select a location for easy maintenance 2 Power supply connection to the conditioner Connect the power supply cord of the air conditioner to the mains using on...

Page 4: ...540 21 1 4 Width mm inch 998 39 9 32 780 30 23 32 Depth mm inch 230 9 1 16 289 11 3 8 Net Weight kg lbs 11 0 24 39 0 86 Pipe Diameter Gas mm inch 12 7 1 2 Liquid mm inch 6 35 1 4 Standard Length m ft 5 16 4 Pipe Length Range m ft 3 9 8 25 82 0 Height Difference m ft 20 0 65 6 Additional Gas Amount g m oz ft 20 0 2 Refrigeration Charge Less m ft 7 5 24 6 Drain Hose Inner Diameter mm 16 Length mm 65...

Page 5: ...20 240 Hz 50 Input Power kW 1 99 2 05 Starting Current A 42 Running Current A 9 8 10 0 Power Factor 92 85 Power factor means total figure of compressor indoor fan motor and outdoor fan motor Maximum over current protection A 15 Power Cord Number of core 3 1 5 mm2 Length m 1 9 Thermostat Mechanical Control Protection Device Inner Protector ...

Page 6: ... 29 17 32 Width mm inch 998 39 9 32 875 34 7 16 Depth mm inch 230 9 1 16 345 13 19 32 Net Weight kg lbs 11 0 24 58 0 128 Pipe Diameter Gas mm inch 15 8 5 8 Liquid mm inch 6 35 1 4 Standard Length m ft 5 16 4 Pipe Length Range m ft 3 9 8 25 82 0 Height Difference m ft 20 0 65 6 Additional Gas Amount g m oz ft 30 0 3 Refrigeration Charge Less m ft 7 5 24 6 Drain Hose Inner Diameter mm 16 Length mm 6...

Page 7: ... 240 Hz 50 Input Power kW 2 57 2 70 Starting Current A 67 Running Current A 12 5 12 8 Power Factor 93 88 Power factor means total figure of compressor indoor fan motor and outdoor fan motor Maximum over current protection A 17 2 Power Cord Number of core 3 2 5 mm2 Length m 1 9 Thermostat Mechanical Control Protection Device Inner Protector ...

Page 8: ...er range of horizontal discharge air Auto Restart Random auto restart after power failure for safety restart operation Removable and washable Front Panel Quality Improvement Gas leakage detection Prevent Compressor reverse cycle Inner protector Long Installation Piping Long piping up to 25 meter 24 hour timer setting ...

Page 9: ...9 4 Location of Controls and Components 4 1 Product Overview 4 1 1 Indoor Unit 4 1 2 Outdoor Unit 4 1 3 Remote Control ...

Page 10: ...10 5 Dimensions 5 1 Indoor Unit ...

Page 11: ...11 5 2 Outdoor Unit ...

Page 12: ...12 ...

Page 13: ...13 6 Refrigeration Cycle Diagram ...

Page 14: ...14 7 Block Diagram ...

Page 15: ...15 8 Wiring Connection Diagram ...

Page 16: ...16 ...

Page 17: ...17 9 Electronic Circuit Diagram ...

Page 18: ...18 10 Printed Circuit Board 10 1 Main Printed Circuit Board ...

Page 19: ...19 ...

Page 20: ...20 10 2 Power Printed Circuit Board ...

Page 21: ...21 10 3 Indicator panel ...

Page 22: ... or rain be careful that heat radiation from the condenser is not obstructed There should not be any animal or plant which could be affected by hot air discharged Keep the spaces indicated by arrows from wall ceiling fence or other obstacles Do not place any obstacles which may cause a short circuit of the discharged air If piping length is over 7 5m additional refrigerant should be added as shown...

Page 23: ...hole Another method is by putting measuring tape at position as shown in the diagram above The hole center is obtained by measuring the distance namely 150 mm and 125 mm for left and right hole respectively Drill the piping hole at either the right or the left and the hole should be slightly slanted to the outdoor side 11 1 3 2 TO DRILL A HOLE IN THE WALL AND INSTALL A SLEEVE OF PIPING 1 Insert th...

Page 24: ...24 3 For the embedded piping This can be used for left rear piping and left bottom piping also ...

Page 25: ...hloroprene sheathed 3 2 5 mm2 flexible cord type designation 245 IEC 57 or heavier cord Ensure the colour of wires of outdoor unit and the terminal Nos are the same to the indoor s respectively Earth lead wire shall be longer than the other lead wires as shown in the figure for the electrical safety in case of the slipping out of the cord from the anchorage Secure the cable onto the control board ...

Page 26: ...ufficiently tighten the flare nut with fingers Further tighten the flare nut with torque wrench in specified torque as stated in the table Connecting The Piping To Outdoor Unit Decide piping length and then cut by using pipe cutter Remove burrs from cut edge Make flare after inserting the flare nut locate at valve onto the copper pipe Align center of piping to valves and then tighten with torque w...

Page 27: ...ontains moisture may cause malfunction on the Compressor 1 To purge the air push the pin on the Gas side 3 way valve for three seconds with a Hexagonal wrench and set it free for one minute Repeat this for three times 2 To balance the refrigerant close the low pressure side valve on the Manifold gauge and release refrigerant from the piping through service port until the gauge indicates 0 5 0 3 MP...

Page 28: ...eful that heat radiation from the condenser is not obstructed There should not be any animal or plant which could be affected by hot air discharged Keep the spaces indicated by arrows from wall ceiling fence or other obstacles Do not place any obstacles which may cause a short circuit of the discharged air If piping length is over 7 5 m additional refrigerant should be added as shown in the table ...

Page 29: ...hole Another method is by putting measuring tape at position as shown in the diagram above The hole center is obtained by measuring the distance namely 150 mm and 125 mm for left and right hole respectively Drill the piping hole at either the right or the left and the hole should be slightly slanted to the outdoor side 11 2 3 2 TO DRILL A HOLE IN THE WALL AND INSTALL A SLEEVE OF PIPING 1 Insert th...

Page 30: ...30 3 For the embedded piping This can be used for left rear piping and left bottom piping also ...

Page 31: ...hloroprene sheathed 3 2 5 mm2 flexible cord type designation 245 IEC 57 or heavier cord Ensure the colour of wires of outdoor unit and the terminal Nos are the same to the indoor s respectively Earth lead wire shall be longer than the other lead wires as shown in the figure for the electrical safety in case of the slipping out of the cord from the anchorage Secure the cable onto the control board ...

Page 32: ...ufficiently tighten the flare nut with fingers Further tighten the flare nut with torque wrench in specified torque as stated in the table Connecting The Piping To Outdoor Unit Decide piping length and then cut by using pipe cutter Remove burrs from cut edge Make flare after inserting the flare nut locate at valve onto the copper pipe Align center of piping to valves and then tighten with torque w...

Page 33: ...ontains moisture may cause malfunction on the Compressor 1 To purge the air push the pin on the Gas side 3 way valve for three seconds with a Hexagonal wrench and set it free for one minute Repeat this for three times 2 To balance the refrigerant close the low pressure side valve on the Manifold gauge and release refrigerant from the piping through service port until the gauge indicates 0 5 0 3 MP...

Page 34: ...the room temperature reaches the setting temperature set on the remote control The remote control setting temperature which takes the reading of intake air temperature sensor can be adjusted from 16 C to 30 C During cooling operation the compressor will stop running and restart as shown in below figure 12 1 1 Cooling Operation Time Diagram ...

Page 35: ...egins Soft Dry will be switched ON for a maximum 10 minutes then Soft Dry operation will be turned OFF for a minimum 6 minutes After that the Soft Dry operation will be ON and OFF based on the setting temperature as shown in below figure However after 3 minutes of compressor off during Soft Dry OFF within 6 minutes Soft Dry restart control the indoor unit will start to operate at normal Cooling mo...

Page 36: ... determined operation mode until it is switched off using remote control with the setting temperature as shown in below table The setting temperature for all the operations can be changed one level up or one level down from the standard temperature as shown in below table by pressing on the temperature up or temperature down button at remote control The operation mode judging temperature and stand...

Page 37: ...ng the period This phenomenon is to reduce the built up humidity inside a room 12 4 3 60 Seconds Forced Operation Once the air conditioner is turned on the compressor will not stop within 60 seconds in a normal operation although the intake air temperature has reached the thermo off temperature However force stop by pressing the OFF ON operation button at the remote control is permitted The reason...

Page 38: ...te at 1 6 second later The reason of the difference is to reduce the starting current flow 12 4 7 Anti Dew Formation Control Purpose is to prevent dew formation on indoor unit air discharge area When room temperature is constant 1 C the following conditions occur for 30 minutes continuously anti dew formation will activate Remote Control setting temperature is less than 25 C Compressor is on Cooli...

Page 39: ...13 16 19 22 under Cooling and Soft Dry operation mode 12 5 Indoor Fan Speed Control Indoor Fan Speed can be set using remote control 12 5 1 Fan Speed Rotation Chart 12 5 2 Automatic Fan Speed Control When set to Auto Fan Speed the fan speed is adjusted between maximum and minimum setting as shown in the table Fan speed rotates in the range of Hi Me and Lo Deodorizing Control will be activated COOL...

Page 40: ...comfort and lesser noise environment after 70 seconds from the restart of compressor Auto Fan Speed during Soft Dry operation 1 Indoor fan will rotate alternately between off and Lo 2 At the beginning of each compressor start operation indoor fan will increase fan speed gradually for deodorizing purpose 3 When compressor at turn off condition for 6 minutes indoor fan will start fan speed at Lo to ...

Page 41: ...Lo speed for 20 seconds 15 minutes before the set time to detect the intake air temperature to determine the operation mode The operation indication lamp will blink at this time 12 8 2 OFF Timer When the OFF Timer is set by using the remote control the unit will stop operate according to the desired setting Notes 1 By pressing ON OFF operation button the ON Timer or OFF Timer setting will not be c...

Page 42: ... control transmission code could be selected and stored in EEPROM of indoor unit The indoor unit will only operate when received signal with same transmission code from remote control This could prevent signal interference when there are 2 or more indoor unit installed nearby together To change remote control transmission code short or open jumpers at the remote control printed circuit board Under...

Page 43: ...rt circuited Time Remarks Real Timer 1 hr 1 min 10 min 10 sec 1 min 1 sec Timer Delay Safety Control 2 min 58 sec 0 sec Forced Operation 60 sec 0 sec Timer Save Control 7 min 42 sec Anti Freezing 4 min 0 sec Auto Mode Judgement 20 sec 0 sec Soft Dry OFF 6 min 36 sec ON 10 min 60 sec Soft Dry 10 min operation Deodorizing Control Cooling 40 sec 4 sec 70 sec 7 sec 20 sec 2 sec 180 sec 18 sec Soft Dry...

Page 44: ... problems before inspecting the refrigeration cycle Such problems include insufficient insulation problem with the power source malfunction of a compressor and a fan The normal outlet air temperature and pressure of the refrigeration cycle depends on various conditions the standard values for them are shown in the table on the right ...

Page 45: ...logged capillary tube or Strainer Short circuit in the indoor unit Heat radiation deficiency of the outdoor unit Inefficient compression Nature of fault Symptom Insufficient compressing of a compressor Electric current during operation becomes approximately 20 lower than the normal value The discharge tube of the compressor becomes abnormally hot normally 70 to 90 C The difference between high pre...

Page 46: ...easing the 3 hooks at the top of the Front Grille Fig 1 Unhook the tabs at the Control Board to remove the Control Board Cover Fig 2 Fig 1 Fig 2 15 1 2 To remove the Main Electronic Controller Release the 2 Particular Piece Fig 3 Release the Indicator Fig 3 Release the 2 screws for the earth wire Fig 3 Release the screw Holder Terminal Board Fig 3 Release the hooks that hold the Main Electronic Co...

Page 47: ...that hold the Particular Piece and pull out the Power Electronic Controller Fig 6 Release the AC 303 connector Fig 7 Release the CN FM connector Fig 7 Release the 2 connector P Terminal BROWN and L Terminal BLACK at the RY PWR 15 1 4 To remove the Discharge Grille Pull out the Drain Hose behind the Discharge Grille from outlet to remove the Discharge Grille Fig 8 Fig 6 Fig 7 Fig 8 ...

Page 48: ...r Fan Motor Remove the screw at the Cross Flow Fan Fig 10 Reminder To reinstall the Fan Motor please adjust the connector location is positioned 90 with Fan Motor before fixing Control Board Fig 10 Remove the Bearing Fig 11 Remove the screws at the left of the Evaporator Fig 11 Push up the Evaporator and pull out the Cross Flow Fan from shaft By then Fan Motor can be taken out Fig 12 Fig 10 Fig 11...

Page 49: ...49 16 Technical Data 16 1 Thermostat Characteristics ...

Page 50: ...50 16 2 Operation Characteristics CS PC18GKF CU PC18GKF ...

Page 51: ...51 ...

Page 52: ...52 CS PC24GKF CU PC24GKF ...

Page 53: ...53 ...

Page 54: ...Fan Speed rpm 1450 1330 1150 Air Flow m3 min 15 5 14 5 13 0 ft3 min 547 512 459 Outdoor Fan Speed rpm 830 Air Flow m3 min 34 0 ft3 min 1200 CS PC24GKF CU PC24GKF Hi Me Lo Indoor Fan Speed rpm 1640 1460 1310 Air Flow m3 min 17 5 15 9 14 6 ft3 min 618 561 515 Outdoor Fan Speed rpm 890 Air Flow m3 min 55 8 ft3 min 1970 ...

Page 55: ...55 ...

Page 56: ...56 CS CU PC24GKF ...

Page 57: ...57 16 5 Sound Data CS PC18GKF ...

Page 58: ...58 CS PC24GKF ...

Page 59: ...7 Exploded View and Replacement Parts List 17 1 Indoor Unit Note The above exploded view is for the purpose of parts disassembly and replacement The non numbered parts are not kept as standard service parts ...

Page 60: ...1153A 18 CAP DRAIN TRAY 1 CWH52C1001 19 BACK COVER CHASIS 1 CWD932162B 20 CONTROL BOARD CASING 1 CWH102291 21 TERMINAL BOARD COMPLETE 1 CWA28C2153 CWA28C2154 O 22 POWER SUPPLY CORD 1 CWA20C2508 CWA20C2530 23 ELECTRONIC CONTROLLER MAIN 1 CWA73C2661 CWA73C2662 O 23a ELECTRONIC CONTROLLER POWER 1 CWA744053 O 24 INDICATOR COMPLETE 1 CWE39C1120 O 25 INDICATOR HOLDER 1 CWD932435 26 INDICATOR HOLDER 1 CW...

Page 61: ...61 17 2 Outdoor Unit Note The above exploded view is for the purpose of parts disassembly and replacement The non numbered parts are not kept as standard service parts ...

Page 62: ...2 WAY VALVE 1 CWB02306 15 HOLDER COUPLING ASS Y 1 CWH351046 16 3 WAY VALVE LIQUID 1 CWB011397 O 17 3 WAY VALVE GAS 1 CWB011482 O 20 TERMINAL COVER 1 CWH171012 21 NUT TERMINAL COVER 1 CWH7080300J 22 SOUND PROOF BOARD 1 CWH151023 24 TERMINAL BOARD ASS Y 1 CWA28K1033J 25 CAPACITOR COMPRESSOR 1 DS441456CPND O 26 HOLDER CAPACITOR 1 CWH30071 27 CAPACITOR FAN MOTOR 1 DS441205NPQA O 28 CABINET SIDE PLATE ...

Page 63: ...63 Note The above exploded view is for the purpose of parts disassembly and replacement The non numbered parts are not kept as standard service parts ...

Page 64: ...J 14 HOLDER COUPLING 1 CWH351036 15 3 WAY VALVE LIQUID 1 CWB011161 O 16 TUBE ASS Y CAPILLARY TUBE 1 CWT024668 17 3 WAY VALVE GAS 1 CWB011213 O 18 TERMINAL COVER 1 CWH171012 19 NUT TERMINAL COVER 1 CWH7080300J 21 CAPACITOR F M 1 DS441505NPQB O 22 CAPACITOR COMP 1 CWA312079 O 23 HOLDER CAPACITOR 1 CWH30060 24 TERMINAL BOARD ASS Y 1 CWA28K1064J 25 CABINET SIDE PLATE L 1 CWE041082A 26 HANDLE 1 CWE1610...

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