Service manual

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SERVICE MANUAL

SPLIT-TYPE, HEAT PUMP AIR CONDITIONERS

SPLIT-TYPE, AIR CONDITIONERS

No. OC368

REVISED EDITION-B

INDOOR UNIT

REMOTE CONTROLLER

CONTENTS

1. TECHNICAL CHANGES··································2

2. REFERENCE MANUAL ······································2

3. SAFETY PRECAUTION···································3

4. PART NAMES AND FUNCTIONS ···················5

5. SPECIFICATIONS············································8

6. NOISE CRITERION CURVES··························9

7. OUTLINES AND DIMENSIONS ·····················10

WIRING DIAGRAM

············································12

REFRIGERANT SYSTEM DIAGRAM

··················13

10. TROUBLESHOOTING ···································14

11. DISASSEMBLY PROCEDURE·······················26

12. PARTS LIST ···················································31

13. RoHS PARTS LIST ········································34

ON/OFF

TEMP.

Indoor unit

[Model names] [Service Ref.]

PCA-A24GA

PCA-A30GA

PCA-A36GA

PCA-A42GA

Model name

indication

June 2007

NOTE:

• This manual describes only

service data of the indoor

units.

• RoHS compliant products have

<G> mark on the spec name

plate.

• For servicing RoHS compli-

ant products, refer to the RoHS

PARTS LIST.

Revision:

• WIRING DIAGRAM has been

changed in REVISED EDI-

TION-B.

• Some descriptions have been

modified.

• Please void OC368 REVISED

EDITION-A.

3 3 2 2 3

OC368B--1.qxp 07.6.20 1:01 PM Page 1

Summary of content (36 pages)

PAGE 1
OC368B--1.qxp 07.6.20 1:01 PM Page 1 SPLIT-TYPE, HEAT PUMP AIR CONDITIONERS SPLIT-TYPE, AIR CONDITIONERS June 2007 No. OC368 REVISED EDITION-B SERVICE MANUAL Indoor unit [Model names] [Service Ref.] PCA-A24GA PCA-A24GA1 PCA-A30GA PCA-A30GA1 PCA-A36GA PCA-A36GA1 PCA-A42GA PCA-A42GA1 PCA-A24GA PCA-A30GA PCA-A36GA PCA-A42GA Revision: • WIRING DIAGRAM has been changed in REVISED EDITION-B. • Some descriptions have been modified. • Please void OC368 REVISED EDITION-A.
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OC368B--1.qxp 1 07.6.20 1:01 PM Page 2 TECHNICAL CHANGES PCA-A24GA ➔ PCA-A30GA ➔ PCA-A36GA ➔ PCA-A42GA ➔ PCA-A24GA1 PCA-A30GA1 PCA-A36GA1 PCA-A42GA1 • Indoor controller board has been changed. 2 REFERENCE MANUAL 2-1. OUTDOOR UNIT SERVICE MANUAL Service Manual No. Service Ref. PUZ-A18/24/30/36/42NHA PUZ-A18/24/30/36/42NHA-BS PUY-A12/18/24/30/36/42NHA(1) PUY-A12/18/24/30/36/42NHA(1)-BS OC367 2-2. TECHNICAL DATA BOOK Manual No.
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OC368B--1.qxp 07.6.20 1:01 PM 3 Page 3 SAFETY PRECAUTION 3-1. ALWAYS OBSERVE FOR SAFETY Before obtaining access to terminals, all supply circuits must be disconnected. 3-2. CAUTIONS RELATED TO NEW REFRIGERANT Cautions for units utilising refrigerant R410A Use new refrigerant pipes. Do not use refrigerant other than R410A. If other refrigerant (R22 etc.) is used, chlorine in refrigerant can cause deterioration of refrigerant oil etc.
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OC368B--1.qxp 07.6.20 1:01 PM Page 4 [2] Additional refrigerant charge When charging directly from cylinder · Check that cylinder for R410A on the market is syphon type. · Charging should be performed with the cylinder of syphon stood vertically. (Refrigerant is charged from liquid phase.) Unit Gravimeter [3] Service tools Use the below service tools as exclusive tools for R410A refrigerant. No. 1 Specifications Gauge manifold ·Only for R410A ·Use the existing fitting specifications.
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OC368B--1.qxp 07.6.20 1:01 PM 4 Page 5 PART NAMES AND FUNCTIONS ● Indoor Unit Left/right guide vanes Change the direction of airflow from the horizontal blower. Air outlet Long-life filter Removes dust and foreign matter from air coming in through the grille (Recommended cleaning interval : Approx. every 2,500 operating hours) Up/down guide vanes Change the direction of airflow from the vertical blower.
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OC368B--1.qxp 07.6.20 1:01 PM Page 6 ● Wired remote controller Display Section For purposes of this explanation, all parts of the display are shown as lit. During actual operation, only the relevant items will be lit. Day-of-Week “Sensor” indication Shows the current day of the week. Displayed when the remote controller sensor is used. Time/Timer Display Shows the current time, unless the simple or Auto Off timer is set. If the simple or Auto Off timer is set, the time to be switched off is shown.
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OC368B--1.qxp 07.6.20 1:01 PM Page 7 ● Wireless remote controller CHECK TEST RUN display Indicate that the unit is being checked or test-run. MODEL SELECT display display Blinks when model is selected. Lights up while the signal is transmitted to the indoor unit when the button is pressed. Temperature setting display indicates the desired temperature setting which is set. CLOCK display OPERATION MODE display Displays the current time.
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OC368B--1.qxp INDOOR UNIT INDOOR UNIT INDOOR UNIT 5 07.6.20 1:01 PM Page 8 SPECIFICATIONS Service Ref. Power supply(phase, cycle, voltage) Max. Fuse Size Min.Circuit Ampacity External finish Heat exchanger Fan Fan(drive) o No. Fan motor output Fan motor PCA-A24GA, PCA-A24GA1 Single phase, 60Hz, 208/230V 15 1 Munsell 0.70Y 8.59/0.97 Plate fin coil Sirocco fan (direct) o 3 0.070 0.
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07.6.20 1:01 PM Page 9 Service Ref. Power supply(phase, cycle, voltage) Max. Fuse Size Min.Circuit Ampacity External finish Heat exchanger Fan Fan(drive) o No. Fan motor output Fan motor PCA-A42GA, PCA-A42GA1 Single phase, 60Hz, 208/230V 15 1 Munsell 0.70Y 8.59/0.97 Plate fin coil Sirocco fan (direct) o 3 0.090 0.
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OC368B--1.qxp 07.6.
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Unit : inch(mm) 6 5-1/2(140) 2-3/4(70) 51-9/16(1310) 36/42 5 Liquid pipe 3/8F 4 Gas pipe 5/8F 8-17/32(217) 5/8(16) 10-5/8(270) 3-25/32(96) 47-13/16(1214) MODEL 3-7/16(87) 8-5/32(207) Air outlet 50-13/16(1290) 3-3/16(81) 48-13/16(1240)(Suspension bolt pitch) NOTES: Use M10 or W3/8 screw for anchor bolt.
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OC368B--1.qxp 07.6.20 1:01 PM Page 12 WIRING DIAGRAM 8 PCA-A24GA PCA-A30GA PCA-A24GA1 PCA-A30GA1 [LEGEND] SYMBOL P.B I.B FUSE ZNR CN2L CN32 CN41 CN51 SW1 SW2 SWE X1 X4 BCR LED1 LED2 LED3 PCA-A36GA PCA-A36GA1 SYMBOL C MF MV TB4 NAME INDOOR POWER BOARD INDOOR CONTROLLER BOARD FUSE (6.3A/250V) VARISTOR CONNECTOR CONNECTOR CONNECTOR CONNECTOR SWITCH wSee Table 1. SWITCH wSee Table 2.
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OC368B--1.qxp 9 07.6.
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OC368B--1.qxp 10 07.6.20 1:01 PM Page 14 TROUBLESHOOTING 10-1. TROUBLESHOOTING Present and past error codes are logged and displayed on the wired remote controller or controller board of outdoor unit. Actions to be taken for service and the inferior phenomenon reoccurrence at field are summarized in the table below. Check the contents below before investigating details.
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OC368B--1.qxp 07.6.20 1:01 PM Page 15 Note: Refer to the manual of outdoor unit for the details of display such as F, U, and other E. 10-2. SELF-DIAGNOSIS ACTION TABLE Error Code P1 Abnormal point and detection method Room temperature thermistor (TH1) 1 The unit is in 3-minute resume prevention mode if short/open of thermistor is detected. Abnormal if the unit does not reset normally after 3 minutes. (The unit returns to normal operation, if it has been reset normally.
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OC368B--1.qxp Error Code 07.6.20 1:01 PM Page 16 Abnormal point and detection method Cause Freezing/overheating protection is working 1 Freezing protection (Cooling mode) The unit is in 6-minute resume prevention mode if pipe temperature stays under -15:(5˚F) for 3 minutes, 3 minutes after the compressor started. Abnormal if it stays under -15:(5˚F) for 3 minutes again within 16 minutes after 6-minute resume prevention mode.
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OC368B--1.qxp 07.6.20 1:01 PM Page 17 Error Code Abnormal point and detection method Cause Countermeasure P9 Pipe temperature thermistor / Condenser-Evaporator (TH5) 1 The unit is in 3-minute resume protection mode if short/open of thermistor is detected. Abnormal if the unit does not get back to normal within 3 minutes. (The unit returns to normal operation, if it has been reset normally.
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OC368B--1.qxp 07.6.20 1:01 PM Page 18 Error Code Abnormal point and detection method E6 Indoor/outdoor unit communication error (Signal receiving error) 1 Abnormal if indoor controller board cannot receive any signal normally for 6 minutes after turning the power on. 2 Abnormal if indoor controller board cannot receive any signal normally for 3 minutes.
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OC368B--1.qxp 07.6.20 1:01 PM Page 19 10-3. TROUBLESHOOTING BY INFERIOR PHENOMENA Phenomena (1)LED2 on indoor controller board is off. Note: Refer to the manual of outdoor unit for the detail of remote controller. Cause Countermeasure • When LED1 on indoor controller board is also off. 1 Power supply of rated voltage is not supplied to out- 1 Check the voltage of outdoor power door unit. supply terminal block (L1,L2).
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OC368B--1.qxp 07.6.20 1:01 PM Page 20 Note: Refer to the manual of the outdoor unit for the detail of remote controller. Phenomena (1)LED2 on indoor controller board is off. Cause Countermeasure • When LED1 on indoor controller board is lit. 1 Mis-setting of refrigerant address for outdoor unit (There is no unit corresponding to refrigerant address “0”.) 1 Reconfirm the setting of refrigerant address for outdoor unit. Set the refrigerant address to “0”.
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OC368B--1.qxp 07.6.20 1:01 PM Page 21 10-4. WHEN WIRED REMOTE CONTROLLER OR INDOOR UNIT MICROCOMPUTER TROUBLES 1. If there is not any other problem when trouble occurs, emergency operation starts as the indoor controller board switch (SWE) is set to ON. During the emergency operation the indoor unit operates with Indoor fan at high speed. 2.
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OC368B--1.qxp 07.6.20 1:01 PM Page 22 10-5. HOW TO CHECK THE PARTS PCA-A24GA PCA-A30GA PCA-A36GA PCA-A24GA1 PCA-A30GA1 PCA-A36GA1 PCA-A42GA PCA-A42GA1 Parts name Check points Room temperature thermistor (TH1) Pipe temperature thermistor (TH2) Condenser/evaporator temperature thermistor (TH5) Fan motor (MF) Relay connector 1 Red 2 White 3 Black 1 2 Disconnect the connector then measure the resistance using a tester. (At the ambient temperature 10:(50˚F)~30:(86˚F)) Normal Abnormal 4.3k"~9.
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OC368B--1.qxp 07.6.20 1:01 PM Page 23 < Thermistor for lower temperature > 50 Room temperature thermistor(TH1) Pipe temperature thermistor(TH2) Condenser/evaporator temperature thermistor(TH5) Thermistor R0=15kΩ ± 3% Fixed number of B=3480 ± 2% 1 273+t t(:):Rt=15exp { 3480( T(˚F):Rt=15exp { 3480( 1 )} 273 1 273+ T-32 1.
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OC368B--1.qxp 07.6.20 1:01 PM Page 24 10-6-2. Indoor controller board PCA-A24GA PCA-A30GA PCA-A24GA1 PCA-A30GA1 CN2D Connect to the indoor power board (CN2S) (12.5~13.7V DC) PCA-A36GA PCA-A36GA1 LED1 Power supply (I.B) PCA-A42GA PCA-A42GA1 LED2 Power supply (R.B) LED3 Transmission (Indoor/outdoor) CN3C Transmission (Indoor/outdoor) (0~24V DC) CN22 Connect to the terminal block(TB5) (Remote controller connecting wire) (10.4~14.
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OC368B--1.qxp 07.6.20 1:01 PM Page 25 10-7. FUNCTIONS OF DIP SWITCH AND JUMPER WIRE Each function is controlled by the dip switch and the jumper wire on control P.C. board. SW1 and SW2 are equipped only for service parts. Model setting and capacity setting are memorized in the nonvolatile memory of the control P.C. board of the unit.
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OC368B--1.qxp 11 07.6.20 1:01 PM Page 26 DISASSEMBLY PROCEDURE PCA-A24GA PCA-A30GA PCA-A36GA PCA-A24GA1 PCA-A30GA1 PCA-A36GA1 OPERATING PROCEDURE PCA-A42GA PCA-A42GA1 PHOTOS & ILLUSTRATIONS 1. Removing the air intake grille (1) Slide the intake grille holding 2 knobs backward to open the intake grille. (2) When the intake grille left open, push the stoppers on the rear 2 hinges to pull out the intake grille.
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OC368B--1.qxp 07.6.20 1:01 PM Page 27 OPERATING PROCEDURE PHOTOS & ILLUSTRATIONS 3. Removing the fan motor (1) Remove the intake grille. (2) Disconnect the fan motor connector. (3) Remove the screw for removing the motor support at both left and right side. (4) Loosen the set screws at the fan motor side of the connecting joint. (5) Slide the fan motor to the left side and pull it out. Photo 2 Motor Screws Motor support 4. Removing the sirocco fan (1) Remove the air intake grille.
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OC368B--1.qxp 07.6.20 1:01 PM Page 28 OPERATING PROCEDURE PHOTOS 6. Removing the vane motor (1) Remove the air intake grille. (See the figure 1) (2) Remove the left side panel. (See the figure 3) (3) Remove the relay connector of vane motor. (4) Remove the electrical box. (5) Remove the screws of vane motor, then remove vane motor . (Note) Connect the lead wires and connectors properly and place them in the proper position so that the wires are not pinched by other parts.
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OC368B--1.qxp 07.6.20 1:01 PM Page 29 OPERATING PROCEDURE PHOTOS 9. Removing the drain pan (1) Remove the air intake grille. (See the figure 1) (2) Remove the beam. (3) Remove the side panels of right and left. (See the figure 3) (4) Remove the under panel. Remove the screws of the right and left side drain pan. (5) Remove the 2 insulations in centre of the drain pan, and after removing the 2 screws, remove the drain pan.
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OC368B--1.qxp 07.6.20 1:01 PM Page 30 OPERATING PROCEDURE PHOTOS 12. Removing the heat exchanger (1) Remove the air intake grille. (See the figure 1) (2) Remove the beam. (3) Remove the side panel (right and left). (See the figure 3) (4) Disconnect the relay connector of the pipe thermistor. (5) Remove the under panel. (See the photo 7) (6) Remove the drain pan. (See the photo 8) (7) Unscrew the screw of the pipe cover, and remove the pipe cover.
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OC368B--2.qxp 07.6.20 0:59 PM 12 Page 31 PARTS LIST (non-RoHS compliant) FAN AND FUNCTIONAL PARTS PCA-A24GA PCA-A30GA PCA-A36GA PCA-A42GA 16 1 15 2 3 4 5 14 13 12 11 6 7 8 No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Parts No.
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OC368B--2.qxp 07.6.20 0:59 PM STRUCTURAL PART PCA-A24GA PCA-A30GA PCA-A36GA PCA-A42GA Page 32 24 23 22 21 20 19 18 1 2 3 4 5 17 16 15 14 13 12 6 7 11 8 9 10 Part numbers that are circled are not shown in the figure. Q'ty/set No. Parts No.
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OC368B--2.qxp 07.6.20 0:59 PM Page 33 ELECTRICAL PARTS PCA-A24GA PCA-A30GA PCA-A36GA PCA-A42GA 6 1 2 3 4 5 TEMP. ON/OFF 8 7 No. 1 Parts No. Parts Name Specifications T7W E18 255 CAPACITOR 4= 440V T7W E19 255 CAPACITOR 5= 440V 2 T7W E56 310 INDOOR CONTROLLER BOARD Q'ty/ set PCA-A 36/42 24/30 GA 1 Remarks (Drawing No.) Wiring RecomDiagram mended Symbol Q'ty C 1 C 1 1 I.
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OC368B--2.qxp 13 07.6.20 0:59 PM Page 34 RoHS PARTS LIST FAN AND FUNCTIONAL PARTS PCA-A24GA1 PCA-A30GA1 PCA-A36GA1 PCA-A42GA1 16 1 15 2 3 4 5 14 13 12 11 6 7 No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 RoHS 8 G G G G G G G G G G G G G G G G G G G G G G G G Parts No.
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OC368B--2.qxp 07.6.20 0:59 PM Page 35 STRUCTURAL PART PCA-A24GA1 PCA-A30GA1 PCA-A36GA1 PCA-A42GA1 24 23 22 21 20 19 18 17 16 15 14 13 12 1 2 3 4 5 6 7 11 8 9 10 No. RoHS Part numbers that are circled are not shown in the figure. G 1 G 2 G G 3 G G 4 G 5 G 6 G 7 G 8 G 9 G 10 G G 11 G G 12 G 13 G G 14 G G 15 G G 16 G G 17 G G 18 G 19 G 20 G 21 G G 22 G G 23 G G 24 G 25 G 26 G Parts No.
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OC368B--2.qxp 07.6.20 0:59 PM Page 36 ELECTRICAL PARTS PCA-A24GA1 PCA-A30GA1 PCA-A36GA1 PCA-A42GA1 6 1 2 3 4 5 TEMP. ON/OFF 8 No. 1 RoHS 7 Parts No. Parts Name G T7W E18 255 CAPACITOR G T7W E19 255 CAPACITOR Specifications 4= 440V Q'ty/ set PCA-A 24/30 36/42 GA1 1 Wiring RecomDiagram mended Symbol Q'ty C 1 5= 440V 2 G T7W E56 310 INDOOR CONTROLLER BOARD Remarks (Drawing No.) C 1 1 I.