Sanyo SPW-C253GH5 Service Manual Download

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SM830035

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4. Service procedures

11) Symptom: LCD on the remote controller displays “CHECK P02”. (Compressor /

outdoor fan protection thermostat operation warning / power supply
voltage abnormality)

Yes

0342_M_I

Start

Is the outdoor fan wire winding
protection thermostat (49FO) off?

Replace the outdoor fan.

Is there connector contact defect?

Replace the outdoor unit PCB.

Correct the connection

Yes

Replace the outdoor unit PCB.

Is there 220-240 V AC between
CN19-9 and CN19-1 on the
outdoor unit PCB?

Yes

Replace the outdoor unit PCB.

Is the high voltage switch
(63 PH) off?

Yes

Replace the fuse.

Is the fuse on the outdoor unit
PCB blown (F1 and F2)?

Is the compressor protection
thermostat (49C) off except 48 type?

• No refrigerant
• High load
• 4-way valve defect
• Clogged refrigerant circuit
• Electronic refrigerant control valve
defect (indoor unit)

Yes

Check the power breaker etc.
and repair.

Is the power supply to the outdoor
unit normal?
(Voltage / defective phase?)

Summary of Contents for SPW-C253GH5

Page 1: ...DEL No PRODUCT CODE No SPW U253GH56 854 011 53 SPW C253GH5 854 012 18 SPW U253GH56 854 011 53 SPW C253GH8 854 012 19 SPW U363GH56 854 011 54 SPW C363GH8 854 012 20 SPW U483GH56 854 011 55 SPW C483GH8 854 012 21 Indoor Unit Outdoor Unit SPW C253GH5 SPW C253GH8 SPW C363GH8 SPW C483GH8 0408_C_S 0409_C_S 85464849135001 REFERENCE NO SM830035 1 2 3 4 5 Section SPW U253GH56 SPW U363GH56 SPW U483GH56 ...

Page 2: ...e site when finished servicing Don t forget to check that no metal scraps or bits of wiring have been left inside the unit 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 an...

Page 3: ... arrives on the job and therefore be better able to work by himself as well as assist the more experienced technician TABLE OF CONTENTS 1 SPECIFICATIONS 7 1 1 Unit Specifications 8 1 2 Major Component Specifications 12 A Indoor Unit 12 B Outdoor Unit 15 1 3 Other Component Specifications 18 1 4 Dimensional Data 20 A Indoor Unit 20 B Outdoor Unit 22 1 5 Refrigerant Flow Diagram 24 1 6 Operating Ran...

Page 4: ...1 A Cooling 41 B Heating Except During Defrosting 41 2 15 Compressor Current Detection Circuit 42 2 16 Dehumidifying Operation 43 2 17 Drain Pump Control 44 2 18 Electronic Refrigerant Control Valve Control 45 2 19 Voltage Detection Control 46 3 ELECTRICAL DATA 47 3 1 Indoor Unit Electric Wiring Diagram Schematic Diagram 48 3 2 Outdoor Unit Electric Wiring Diagram Schematic Diagram 52 4 SERVICE PR...

Page 5: ...ation to help you set up and maintain the unit When this unit is not working properly and the cause is not known you can use the procedures in Section 3 Servicing Procedures to find the problem fix it and restore the unit to its proper functioning This air conditioner has many helpful self diagnostic features to help you identify problem areas quickly So you will be ready when a problem happens we...

Page 6: ... 6 SM830035 ...

Page 7: ...ecifications 8 1 2 Major Component Specifications 12 A Indoor Unit 12 B Outdoor Unit 15 1 3 Other Component Specifications 18 1 4 Dimensional Data 20 A Indoor Unit 20 B Outdoor Unit 22 1 5 Refrigerant Flow Diagram 24 1 6 Operating Range 25 1 ...

Page 8: ...ration sound Indoor Hi Me Lo dB A 36 31 26 41 38 35 using the booster cable Outdoor Hi dB A 52 REFRIGERANT TUBING Limit of tubing length m ft 50 164 Limit of tubing length at shipment m ft 30 98 Limit of elevation difference m ft Outdoor unit is higher than indoor unit 50 164 between the two units Outdoor unit is lower than indoor unit 30 98 Refrigerant tube Narrow tube mm in 6 35 1 4 outer diamet...

Page 9: ...peration sound Indoor Hi Me Lo dB A 36 31 26 41 38 35 using the booster cable Outdoor Hi dB A 52 REFRIGERANT TUBING Limit of tubing length m ft 50 164 Limit of tubing length at shipment m ft 30 98 Limit of elevation difference m ft Outdoor unit is higher than indoor unit 50 164 between the two units Outdoor unit is lower than indoor unit 30 98 Refrigerant tube Narrow tube mm in 6 35 1 4 outer diam...

Page 10: ...on sound Indoor Hi Me Lo dB A 42 36 30 46 42 38 using the booster cable Outdoor Hi dB A 53 REFRIGERANT TUBING Limit of tubing length m ft 50 164 Limit of tubing length at shipment m ft 30 98 Limit of elevation difference m ft Outdoor unit is higher than indoor unit 50 164 between the two units Outdoor unit is lower than indoor unit 30 98 Refrigerant tube Narrow tube mm in 9 52 3 8 outer diameter W...

Page 11: ...peration sound Indoor Hi Me Lo dB A 42 36 30 46 42 38 using the booster cable Outdoor Hi dB A 55 REFRIGERANT TUBING Limit of tubing length m ft 50 164 Limit of tubing length at shipment m ft 30 98 Limit of elevation difference m ft Outdoor unit is higher than indoor unit 50 164 between the two units Outdoor unit is lower than indoor unit 30 98 Refrigerant tube Narrow tube mm in 9 52 3 8 outer diam...

Page 12: ...ient temperature 20 C WHT VLT 10 3 YEL BLK 90 0 VLT ORG 8 7 ORG PNK 30 6 Safety device Operating temperature Open C 130 5 C Close C Differential 15 deg min Run capacitor VAC µF 440 V 2 5 µF Electronic refrigerant control valve Solenoid control model DKV MOZS550E0 Coil resistance at 20 C Ω ORG GRY 46 YEL GRY 46 RED GRY 46 BLK GRY 46 Solenoid control valve model IKV 24D12 Heat exchanger Coil Aluminu...

Page 13: ...HT VLT 18 6 WHT VLT 9 6 VLT ORG 21 2 VLT ORG 33 1 ORG YEL 44 3 ORG YEL 32 0 YEL BLK 310 5 YEL BLK 74 0 PNK ORG 42 1 PNK ORG 35 7 Safety device Operating temperature Open C 130 5 C Close C Differential 15 deg min Run capacitor VAC µF 440 V 3 5 µF 440 V 6 0 µF Electronic refrigerant control valve Solenoid control model EKV MOZS559E0 Coil resistance at 20 C Ω ORG GRY 46 YEL GRY 46 RED GRY 46 BLK GRY ...

Page 14: ... 6 WHT VLT 9 6 VLT ORG 21 2 VLT ORG 33 1 ORG YEL 44 3 ORG YEL 32 0 YEL BLK 310 5 YEL BLK 74 0 PNK ORG 42 1 ORG PNK 35 7 Safety device Operating temperature Open C 130 5 C Close C Differential 15 deg min Run capacitor VAC µF 440 V 3 5 µF 440 V 6 0 µF Electronic refrigerant control valve Solenoid control model EKV MOZS559E0 Coil resistance at 20 C Ω ORG GRY 46 YEL GRY 46 RED GRY 46 BLK GRY 46 Soleno...

Page 15: ...l type Operating temperature Open C 160 5 Close C 87 11 Crank case heater 240V 25 W Refrigerant amount at shipment kg R22 3 0 High pressure switch ACB 1TB07 Set pressure OFF kg cm2 30 ON kg cm2 24 2 0 Fan Propeller Number diameter mm 1 ø460 Fan speeds 2 AUTO Fan motor Model KFC6T 91C5P Source 220 230 240 V 1 phase 50 Hz No of pole rpm 230V High Med 6 772 376 Nominal output W 70 Coil resistance Ω W...

Page 16: ...perating temperature Open C 120 5 Close C 98 11 Crank case heater 240V 25 W Refrigerant amount at shipment kg R22 3 0 High pressure switch ACB 1TB07 Set pressure OFF kg cm2 30 ON kg cm2 24 2 0 Fan Propeller Number diameter mm 1 ø460 Fan speeds 2 AUTO Fan motor Model KFC6T 91C5P Source 220 230 240 V 1 phase 50 Hz No of pole rpm 230 V High Med 6 772 376 Nominal output W 70 Coil resistance Ω WHT BRN ...

Page 17: ...ater 240 V 25 W 240 V 36 W Safety devices Overload relay models Internal type Operating temperature Open C 120 5 130 Close C 98 11 61 Refrigerant amount at shipment kg R22 3 5 R22 4 5 High pressure switch ACB 1TB07 Set pressure OFF kg cm2 30 ON kg cm2 24 2 0 Fan Propeller Number diameter mm 2 ø460 Fan speeds 2 AUTO Fan motor Model KFC6T 91C5P 2 Source 220 230 240 V 1 phase 50 Hz No of pole rpm 230...

Page 18: ...stance kΩ 10 C 23 7 10 C 9 7 5 C 18 8 20 C 6 5 0 C 15 0 30 C 4 4 5 C 12 1 40 C 3 1 45 C 2 6 Thermistor Room or coil sensor KTEC 35 S6 PTC 51H S1 Coil resistance kΩ 0 C 16 5 40 C 2 7 60 C 13 8 90 C 5 1 5 C 12 8 45 C 2 2 70 C 9 7 100 C 3 8 10 C 10 0 50 C 1 8 75 C 8 2 110 C 2 8 20 C 6 3 55 C 1 5 80 C 7 0 120 C 2 2 30 C 4 0 85 C 5 9 130 C 1 7 Relay FMCA 1SZ607 Coil rated V AC 220 240 V Contact rating ...

Page 19: ...C 9 7 5 C 18 8 20 C 6 5 0 C 15 0 30 C 4 4 5 C 12 1 40 C 3 1 45 C 2 6 Thermistor Room or coil sensor KTEC 35 S6 PTC 51H S1 Coil resistance kΩ 0 C 16 5 40 C 2 7 60 C 13 8 90 C 5 1 5 C 12 8 45 C 2 2 70 C 9 7 100 C 3 8 10 C 10 0 50 C 1 8 75 C 8 2 110 C 2 8 20 C 6 3 55 C 1 5 80 C 7 0 120 C 2 2 30 C 4 0 85 C 5 9 130 C 1 7 Relay FMCA 1SZ607 Coil rated V AC 220 240 V Contact rating V A AC 440 V 13 A Coil ...

Page 20: ... 13 20 4 ø 3 1 Hole 175 120 120 125 256 O D 26 29 992 2 ø 3 3 Hole 7 ø3 3 Hole Opposite side 150 O D 42 9 46 200 Refrigerant liquid line Narrow tube ø 6 35 In case of 25 type use the tube connector Refrigerant gas line Wide tube ø 15 88 Drain connection 25 A OD 32 mm Electrical junction box Power supply entry Mounting for suspension Duct connection for discharge ø200 Duct connection for suction Fr...

Page 21: ... 280 280 60 195 74 12 ø 3 1 Hole 107 107 13 20 4 ø 3 1 Hole 175 120 120 125 256 O D 26 29 1422 2 ø 3 3 Hole 10 ø 3 3 Hole Opposite side 1350 O D 42 9 36 200 Refrigerant liquid line Refrigerant gas line Drain connection Electrical junction box Power supply entry Mounting for suspension Duct connection for discharge ø200 Duct connection for suction Fresh air intake ø150 Dimension mm 9 Narrow tube ø ...

Page 22: ...g 2 400 380 20 340 20 110 660 170 735 280 307 940 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 23: ...483GH8 400 380 20 340 20 110 660 170 1235 580 607 940 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 Fig 3 ...

Page 24: ...switch Compressor Accumulator Accumulator EC P Heat exchanger 4 way valve EC P Heat exchanger Distributor Electronic ref control valve Strainer Liquid line nipple Liquid line service valve O D ø6 35mm 1 4 O D ø15 88mm 5 8 Gas line nipple Gas line service valve Distributor Sub heat exchanger Cooling Cycle Heating Cycle Strainer M 0417_C_S Muffler ...

Page 25: ... DB WB Outdoor Unit SPW C363GH8 Indoor Unit SPW U363GH56 SPW C483GH8 SPW U483GH56 HP High pressure switch Compressor Accumulator Hot equipped in SPW C483GH8 Accumulator EC P Heat exchanger 4 way valve EC P Heat exchanger Distributor Electronic ref control valve Strainer Liquid line nipple Liquid line service valve O D ø9 52mm 3 8 O D ø19 05mm 3 4 Gas line nipple Gas line service valve Distributor ...

Page 26: ... 26 SM830035 1 Specifications 1 ...

Page 27: ...erature Control Cooling and Heating 36 2 9 Auto Mode for Automatic Heating Cooling Switching 36 2 10 Defrosting Control Outdoor Heat Exchanger Coil Heating 38 2 11 4 Way Valve Solenoid Control 39 A Normal Control Mode 39 B AUTO Control Mode 40 2 12 Automatic Restart after Power Interruption 40 2 13 Electronic Refrigerant Control Valve 41 2 14 Compressor Discharge Gas Temperature 41 A Cooling 41 B ...

Page 28: ... Refer to 2 4 Outdoor Fan Speed Control MORE THAN 3 MINUTES MORE THAN 5 MINUTES ON ON ON ON ON ON SET SPEED OFF OFF OFF OFF ON ON ON ON ON ON DRAIN PUMP DEW PROOF HEATER BODY SENSOR 0671_X_S THERMO OFF Chart Summary and Explanations Once the compressor starts it keeps running for 5 minutes Once the compressor stops it will not start running again for 3 minutes If you change the operation mode HEAT...

Page 29: ... above the set temperature T T 1 C Compressor OFF When set on body sensor NOTE In case of Body sensor operating temperature is shifted to setting temperature 4 C Fig 2 THERMO ON THERMO ON 1 C OFF OFF 2 1 Refer to 2 4 Outdoor Fan Speed Control OFF SET SPEED ON ON ON ON REVERSING CYCLE ON TEMP OPERATION REMOTE CONTROL SENSOR Only for wireless remote controller BODY SENSOR OFF OFF SET SPEED SET SPEED...

Page 30: ... has past The indoor fan motor operates in L instead of LL for 3 seconds as it starts to give the fan an initial boost Chart Summary and Explanations The main idea of this chart is to show that the indoor fan speed increases and gets closer to the set fan speed as the coil temperature E2 rises The indoor unit s coil temperature is taken from sensor E2 located in the middle of the indoor heat excha...

Page 31: ...rature changes to another speed step during the time Fig 4 2 3 Automatic Fan Speed Indoor Unit A Cooling 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 INDOOR FAN SPEED L H M M H 0433_M_S ROOM TEMP...

Page 32: ...ficult for the fan to start this sudden surge of power may be necessary The outdoor fan operates in H mode for 3 minutes after the compressor stops excluding defrosting operation period Charts below show how the outdoor fan speed changes with the change in outdoor temperature A Cooling Outdoor unit coil Outdoor fan temperature C2 motor FMo Not less than 25 c H Not more than 25 c M OUTDOOR TEMPERAT...

Page 33: ...ntrolled by the lower temperature sensed at either of the two sensors Chart Explanations and notes This chart shows when the electronic refrigerant control valve opens to regulate the temperature of the indoor unit coil to prevent freezing If the refrigerant control is not effective and the temperature continues to drop and stays below 0 C for 2 minutes continuously the control circuit stops the c...

Page 34: ...d and the electronic refrigerant control valve react to coil temperature to control condensing temperature Sensor C2 is located in the middle of the outdoor unit heat exchange coil When C2 rises above 60 C the electronic refrigerant control valve opens at 50 steps 30 seconds and the outdoor fan speed is forced to change to high H until C2 falls below 55 C 60 55 OUTDOOR UNIT COIL TEMP C2 C OUTDOOR ...

Page 35: ...59 C Sensor E2 is located in the middle of the indoor unit heat exchange unit When sensor E2 rises above 62 C the control circuit stops the outdoor fan motor till the temp drops to 55 C Fuzzy control controls the electronic refrigerant control valve Fig 10 2 7 Overload Protection Heating This function prevents the air conditioner from overloading C ELECTRONIC REF CONTROL VALVE INDOOR UNIT COIL TEM...

Page 36: ... at heating mode Fig 11 2 9 Auto Mode for Automatic Heating Cooling Switching When the AUTO mode is selected the microprocessor calculates the difference between the set temperature and the room temperature and automatically switches to the COOLING or HEATING mode to maintain the desired temperature Room temp Set temp COOLING Room temp Set temp HEATING This means that if the room temperature is hi...

Page 37: ...room temperature rises above 22 5 C 22 0 5 during the cooling operation at the room temperature 20 C set by the remote controller the operation changes to cooling When the room temperature lowers below 17 C 18 1 0 thereafter the operation changes to heating again In heating operation using the body sensor room temperature control is designed so that room air temp is sensed as 4 deg lower than suct...

Page 38: ...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 Occurs either when the temperature of C1 the outdoor heat exchanger coil has reached 10 C or above or when the maximum defrosting time 9 minutes has elapsed Refer to time chart Minimum continuous operating time by defrosting is 48 minute...

Page 39: ...rt Summary and Explanations For the first 3 minutes after power is applied the 4 way valve remains OFF and the compressor will not operate even if the ON button is pushed If the 4 way valve is turned OFF with the compressor operating the air conditioner operates in COOLING mode See Table below If the 4 way valve is turned ON with the compressor operating the air conditioner operates in HEATING mod...

Page 40: ...covery function Compressor has stopped under the operation of AUTO mode condition 4 way valve delays its switching for 30 50 seconds after compressor has been turned ON 0446_M_S Fig 17 SOLENOID COIL 4 WAY VALVE COMPRESSOR COOL AUTO MODE CONTROL HEAT OFF OFF OFF OFF POWER SOURCE OPERATION BUTTON OFF MORE THAN 10 MINUTES THERMO OFF MORE THAN 10 MINUTES THERMO OFF 3 MINUTES THERMO OFF THERMO ON MORE ...

Page 41: ...itions of temperature fan speed etc These control circuits work automatically to send just the right amount of refrigerant through the Electronic Refrigerant Control Valve 2 14 Compressor Discharge Gas Temperature Model Min open Max open HEAT COOL 25 type 100 step 120 step 36 type 90 step 90 step 480 step 48 type 100 step 110 step A Cooling Indoor temp C 20 25 26 28 29 32 Outdoor temp C 13 or belo...

Page 42: ... detected current is 1 4 times greater than the rated current value ls and continues for 2 seconds both compressor and outdoor fan stop Thermostat OFF After 3 minute pause if the air conditioner is ready for Thermostat ON it starts again However if the condition mentioned above repeats twice the remote controller displays the alarm message H02 compressor locked Failure of Compressor Current Detect...

Page 43: ...emperature is monitored every 8 minutes when it is in the B range to select the best operation mode Fig 19 Fig 20 A range When the room temperature is in this range cooling operation starts However when the temperature is below 18 C the cooling operation does not start B range When the room temperature is in this range the air conditioner automatically repeats the dehumidifying cycle of 5 minutes ...

Page 44: ...ooling operation the drain pump will start to operate 2 When the compressor is stopped by freeze prevention function the drain pump will run for 20 minutes 3 After the float switch turns ON the drain pump will start to operate 5 minues After the recovery of the float switch the drain pump turns OFF ...

Page 45: ...ated at the middle of coil Heating indoor unit coil E1 temperature located at the outlet of coil 2 Fuzzy control optimal refrigerant flow rate control By outputting the fuzzy estimation result corresponding to the fuzzy input variables the indoor unit coil temp the deviation between the actual discharge gas temp and the target discharge gas temperature calculated from the outdoor unit coil tempera...

Page 46: ...ses and functions 2 19 Voltage Detection Control When the power voltage falls below 160 V voltage between N phase and each phase or rises above 260 V the P2 alarm is issued to protect the compressor and electrical components ...

Page 47: ... 47 SM830035 3 3 Electrical data 3 ELECTRICAL DATA 3 1 Indoor Unit Electric Wiring Diagram Schematic Diagram 48 3 2 Outdoor Unit Electric Wiring Diagram Schematic Diagram 52 ...

Page 48: ...BLK BLK ORG RED YEL BLK GRY BLK BLK BLK BLK BLK BLK BRN BRN YEL ORG BRN PNK BRN RED RED RED RED BRN YEL ORG VLT WHT GRY GRY PNK BRN BLK Connector 9P WHT 1 2 3 4 5 6 7 8 9 1 P S 2 3 4 5 6 7 8 9 YEL ORG VLT WHT GRY GRY PNK BRN BLK WHT WHT WHT BLK GRY GRY WHT VLT FMI 2 1 4 5 3 2 1 4 5 S Connector 5P WHT P 3 ORG RED BLK BLK WHT BLU YEL BLK GRY 2 1 2 1 DP P S 2 1 2 1 P S BLK BLK PNK BRN BRN 2 3 1 ORG G...

Page 49: ...DP 1 3 1 7 5 3 1 6 7 5 4 3 LL L HH H HT DP RY2 49FI T20 RCS F1 5A 1X 2X 3X 3X 8P 1 L 8P 2 N DPH LL L HH H R MOV Symbols Description FMI 49FI RC1 F1 TR1 1X 3X RY2 MOV RCS TH1 TH2 TH3 Indoor Fan Motor Indoor Motor Thermal Protector Running Capacitor Fuse Power Transformer Auxiliary Relay Auxiliary Relay Motor Operated Valve Remote Control Switch Room Thermistor Thermistor Indoor Coil E1 Thermistor I...

Page 50: ...YEL ORG VLT WHT GRY GRY PNK BRN BLK WHT WHT WHT GRY FMI 1 2 1 4 5 3 2 1 4 5 S Connector 5P WHT P 3 ORG RED BLK BLK BLU WHT YEL BLK GRY 2 1 2 1 DP S P 2 1 2 1 S P BLK BLK PNK BRN BRN Connector 9P BLK 1 2 3 4 5 6 7 8 9 1 P S 2 3 4 5 6 7 8 9 RC1 GRN YEL 49FI YEL ORG VLT WHT GRY GRY PNK BRN BLK Connector 9P BLK 1 2 3 4 5 6 7 8 9 1 P S 2 3 4 5 6 7 8 9 YEL ORG VLT WHT GRY GRY PNK BRN BLK FMI 2 BLU BRN 2...

Page 51: ...H H HT 7 HT DP RY2 49FI1 T20 RCS F1 5A 1X 2X 3X 8P 1 L 8P 2 N DPH LL 4Z L HH H 3Z 2Z 1Z 8 9 49FI2 FMI 2 RC1 2 1 6 5 4 3 LL L HH H 4Z 3Z 2Z 1Z MOV Symbols Description FMI1 2 49FI1 2 RC0 1 F1 TR1 1X 3X RY2 MOV RCS TH1 TH2 TH3 Indoor Fan Motor Indoor Motor Thermal Protector Running Capacitor Fuse Power Transformer Auxiliary Relay Auxiliary Relay Motor Operated Valve Remote Control Switch Room Thermis...

Page 52: ...onnector 2P YEL RC2 S 7 BRN BRN BRN YEL C S R BLK WHT RED GRN YEL Power Supply To Indoor Unit Terminal Plate 6P Terminal Plate 2P 2 1 W 854 2 5268 452 00 2 C253GH5 BRN GRN YEL RED BLK BLK BLU PNK ORG GRY BRN BRN GRY BLK WHT VLT PNK RED BRN BLU BLU BRN BLU BLU BRN WHT WHT WHT GRN YEL 49FO WHT RED YEL WHT WHT RED GRN YEL 2 1 1 2 52C 20S C1 BLK 2P WHT VCC 3P RED 63PH 3P YEL 20S 3P WHT RS 9P WHT CN24 ...

Page 53: ... Compressor Motor Magnetic Contactor Outdoor Fan Motor Thermal Protector High Pressure Switch Current Transmitter Running Capacitor Power Transformer Crank Case Heater Four Way Valve Fuse Thermistor Outdoor Coil C1 Thermistor Outdoor Coil C2 Thermistor Discharge Gas Symbols Description CR C253GH5 RY1 4 Outdoor Controller Auxiliary Relay Terminal Plate Terminal Connector 63PH 49 FO 49 C CM 52C C R ...

Page 54: ...7 8 P Connector 8P WHT Connector 2P YEL RC2 S 7 BRN BRN BRN YEL R S T BLU GRY GRY WHT RED GRN YEL Power Supply To Indoor Unit Terminal Plate 8P Terminal Plate 2P 52C 2 1 W 854 2 5268 453 00 0 C253GH8 WHT BRN BLU GRN YEL RED BLK BLK BLU PNK ORG GRY BRN BRN GRY WHT VLT PNK RED BRN BLU BLU BRN BLU BLU BRN WHT WHT WHT GRN YEL 49FO BRN RED YEL WHT BLU RED GRN YEL 2 1 49C 1 2 L1 L2 L3 N 20S 3P RED 63PH ...

Page 55: ...agnetic Contactor Compressor Motor Termal Protector Outdoor Fan Motor Thermal Protector High Pressure Switch Current Transmitter Running Capacitor Power Transformer Crank Case Heater Four Way Valve Fuse Thermistor Outdoor Coil C1 Thermistor Outdoor Coil C2 Thermistor Discharge Gas Symbols Description CR C253GH RY1 4 Outdoor Controller Auxiliary Relay Terminal Plate Terminal Connector 63PH 49 FO 49...

Page 56: ...T BLU GRY GRY WHT RED GRN YEL Power Supply To Indoor Unit Terminal Plate 8P L1 L2 L3 N Terminal Plate 2P 52C 2 1 W 854 2 5268 454 00 1 C363GH8 WHT BRN BLU GRN YEL RED BLK BLK BLU PNK ORG GRY BRN BRN WHT VLT PNK RED BRN BLU BLU BRN WHT VLT BLU BLU BRN WHT WHT WHT GRN YEL 49FO2 FMO1 PNK BRN GRY GRY WHT VLT YEL 2 1 2 1 4 3 4 3 6 5 6 5 8 7 8 P Connector 8P WHT RC2 S 7 BLK BLK GRY GRY WHT VLT RED GRN Y...

Page 57: ...r Compressor Motor Magnetic Contactor Compressor Motor Termal Protector Outdoor Fan Motor Thermal Protector High Pressure Switch Current Transmitter Running Capacitor Power Transformer Crank Case Heater Four Way Valve Fuse Thermistor Outdoor Coil C1 Thermistor Outdoor Coil C2 Thermistor Discharge Gas Symbols Description CR C253GH RY1 4 Outdoor Controller Auxiliary Relay Terminal Plate Terminal Con...

Page 58: ...r Unit Terminal Plate 8P L1 L2 L3 N Terminal Plate 2P 52C 2 1 W 854 2 5268 457 00 2 C483GH8 WHT BRN BLU GRN YEL RED BLK BLK BLU PNK ORG GRY BRN BRN GRY WHT VLT PNK RED BRN BLU BLU BRN WHT VLT BLU BLU BRN WHT WHT WHT GRN YEL 49FO2 FMO1 PNK BRN GRY GRY WHT VLT YEL 2 1 2 1 4 3 4 3 6 5 6 5 8 7 8 P Connector 8P WHT RC2 S 7 BLK BLK GRY GRY WHT VLT RED GRN YEL 49FO1 BRN YEL RED WHT BLU RED GRN YEL 2 1 1 ...

Page 59: ...S F1 2 TH6 TH7 TH8 Compressor Motor Outdoor Fan Motor Compressor Motor Magnetic Contactor Outdoor Fan Motor Thermal Protector High Pressure Switch Current Transmitter Running Capacitor Power Transformer Crank Case Heater Four Way Valve Fuse Thermistor Outdoor Coil C1 Thermistor Outdoor Coil C2 Thermistor Discharge Gas Symbols Description CR C253GH RY1 4 Outdoor Controller Auxiliary Relay Terminal ...

Page 60: ...SM830035 60 3 3 Electrical data ...

Page 61: ...Specific Component Does Not Work 80 7 Service Functions of Remote Controller 82 4 2 Checking the Electrical Components 95 1 Measurement of Insulation Resistance 95 2 Checking the Protective Devices 97 3 Checking the Electrical Parts 98 4 Sensor and Solenoid Layout Diagram 101 5 Thermistor Characteristic Curve 103 6 PCB Setting 104 7 R C Address Setting Method 105 8 Automatic Address Setting Method...

Page 62: ...ed into two sections Poor heating and Poor Cooling Under each heading you will find the main things that can go wrong and cause either of these problems Sometimes you can start with this chart and find the problem right away but often you will come here for more suggestions after you have looked at the error code on the remote control unit display This chart gives you the big picture of problems a...

Page 63: ...z single phase 220 230 240 V 3 3 3 3 3 Check power supply Check that voltage is within the specified range 10 of the rating Check that power is being supplied If the following troubleshooting must be done with power being supplied be careful not to touch any uninsulated live part that can cause ELECTRIC SHOCK 4 4 4 4 4 Check the lead wires and connectors in indoor and outdoor units Check that the ...

Page 64: ...e correctly connected to terminal No 5 through No 8 on the 8P terminal plate in the outdoor unit Check the power supply wires are correctly connected between terminal No 1 and 2 on the 3P terminal plate in the indoor unit and terminal No 1 and 2 on the 8P terminal plate in the outdoor unit 2 2 2 2 2 Check inter unit wiring Check that inter unit control wiring DC low voltage is correctly connected ...

Page 65: ... Cooling Poor cooling Is setting temp suitable Change the setting temp Is cooling load too heavy Review cooling load estimate 4 way valve is defective Replace the 4 way valve Refrigerant shortage Charge refrigerant gas Refrigerant flow failure Electronic refrigerant control valve is defective Service valves are not fully open Replace the compressor Compressor is defective Open the valves fully Air...

Page 66: ...en Replace the compressor Compressor is defective Open the valves fully Air filter is clogged Clean the filter Not enough air circulation Is fan speed set to LOW Set the fan speed to either MEDIUM or HIGH Refrigerant tubes between indoor and outdoor units are not insulated Insulate wide and narrow tubes separately Replace the valve 4 way valve is defective Replace the valve Cold air is discharged ...

Page 67: ... lamp v Timer lamp O Heat stand by lamp Error receiving of serial communications signal Error transmitting of serial communications signal Indoor unit address setting is duplicated Remote controller address RCU ADR is duplicated Error transmitting of serial communications signal Error receiving of serial communications signal When using flexible combination control main indoor unit address setting...

Page 68: ...ration lamp O Timer lamp v Heat stand by lamp Indoor thermistor is either open or short Outdoor thermistor is either open or short Protective device for compressor is activated Indoor coil temp E1 TH2 cannot be detected Indoor coil temp E2 TH3 cannot be detected Indoor room temperature cannot be detected Discharge gas temp A PC compressor TH0A cannot be detected Outdoor coil liquid temp C1 TH0E ca...

Page 69: ...essor damage Fig 30 LED 2 on P C board Remote controller LED 1 on P C board Possible cause of trouble v v No message v V E06 E07 L04 v No message V v P02 V V P04 P05 V F04 F09 v H01 H02 V H04 H05 E15 E16 Flash at the same time SETTING flashes Flash alternately 0654_C_I LED 1 LED 2 Normal Outdoor unit serial communication signal is abnormal Outdoor unit address is duplicated Other outdoor units are...

Page 70: ... Replace the indoor unit PCB Is there 220 240 V AC between R and S of the indoor PCB Is the LED D80 on the indoor unit PCB lit Is there 12 V DC between R2 and R3 on the 8P terminal plate of the indoor unit Is the primary side of the indoor power transformer shorted Is there 220 240 V AC between U1 and U2 of the 8P terminal plate Are the connections for the 4P connector for the indoor unit s PCB po...

Page 71: ...1 line of the remote controller wiring from the indoor unit terminal plate Replace the indoor unit PCB OK No No No Yes Yes Yes NG 0655_M_I Start Remote controller judges itself with self diagnostic functions Replace the remote controller Correct the wiring Correct the setting Open the inspection pin Is there an open or a contact defect in the No 1 line of the remote controller Is the indoor unit P...

Page 72: ...ood at the 2P connector for indoor serial communications on the outdoor unit PCB Correct the connections No Correct the connections Replace the indoor unit PCB Replace the indoor unit PCB Indoor outdoor unit control lines are cut off Correct the wiring Cut the breaker remove the indoor outdoor unit control lines connected to U1 and U2 of the outdoor unit 8P terminal plate After shorting the test p...

Page 73: ...rolling remote controller switches when there are two remote controllers 8 Symptom LCD on the remote controller is displaying CHECK E09 Duplicate setting of RCU address switch of remote controllers No No Yes Yes 0337_M_I Start Correct the setting Correct wiring Influenced by external noise Is the setting for the indoor address on the indoor unit PCB inappropriate Is there a cut line or contact def...

Page 74: ... 220 240 V AC between S4 and T20 3 on the indoor unit PCB Is there 220 240 V AC between T20 3 and S4 after T20 1 and T20 3 on the indoor unit PCB shorted Is the indoor fan wire winding protection thermostat 49FI off Replace the indoor fan Correct the connection Replace the indoor unit PCB Yes Yes No No 0341_M_I Start Is there 12 V DC between FS 1 and FS 3 on the indoor unit PCB Is the float switch...

Page 75: ...ct the connection Yes No No No Replace the outdoor unit PCB Is there 220 240 V AC between CN19 9 and CN19 1 on the outdoor unit PCB Yes Replace the outdoor unit PCB Is the high voltage switch 63 PH off Yes Replace the fuse Is the fuse on the outdoor unit PCB blown F1 and F2 Is the compressor protection thermostat 49C off except 48 type No refrigerant High load 4 way valve defect Clogged refrigeran...

Page 76: ...igerant control valve defect indoor unit No Yes No Yes 0344_M_I Start Are there connection defects in the wiring High pressure switch defect Repair the wiring The system does not operate again High pressure switch activation Both cooling and heating Electronic refrigerant control valve defect Refrigerant over charged Cooling Outdoor unit heat exchanger dirty clogged Outdoor unit air short Outdoor ...

Page 77: ...negative phase protector Is there a contact defect in the 3P connector No Yes Replace the fuse Is the fuse F1 F2 on the indoor unit PCB blown 15 Symptom LCD on the remote controller displays CHECK E15 No No No Yes Yes Yes 0646_M_S Start Repair the wiring Select an indoor unit which matches with the outdoor capacity Check the contact Perform the same as CHECK E04 When the group of the units are ins...

Page 78: ...ndoor units which match with the outdoor capacity Are the total capacities of indoor units to that of outdoor units more than 107 No Yes 0648_M_S Start Repair the wiring When the group of the units are installed is there any mis cross between inter unit control wiring and refrigerant tubing Check the capacity of the indoor unit by remote controller See Test Run Manual 18 Check P9 is displayed on t...

Page 79: ... and correct it Normal No Failure in the electronic control valve activation No Replace the sensor Operate the unit in cooling mode 30 minutes after its operation Cooled air comes out Is the temperature of each indoor coil sensor almost the same Refer to the sensor temperature display function of the remote controller Does each indoor coil sensor detect the temperature correctly Is there any leaka...

Page 80: ...oes Not Work 1 Indoor fan does not operate No Yes Is fan motor capacitor normal Is there voltage output of P C B Ass y for fan motor Check resistance of fan motor winding Replace the fan motor Replace the capacitor Replace the P C B Ass y in the indoor unit No Yes Out 0650_M_S ...

Page 81: ...or fan motor Yes Check resistance of fan motor winding NG Replace the fan motor Replace the relays Replace the capacitor Replace P C B Ass y in the outdoor unit Are auxiliary relays 1Y 2Y normal 0462_M_I No Yes Does compressor motor magnetic contactor 52C actuate Replace the compressor motor magnetic contactor Check resistance of compressor motor winding Replace the compressor NG 0461_M_I ...

Page 82: ... change the indoor unit address H Change the shift temperature in heating mode I Set the indoor unit address A Set service check switches The service check switch RCU CK is located on the back of the remote controller s P C B Ass y as follows The followings are the correct switch settings for ordinary use of the unit Only change the settings temporarily for making service checks When you finish th...

Page 83: ...ton 0355_M_I SET CL MODE FAN SPEED ON OFF SET TEMP UNIT FLAP AIR FLOW TEST C TIMER SET A TEST CHK a Press the TEST CHK button at the bottom right on the remote controller b Press the ON OFF operation button to start the test run c Press the MODE button to select either COOLING or HEATING mode d When the test run starts TEST shows on the remote controller s display e During the test run the air con...

Page 84: ...more than 4 seconds SET CL MODE FAN SPEED ON OFF SET TEMP UNIT FLAP AIR FLOW R C No UNIT No No CODE SET TEMP C TIMER SET AIM SWEEP A SETTING TEST CHK 0356_M_I b The UNIT No the address and temperature of the sensors instead of its usual information will flash on the display Following example shows the UNIT No Indoor unit address is fixed at 01 01 In case of group control select the UNIT NO Indoor ...

Page 85: ...function is usable even if the unit is not working To display the past error codes follow the procedure below Procedure a On the remote controller press both TEST CHK and SET buttons at the same time for more than 4 seconds b Once in this mode display changes from the normal display to service check display as shown in the table below È NORMAL DISPLAY Display Change SERVICE CHECK DISPLAY Set temp ...

Page 86: ... accessed by pressing either SET TEMP button or as follows SERVICE R C No CHECK UNIT No No CODE 0358_M_I CODE No No UNIT No 1 1 Alarm message Refrigerant Circuit No 0359_M_I Present Past Present Past MODE FAN SPEED SET TEMP NOTE Pressing CL Clear button will clear all the service history accessed in order of Past È Present accessed in order of Present È Past 0360_M_I SERVICE R C No CHECK UNIT No N...

Page 87: ...oller has a self diagnostic function to check if it works properly Use this procedure to find out if the remote controller itself is in trouble a Turn ON the RCU CK switch on the back of the P C B Ass y in the remote controller See section A for exact location b The appearance of the display will tell you whether or not the remote controller is working correctly or not Normal condition All display...

Page 88: ...changes from flashing to ON state e If an error occurs during operation the alarm message will be displayed Check and remove the cause If you want to stop the operation press the CL button then the unit stands in waiting mode Press the SET button again f If the automatic address operation finishes the display will disappear g Execute the operation of the other R C line in the same way by following...

Page 89: ...s the SET button to confirm the R C No The smallest registered indoor No and the selected R C No will be displayed Ex R C No 3 is selected Indoor No 2 is the smallest indoor No of the R C No 3 d Select the indoor No which you want to change with UNIT button Once in this mode the fan motor of selected indoor unit will turn on and let you confirm the indoor unit address 0362_M_I SET CL MODE FAN SPEE...

Page 90: ...tton h Finally press the TEST CHK button i If you want to change the indoor unit address of the other R C No follow the step a to h in the same way In this case UNIT No 3 6 current 3 8 NEW after pressing the TEST CHK button SET CL MODE FAN SPEED ON OFF SET TEMP UNIT FLAP AIR FLOW R C No SET No CODE TIMER SET DATA SETTING TEST CHK 0364_M_I Ex UNIT No 3 6 currently registered indoor unit address Req...

Page 91: ...nds b In case of group control if you want to change all units in group control collectively proceed next step remaining ALL displayed If you want to change a unit individually select the indoor unit address UNIT No with UNIT button c Select the CODE No 06 with SET TEMP button d Choose the shift temp with button SET CL MODE FAN SPEED ON OFF SET TEMP UNIT FLAP AIR FLOW R C No SET UNIT No No CODE TI...

Page 92: ...e controller should be connected with the indoor unit temporarily a Short the two terminals of DISP PIN on indoor unit PCB DISP PIN Refer to P VI 2 b Press the TEST CHK SET and CL buttons at the same time for more than 4 seconds c Set the CODE No 12 to set the No of R C with the SET TEMP button NOTE SET CL MODE FAN SPEED ON OFF SET TEMP UNIT FLAP AIR FLOW R C No SET UNIT No No CODE TIMER SET DATA ...

Page 93: ...u want to set with the button Ex Indoor unit No 4 will be set In this example indoor unit address UNIT No will be set 2 4 Ex No of R C will be set 2 h Press the SET button UNIT No CODE No 13 SETTING and SET DATA 0004 change from flashing to ON state SET CL MODE FAN SPEED ON OFF SET TEMP UNIT FLAP AIR FLOW R C No SET UNIT No No CODE TIMER SET DATA SETTING TEST CHK 0369_M_I SET CL MODE FAN SPEED ON ...

Page 94: ... from flashing to ON state l If you made a mistake press the CL button so that setting returns to the initial state m Press the TEST CHK button to finish this mode The display is disappeared n Confirm the indoor unit address UNIT No with the UNIT button after pressing the ON OFF button o Finally remove the short circuit of DISP PIN And in case of group control be sure to restore the branch wiring ...

Page 95: ...the insulation resistance tester and measure the resistance by placing a probe on high voltage terminal on the terminal plate Fig 40 See Fig 28 3 Outdoor Unit SPW C253GH5 Clamp a metallic part of the unit with the lead clip of the insulation resistance tester and measure the resistance by placing a probe on 1 and then 2 on the 8 or 6P terminal plate Fig 40 See Fig 28 3 Outdoor Unit SPW C253GH8 SPW...

Page 96: ...res from compressor capacitor etc Fig 43 Measure the resistance in the same manner as illustrated on the right Refer to Electrical Wiring Diagram NOTE If the probe does not enter the hole because the hole is too narrow use a probe with a thinner pin Fig 42 Copper tube or metallic part Clip Insulation tester Probe 0640_X_S Fig 43 From fan motor compressor and other parts Clip Probe Insulation teste...

Page 97: ...n motor FMI Check the socket s terminals between No 8 GRY lead wire and No 9 GRY lead wire 2 Compressor motor thermal protector 49C Outdoor unit Only for the SPW C253GH8 and SPW C363GH8 Disconnect the 8P connector white and the 9P connector white on the P C board and check 8P white plug s No 4 GRY lead wire and socket s No 9 GRY lead wire on the P C board 3 Outdoor fan motor thermal protector 49FO...

Page 98: ...cations 3 Indoor fan motor FMI Indoor unit Measure the coil resistance Measure the resistance between each terminal of 9P WHT socket connected to the indoor fan motor Refer to 1 2 A Major component specifications 4 Outdoor fan motor FMO Outdoor unit Measure the coil resistance Measure the resistance in the same manner as explained above 3 Refer to 1 2 B Major component specifications 5 Fan motor c...

Page 99: ...agnetic contactor In case of single phase compressor Remove the cover of compressor terminal and measure the resistance between terminals Refer to 1 2 Major component specifications 8 Compressor motor magnetic contactor 52C Outdoor unit MODEL Push button on the magnetic contactor no press press FMCA 1S Pair of terminals R U S V T W 31 32 YES YES YES YES Measure the resistance between A ORG lead wi...

Page 100: ...or 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 Then check the continuity of the fuse by using the multimeter Fig 47 Fig 47 Fuses Indoor P C B Ass y 0644_X_S Fuses Outdoor P C B Ass y 0653_X_S Fig 46 Fuse 0645_X_S ...

Page 101: ...TH7 C2 RED TH6 7 8 20S 63PH CM CH TH8 GRN Discharge gas 0582_C_S Outdoor Unit SPW C253GH5 SPW C253GH8 Indoor Unit SPW U253GH56 SPW U363GH56 SPW U483GH56 TH3 E2 BLK TH2 E1 RED Electronic refrigerant control valve ERCV TH4 E3 BRN 0478_U_I TH3 E2 BLK TH2 E1 RED Electronic refrigerant control valve ERCV TH4 E3 BRN 0479_U_I ...

Page 102: ... 4 Service procedures SPW C363GH8 0585_C_S TH6 C1 BLK TH7 C2 RED TH6 7 8 CM CH TH8 GRN Discharge gas 63PH 20S 0584_C_S 0585_C_S TH6 C1 BLK TH7 C2 RED SPW C483GH8 TH6 7 8 CM CH TH8 GRN Discharge gas 63PH 20S 0586_C_S ...

Page 103: ...h coil sensor TH6 C1 TH7 C2 3 Compressor discharge gas temp sensor TH8 PTC 51H PBC 41E Resistance kn 10 15 20 25 30 35 40 10 9 8 7 6 5 4 3 2 1 Temperature C 0374_M_I 20 15 10 5 0 5 10 15 20 0 5 10 15 20 25 30 35 40 Temperature C Resistance kn 0375_M_I 80 90 100 110 120 130 1 2 3 4 5 6 7 Temperature C Resistance kn 0376_M_I 5 Thermistor Characteristic Curve ...

Page 104: ...ntrol PCB R C address Refrigerant circuit address 1 30 Regarding the example of R C address for group control please refer to R C Address Setting Method C Central control when using the system controller In case of central control when using the system controller that is when linking outdoor units in a network a Before turning the power supply on set the R C address with S2 S3 on the outdoor contr...

Page 105: ... Automatic address setting start button Used for central control link system and group control Normally not used CN4 2P Black 1 ON ON side OFF side 2 1 ON ON side OFF side 2 1 ON ON side OFF side 2 1 ON ON side OFF side 2 1 ON ON side OFF side 2 1 ON ON side OFF side 2 0 0 1 1 3 2 Both 10 s and 20 s R C address R C address R C address S3 2P dip switch green or Blue S2 Rotary switch Black 00 auto a...

Page 106: ...eration finishes the display will disappear 6 Execute the operation of the other R C line in the same way by following the above steps 2 to 3 7 Complete the auto address operation by pressing the TEST CHK button Required time for auto address operation In case of group control a few minutes for each R C In case of central control max about 20 min for each R C 9 Displaying Indoor Outdoor Unit Combi...

Page 107: ...table The capacity code is set by S4 green or Blue 4P DIP switch on outdoor control PCB The model code is set by S5 black 2P DIP switch on outdoor control PCB S4 Capacity code S5 Model code No Outdoor PCB Model No 1 2 25 type 1 phase ON OFF 25 type 3 phase OFF OFF 36 type 3 phase OFF OFF 48 type 3 phase OFF ON No Outdoor PCB Model No 1 2 3 4 25 type 1 phase ON ON ON OFF 25 type 3 phase ON ON ON OF...

Page 108: ...table and if you find defective parts repair them according to Service Manual Note Check the indoor side drain water Recheck the test items before test operation Check the indoor and outdoor unit combination wiring See 4 2 6 B See 4 2 8 See 4 2 6 C See 4 2 8 See 4 2 10 Return the remote controller to normal Display the combination number See 4 2 9 Set the remote controller to test operation No No ...

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