ABN 68 547 176 720 TECHNICAL MANUAL BOOK 2 2008 Edition AIR GROUP AUSTRALIA MANUFACTURED UNITS ONLY SERVICE GROUP AUSTRALIA 28/30 DIVISION STREET WELSHPOOL WA 6106 www.airgroup.com.
FM774/0708 BOOK 2 2
CONTENTS Page Introduction and Abbreviations 4 Safety and Installation Notes 5 CO Series Specifications 6 CZ Series Specifications 7 CO Roof Unit Board Diagram 8 Fused Roof Unit Board Diagram 9 CO/CZ Schematic Diagram 10 CO/CZ Fault Finding 11 CR Series Specifications 12 CRR Series Specifications 13 CY Series Specifications 16 CA Series Specifications 17 CA Series Dip Switch Diagram 18 Modular Roof Unit Board Diagram 19 CA/CR/CY Schematic Diagram - MS System 20 CA/CR/CY Schemat
INTRODUCTION This document is designed as a guide only, and does not cover all possible faults that may occur. It is intended for use by technicians and trades people with fault finding skills and relevant qualifications. Its aim is to help identify failed components and assist in diagnosis of system faults. The guide has been set out in logical order, from the basic to the more complex faults.
SAFETY NOTES Electrical & Rotary Machinery • All electrical equipment should be isolated before work is performed. If ‘live testing’ is required all necessary safety precautions should be followed. Working at Heights • When work is to be performed at heights all necessary safety precautions should be followed. INSTALLATION NOTES Motor & Fan • A fan clipping two opposite points of the cowling indicates the dropper is ‘out of square’. Diagonal dimensions of dropper must be equal, +/-5mm.
CO (COMFORT) SERIES (1994 - 2000) Wall Control : CO Series 17vdc (SP3212) (Obsolete) replace with QA (SP3221) Compatible Roof Unit: CO R/U (SP3006) or MRU (SP3000) Control Cable: 7-pin 17 vdc pre-terminated (SP5200) Fan Motor: 370 W, 600 W, 750 W Drainage: 240v Electric Drain Valve (SP2062), Hydraulic Drain Valve (SP2064) or Bleed Off Pump: 240v pump Solenoid: 24v or Retro-Fit kit (on CO Roof Unit SP3006 only) Display Reading Modes of Operation: F E C AC FAN EXHAUST COOL AUTO - ventilatio
CZ (COOLZONE) SERIES (1995 - 2000) Wall Control : CZ Series 17vdc (SP3211)(Obsolete) replace with CY (SP3214) Compatible Roof Unit: Fused R/U (SP3003) (Obsolete) replace with MRU (SP3000) Control Cable: 7-pin 17vdc pre-terminated (SP5200) Fan Motor: 370 W, 600 W, 750 W Drainage: 240v Electric Drain Valve (SP2062) or Bleed Off Pump: 240v pump Solenoid: 24v solenoid Modes of Operation: FAN - ventilation with fresh air EXHAUST - to extract air COOL - for cooling Fan Speeds: 10 speeds in all mo
FM774/0708 BOOK 2 8 MOTOR EARTH MAINS EARTH NEUTRAL VALVE MAINS ACTIVE BLUE PUMP BROWN BLUE INLET BROWN 15A FUSE DRAIN FUSE 5A SLOW BLOW PUMP FUSE 5A SLOW BLOW BLUE DUMP VALVE BROWN MOTOR FUSE 15A SLOW BLOW ORANGE CAP CAP MOTOR WHITE AGA COMFORT Ver 98/2 RELAY BLACK BLUE ROOF J2 PUMP EARTH MAINS POWER LED BROWN PUMP UNIT DRAIN EXHAUST SPEED TRIACS 7 PIN HEADER CONTROL CABLE INDICATOR LED’S MINIMUM SPEED ADJUSTMENT JUMPERS (EARLIER VERSIONS FITTED WITH ADJUSTABLE PO
MAINS SUPPLY CONNECTION 240 VOLTS AC SUPLEMENTRY MAINS FILTER CABLE ISOLATOR A N E A N E ISOLATION SWITCH CABLE INCOMING MAINS SUPPLY CONNECTION 240 Volts AC AGA ROOF UNIT 99/3 AGA ROOF UNIT VER 96/7 MAINS POWER AVAILABLE LED PUMP/INLET RELAY 15.0 SLOW BLOW MOTOR FUSE MOTOR 15A SLOWFUSE BLOW 5.0 SLOW BLOW DRAIN FUSE 5A DRAIN SLOW FUSE BLOW 5.
*NOTE: Only fused roof unit ver. 99/3 boards & onwards require this filter as they no longer have C1 & C2 filter capacitors ELECTRO MAGNETIC COMPLIANCE A N E A N E FUSED ROOF UNIT 240 Volts AC PUMP DRAIN ORANGE BLACK DRAIN FUSE 5.0 SLOW BLOW MOTOR FUSE 15.0 SLOW BLOW BLUE DRAIN MOTOR EARTH BLUE WHITE CAP CAP BLUE PUMP PUMP EARTH BROWN BROWN BROWN PUMP FUSE 5.
CO & CZ FAULT FINDING NOTES • R/U Indicator LED’s display incoming control signals only. Outputs must be verified with a multimeter at appliance terminals. • Resetting a CO KDU will reset to factory default any preset valves e.g. drain cycle interval, auto mode temp. • Damage to equipment can occur if power is not isolated when connecting or disconnecting keypads, or appliances from Roof Units. • All version keypads with serial numbers larger than 30516 have internal timers fitted.
CR SERIES 2000 - 2005 (Replaces CO Series) Wall Control : CR Series 17vdc (SP3215) Compatible Roof Unit: Modular R/U (SP3000) Control Cable: 7-pin 17vdc pre-terminated (SP5200) Fan Motor: 600W, 750W, 1000W Drainage: 240v Electric Drain Valve (SP2062) or Counterweight Drain Valve (SP2040) Pump: 240v pump Solenoid: 24v solenoid Display Reading: Modes of Operation F E C AC FAN EXHAUST COOL AUTO - ventilation with fresh air. - to extract air. - operates pump & fan for cooling.
CRR SERIES (SP3216) 2002 - 2003 Wall Control : All functions same as CR CR KEYPAD 2002 - 2003 BACK OF KEYPAD CIRCUIT BOARD 2002 - 2003 GREEN DISPLAY J1 = FIT FOR ROOF UNIT CIRCUIT BOARD J2 = FIT JUMPER WHEN DRAIN VALVE FITTED J3 = MOTOR SPEED KEY SOCKET RESET COOL OFF FAN TIMER EXH AUTO JP1 PALE GREEN OVERLAY JP2 JP3 << WHITE PLASTIC HOUSING >> TEMP REMOTE RECEIVER ROOF UNIT CABLE CABLE CALIB.
CRR SERIES (SP3219) 2003 - 2005 (Replaces CRR SP3216) Wall Control • • All functions same as CR Receiver built into CRR Wall Controller CR KEYPAD 2004 - 2005 BACK OF KEYPAD CIRCUIT BOARD GREEN DISPLAY J1 = FIT FOR ROOF UNIT CIRCUIT BOARD J2 = FIT JUMPER WHEN DRAIN VALVE FITTED J3 = MOTOR SPEED KEY SOCKET RESET JP2 COOL FAN OFF JP1 JP1 PALE GREEN OVERLAY TIMER JP2 ADD EXH << RECEIVER LED CLRJP3 AUTO WHITE PLASTIC HOUSING >> TEMP REMOTE RECEIVER ROOF UNIT CABLE CABLE COR 03/ 3 7 PIN
CRR SERIES 2002 - 2005 Fault Finding for SP3216 and SP3219 • • Remove 8 pin remote control receiver cable from rear of keypad and fault find as per CO/CZ/CA/CR/CY. If fault is attributed to remote control then replace the transmitter and re-programme the receiver Programming additional transmitters The receiver and transmitter supplied in the remote pack are pre-programmed. To attach additional transmitters, program as follows:1. 2. 3. Power to remain connected.
CY SERIES 2000 - 2005 (Replaces CZ Series) Wall Control : CY Series 17vdc (SP3214) Compatible Roof Unit: Modular R/U (SP3000) Control Cable: 7-pin 17vdc pre-terminated (SP5200) Fan Motor: 600W, 750W, 1000W Drainage: Drain 240v Electric Drain Valve (SP2062), or Counterweight Valve (SP2040) Pump: 240v pump Solenoid: 24v solenoid Modes of Operation: FAN - ventilation with fresh air EXHAUST - to extract air COOL - operates pump and fan for cooling Fan Speeds: 10 speeds indicated by fan speed L
CA SERIES 2000 - 2005 Wall Control : CA Series 17vdc (SP3213) Compatible Roof Unit: Modular R/U (SP3000) Control Cable: 7-pin 17vdc pre-terminated (SP5200) Fan Motor: 600W, 750W, 1000W Drainage: Drain 240v Electric Drain Valve (SP2062) or Counterweight Valve (SP2040) Pump: 240v Pump Solenoid: 24v solenoid Modes of Operation: FAN - fan only for ventilation with fresh air EXHAUST - reverse fan direction to extract air COOL - fan and pump both operate for cooling Fan Speeds: Variable speed by
CA SERIES 2000 - 2005 STANDARD SETTING OF DIP SWITCHES FM774/0708 BOOK 2 18
Red Yellow Brown Blue Pin No. & Colour 1. 3. 5. 7. SPEED DRAIN 17 Volts Reverse (EXH) Pump Ground Function 2. Green 4. Black 6. White Pin No.
> < EXH TO ISOLATOR SWITCH INDICATOR LEDS SPEED DRAIN 1 2 3 4 5 6 7 PUMP 17 PIN 17 vdc AUT0O 4 MAX POT REMOVED FROM VER 2001/4 240V OR 15A FUSE MOTOR MRU BOARD MAX MIN 3 PIN CABLE BROWN 3 1 2 E N A MWL BLUE EXH BLACK MS CAP TIMER 240V 240V AGA/MRU/2000 WATER INLET ELECTRIC DRAIN 6 PIN 240V MOTOR LEAD WHITE FAN ORANGE OFF DRAIN COOLLL CAP DRAIN A DRAIN N MOTOR E PUMP A PUMP N 20 PUMP E FM774/0708 BOOK 2 PUMP MS BOARD RELAY CA/CR/CY/CRR/QA/QM KEYPAD 24V 240
DRAIN TO ISOLATOR SWITCH INDICATOR LEDS SPEED EXH 1 2 3 4 5 6 7 PUMP 1 2 3 4 E N A MOTOR MRU BOARD 15A FUSE MAX MIN MAX POT REMOVED FROM VER 2001/4 17 PIN 17 V > < BROWN AUT0O BLACK EXH BLUE TIMER CAP FAN WHITE OFF CAP OR 240V 240V DRAIN A DRAIN N MOTOR E PUMP A 21 PUMP N COOLLL 6 PIN MOTOR LEAD AGA/MRU/2000 PUMP FM774/0708 BOOK 2 2PUMP E WATER INLET 240V ELECTRIC DRAIN RELAY CA/CR/CY KEYPAD COUNTERWEIGHT DRAIN 6 PIN MOTOR PLUG 24V 240V MWL MWL MWL BOARD BO
WW SERIES 2000 - 2005 Wall Control : WW Controller (SP3225) Communication Board : WW BMCU (SP3227) Compatible Roof Unit: Modular R/U (SP3000) Control Cable: 7-pin 17vdc pre-terminated (SP5200) connection between R/U and BMCU board. 7-pin 14vdc pre-terminated (SP5200) connection between BMCU and keypad. 4-pin 14vdc pre-terminated (SP5202) connection between BMCU and keypad for temperature sensing. 8-pin pre-terminated (SP3229) connection to remote receiver board.
WW SERIES SCHEMATIC DIAGRAM 2000 - 2005 Back of WW Keypad (SP3225) WW BMCU (SP3227) c) 4– PIN PRE-TERMINATED CABLE (SP5202) b) 7– PIN PRE-TERMINATED CABLE (SP5200) Roof Unit KDU Remote KDU MRU BOARD (SP3000) AGA/MRU/2000 a) 7– PIN PRE-TERMINATED CABLE (SP5200) MOTOR E WHITE CAP MOTOR 15A FUSE DRAIN ORANGE CAP BLUE d) 8– PIN PRE-TERMINATED CABLE (SP3229) RELAY WW Multifunction Receiver (SP3229) MIN BROWN E N A PUMP DRAIN EXH 3 4 23 SPEED 2 1 2 3 4 5 6 7 1 FM774/0708 BOOK 2
WW SERIES 2003 - 2005 WW Multifunction Receiver Wiring Diagram YELLOW WHITE RED GREEN BLACK GREEN BLACK BROWN BLUE PURPLE FM1953/1203 WW Multifunction Transmitter (SP3223) DECREASE FAN SPEED FAN INCREASE FAN SPEED COOL ON / OFF Note: Conflict situations refer to CRR series page 15 FM774/0708 BOOK 2 24 WIRI NG DI AGRAM FOR WW REMO TE RECEIVE R WW Multifunction Receiver (SP3229)
CO/CZ/CA/CR/CY/WW/EX/I/QA/QM FAULT FINDING ELECTRICAL FAULTS FAULT Ref 1. NO DISPLAY AT KEYPAD 1.1 Display illumination level set too low. (Excludes WW) Whilst in ‘OFF’ mode adjust illumination with speed > (increase) button, or the dial on the CA keypad. 1.2 240v mains supply isolated. Check mains fuse, circuit breaker, unit isolation switch or MRU. 1.3 Keypad not connected. Check 7-pin cable connection and continuity. 1.4 Keypad locked up. Push ‘RESET’ button on keypad. 1.5 MRU failure.
CO/CZ/CA/CR/CY/QA/QM/WW/EX/I FAULT FINDING FAN FAULTS FAULT Ref CAUSE ACTION 6. FAN COMES ON BY ITSELF (AND CAN BE TURNED OFF AT KEYPAD) 6.1 7. FAN CUTS OFF 7.1 Unit has sustained an electrical spike on supply cable. Unit has sustained an electrical spike on the low voltage keypad cable. Loss of power to air-conditioner. Confirm unit is wired on its own dedicated supply. Fit a spike filter on both end of the low voltage keypad cable.
CO/CZ/CA/CR/CY/QA/QM/WW/EX/I FAULT FINDING WATER FAULTS FAULT 10. WATER NOT DRAINING FROM UNIT 11. WATER DRAINING OUT OF CYCLE 12. WATER NOT CIRCULATING Select “COOL” and fault find as follows FM774/0708 BOOK 2 Ref CAUSE ACTION 10.1 Unit may be in AUTO mode (CR or WW only). 10.2 Electric drain valve failed and/or roof If 240v present at drain terminals unit triac shorted as a result. when OFF selected - replace roof unit. Recommend replace Electric Drain Valve. 10.
CM, V, VS, E, EC (TEKELEK) SERIES (Heritage only) Wall Control : TEKELEK 285 or 240v Controller (SP 3016) Compatible Roof Unit: TEKELEK 210 Speed Control Circuit board (SP 3014) Control Cable: 4 conductors, insulated wire rated at 240v 5 amp Fan Motor: 370W, 600W, 750W, 1000W Drainage: Hydraulic Drain Valve (SP2064) and/or Bleed Off and/or Counterweight Drain Valve (SP2040) Pump: 240v pump Solenoid: If fitted 24v with retro-fit kit Modes of Operation: FAN - ventilation with fresh air COOL - p
FM774/0708 BOOK 2 TRANSFORMER TO WALL SWITCH 29 MAINS IN EARTH EARTH STUD ACTIVE/ BROWN NEUTRAL/ BLUE YELLOW/GREEN SOLENOID POWER IN CONTROL WHITE BLACK MAX SPEED MIN SPEED POWER OUT BROWN BLUE BLACK CONNECTOR TEK210 CIRCUIT BOARD MOTOR YELLOW/GREEN BROWN TEKELEK 285 KEYPAD MOTOR CAPACITOR MOTOR CAPACITOR MOTOR CAPACITOR ACTIVE FAN PUMP CONTROL SOLENOID BROWN SOLENOID BLUE ISOLATOR SWITCH WATER SOLENOID COUNTERWEIGHT 240V MWL MWL MS MWL BOARD MWL BOARD V, VS, E, EC (TE
CM (TEKELEK) SERIES WIRING DIAGRAM PRE 2000 WATER PUMP FAN MOTOR BROWN ORANGE BROWN WHITE WHITE GREEN / YELLOW GREEN/YELLOW ORNAGE BLUE BLUE BLACK BLACK GREEN / YELLOW BLUE BROWN ISOLATOR SWITCH CONNECTOR WATER SOLENOID SOLENOID BLUE POWER OUT TO WALL SWITCH SOLENOID BROWN POWER IN CONTROL CONTROL TEK 210 CIRCUIT BOARD MIN FAN MINIMUM SPEED ADJUSTMENT MAX PUMP MAXIMUM SPEED ADJUSTMENT ACTIVE MAINS IN NEUTRAL / BLUE ACTIVE / BROWN EARTH CAPACITOR INSIDE ELECTRICAL BOX V, VS (TEKEL
V, VS, E, EC (TEKELEK) SERIES WIRING DIAGRAM 2000 - 2004 MWL ISOLATOR SWITCH WATER SOLENOID TRANSFORMER SOLENOID BLUE BROWN SOLENOID BROWN MOTOR CAPACITOR TO WALL SWITCH CONTROL PUMP POWER OUT WHITE POWER IN BLACK CONTROL FAN MIN SPEED ACTIVE MAX SPEED MOTOR CAPACITOR TEK210 CIRCUIT BOARD MOTOR CAPACITOR MAINS IN NEUTRAL/ BLUE ACTIVE/ BROWN BLACK BLUE CONNECTOR YELLOW/GREEN WHITE WATER PUMP MINIMUM RPM MOTOR SETTING ORANGE YELLOW/GREEN BROWN BLUE EARTH STUD BROWN EARTH ______
CM, V, VS, E, EC (TEKELEK) SERIES FAULT FINDING ELECTRICAL FAULTS FAULT Ref CAUSE ACTION 1. WALL CONTROL NOT POWERED 1.1 No mains supply to roof unit. Check mains fuse, circuit breaker & unit isolation switch. 1.2 Wall control wiring fault. Check all electrical connections. 2.1 Fuse blown or circuit breaker tripped. Check for short or earth fault in system or arcing in 6-pin motor plug. Ref CAUSE ACTION No mains supply to roof unit.
CM, V, VS, E, EC (TEKELEK) SERIES FAULT FINDING WATER FAULTS FAULT Ref CAUSE ACTION 5. WATER NOT ENTERING UNIT 5.1 Mains isolation tap closed. Open tap. 5.2 Solenoid mesh strainer blocked. Remove solenoid, clean mesh strainer and check water quality. 5.3 Solenoid coil open circuit or failed. Replace solenoid. 5.4 No 240v off board to transformer. Replace roof unit. 5.5 No 24v to MWL. Replace transformer. 5.6 No 24v to solenoid. Replace MWL. 5.
MOBILE FAULT FINDING (M 240) FAN FAULTS FAULT Ref CAUSE ACTION 1. FAN NOT OPERATING Select ‘FAN’ and fault find as follows 1.1 No mains supply to control board. Check mains fuse, circuit breaker or isolation switch. 1.2 Control board failure. If no power out voltage to motor replace board. 1.3 Motor not powered. Check continuity through 6-pin plug motor. 1.4 Capacitor failure - motor will buzz but Replace capacitor. not rotate. 1.
ADDITIONAL PRODUCT SPECIFICATIONS HERITAGE SUMP 2000-2001 WMS FLEXIBLE HOSE (SP2202) FITTED UNDER SUMP MS FLOAT ASSEMBLY (SP2212) or MWL FLOAT ASSEMBLY (SP2210) ELECTRIC DRAIN VALVE (SP2062) 2001-2002 SLOW CLOSE SOLENOID (SP2045) COUNTERWEIGHT DRAIN (SP2040) FM774/0708 BOOK 2 35
HERITAGE SUMP 2002-2008 SHROUDED MOTOR RING (SP6025) 530mm FAN BLADE ASSEMBLY 10 BLADE (SP6054) 9 BLADE (SP6056) RPE SOLENOID (SP2075) ELECTRICAL BOX SHAPE REDESIGNED MRU NOW LOCATED IN LID.
CASCADE SUMP 2000-2001 WATER INLET FLEXIBLE HOSE (SP2202) FITTED UNDER SUMP.
CASCADE SUMP 2002 - 2005 MS FLOAT ASSEMBLY FITTED BEHIND PUMP RPE SOLENOID (SP2075) ELECTRICAL BOX SHAPE REDESIGNED MRU NOW LOCATED IN LID.
ILLUSION SUMP 2004 - 2005 FEEDER PIPES ELECTRICAL BOX FM774/0708 BOOK 2 MS FLOAT ASSY RPE SOLENOID FITTED TO THROUGH SUMP EBOW AND FLEXIBLE HOSE.
EX SERIES SUMP 2002 - 2005 EX Series Sump FM774/0708 BOOK 2 40
WATER INLET TAP AND FILTER (SP2076) Introduced 2002 Purpose: To filter and isolate water supply to unit. Description: ½” brass ball valve with integral filter. Filter Notes:- When 1/4 turn valve is in line with pipe supply on. WMS FLEXIBLE HOSE (SP2202) Introduced 2000 - 2001 (Discontinued 2001/2002) Purpose: To assist the plumber in connecting to water supply pipe. Description: 1.2m, reinforced hose and water inlet assembly. Notes: This WS Hose System is suited to Electric Drain only.
REPLACEMENT SOLENOID KIT 2002 - 2004 CONTENTS OF KIT: A B E D C Rubber Washer Directional Arrow for Water Flow 24V 45° Nozzle Plastic Clip Inline Filter Water Restrictor Care must be exercised to ensure the solenoid is fitted to follow the directional arrow for water flow on the solenoid body. Kit parts required when replacing solenoid.
WATER INLET MAGNETIC WATER LEVEL SYSTEM (MWL) Introduced 2000 MWL CONTROL UNIT (SP2210) Purpose: Determine water level. Adjustable by holding float shaft and rotating ball float. Description: The float assembly is wired in series with the solenoid on the 24v circuit. A schematic wiring diagram of MWL sys tem can be found on page 20. FLOAT ASSEMBLY (SP2200) MAGNETIC SENSOR WATER LEVEL SYSTEM (MS) Introduced 2000-2002 MS CONTROL UNIT (SP2212) Purpose: Determine water level.
WATER OUTLET COUNTERWEIGHT DRAIN VALVE (SP2040) Introduced 2001 Counterweight drain valve shown in the normally open position (dry sump) FLOAT ASSEMBLY REAR BARB 3 mm & 5 mm STAINLESS STEEL SUPPORT FRONT BARB ADJUSTING SCREW Pre 03/04 Water level to be set 10mm below overflow SUPPORT ARM With no adjusting screw Blue 40mm Square Section ‘O’ ring Black 40mm Round Section ‘O’ ring Purpose: To allow the unit to hold water whilst in operation and to drain water when turned off or during a house keeping c
IMPORTANT When reconnecting hoses on counterweight drain valve, ensure original hose configuration is used. Refer to pictures below for configuration options.
NOTES FM774/0708 BOOK 2 46
