TECHNICAL & SERVICE MANUAL CS-KS30NKU + CU-KS30NKUA CS-KS36NKU + CU-KS36NKUA DC INVERTER SPLIT SYSTEM AIR CONDITIONER Indoor Model No. Product Code No. Outdoor Model No. Product Code No. CS-KS30NKU 1 852 360 86 CU-KS30NKUA 1 852 360 84 CS-KS36NKU 1 852 360 87 CU-KS36NKUA 1 852 360 85 Indoor Unit Outdoor Unit AIR CONDITIONER CS-KS30NKU CS-KS36NKU CU-KS30NKUA CU-KS36NKUA IMPORTANT These air conditioners employ new refrigerant R410A. Pay special attention when servicing the unit.
SAFETY PRECAUTIONS • Before doing repair work, please read the " SAFETY PRECAUTIONS" carefully and fully understand them. • The precautionary items here are divided into " Warning" and " Caution" items. Items in particular which may cause death or serious injury to the service personnel if the work is not performed correctly, are included in the " Warning" table. However, even precautionary items identified as " Caution" also have the potential for serious consequences if not performed correctly.
Warning If refrigerant gas blows off during the work, do not touch the refrigerant gas as it may cause frostbite. Prohibit If refrigerant gas leaks during the work, ventilate the room. If refrigerant gas catches fire, harmful gas may be generated. Do not mix any gas other than the specified refrigerant gas in the refrigerating cycle. If air or other contaminants mix with the gas, pressure will become extremely high in the refrigerating cycle, which may cause a unit breakdown.
Table of Contents Page SAFETY PRECAUTIONS .............................................................................................................. 2 TABLE OF CONTENTS ..................................................................................................................... 4 1. OPERATING RANGE ................................................................................................................... 6 2. SPECIFICATIONS 2-1. Unit Specifications .................................
Page 9. CHECKING ELECTRICAL COMPONENTS 9-1. Measurement of Insulation Resistance ............................................................................... 9-2. Checking Continuity of Fuse on PCB Ass'y ......................................................................... 46 47 10. REFRIGERANT R410A: SPECIAL PRECAUTIONS WHEN SERVICING UNIT 10-1. Characteristics of New Refrigerant R410A ......................................................................... 10-2. Checklist before Servicing ......
1. OPERATING RANGE Temperature Cooling Indoor Air Intake Temp. Outdoor Air Intake Temp.
2. SPECIFICATIONS 2-1.
Indoor Unit Outdoor Unit CS-KS30NKU CU-KS30NKUA < 208V > Dimensions & Weight Features Electrical Rating Performance Voltage Rating Total Capacity Sensible Capacity Latent Capacity Air Circulation (Hi/Me/Lo) Moisture Removal (High) Available Voltage Range Running Amperes Power Input Power Factor EER SEER Compressor Locked Rotor Amperes Fuse or Circuit Breaker Capacity Controls / Temperature Control Control Unit Timer Fan Speeds Airflow Direction (Indoor) 208V Single-Phase 60Hz Cooling 30,600 ( 10,900
Indoor Unit Outdoor Unit CS-KS36NKU CU-KS36NKUA < 230V > Dimensions & Weight Features Electrical Rating Performance Voltage Rating Total Capacity Sensible Capacity Latent Capacity Air Circulation (Hi/Me/Lo) Moisture Removal (High) Available Voltage Range Running Amperes Power Input Power Factor EER SEER Compressor Locked Rotor Amperes Fuse or Circuit Breaker Capacity Controls / Temperature Control Control Unit Timer Fan Speeds Airflow Direction (Indoor) 230V Single-Phase 60Hz Cooling 34,000 ( 10,900
Indoor Unit Outdoor Unit CS-KS36NKU CU-KS36NKUA < 208V > Dimensions & Weight Features Electrical Rating Performance Voltage Rating Total Capacity Sensible Capacity Latent Capacity Air Circulation (Hi/Me/Lo) Moisture Removal (High) Available Voltage Range Running Amperes Power Input Power Factor EER SEER Compressor Locked Rotor Amperes Fuse or Circuit Breaker Capacity Controls / Temperature Control Control Unit Timer Fan Speeds Airflow Direction (Indoor) 208V Single-Phase 60Hz Cooling 34,000 ( 10,900
2-2. Major Component Specifications 2-2-1. Indoor Unit Indoor Unit CS-KS30NKU Control PCB Part No. Controls Control Circuit Fuse CB-CS-KS30NKU Microprocessor 250V 3A Fan Type Q'ty ... Dia. and Length Cross-Flow 1 ... D3-15/16 / L32-1 (D100/L838) inch (mm) Fan Motor Type Model ... Q'ty No. of Poles Rough Measure RPM (Cool) Nominal Output Coil Resistance (Ambient Temp.
Indoor Unit CS-KS36NKU Control PCB Part No. Controls Control Circuit Fuse CB-CS-KS36NKU Microprocessor 250V 3A Fan Type Q'ty ... Dia. and Length Cross-Flow 1 ... D3-15/16 / L32-1 (D100/L838) inch (mm) Fan Motor Type Model ... Q'ty No. of Poles Rough Measure RPM (Cool) Nominal Output Coil Resistance (Ambient Temp. 68 °F (20 °C)) Safety Device Type Over-Current Protection Over-Heat Protection Run Capacitor Flap Motor Type Model Rating Coil Resistance (Ambient Temp.
2-2-2. Outdoor Unit Outdoor Unit CU-KS30NKUA P.C.Board Part No. Controls Circuit Fuse Control P.C.B Noise Filer P.C.B H.I.C.Board CR-C3082-F Microprocessor 400V 3.15A POW-CH3082-B2 250V 25A HIC-CH3072R-C1 - Compressor Type Compressor Model / Nominal Output Compressor Oil ... Amount Pints (cc) Coil Resistance (Ambient Temp. 77 °F (25 °C)) Ohm DC Twin Rotary (Hermetic) C-9RVN273H0H / 2,250W FV68S ... 2.98 (1,400) T - R : 0.169 T - S : 0.169 R - S : 0.
Outdoor Unit CU-KS36NKUA P.C.Board Part No. Controls Circuit Fuse Control P.C.B Noise Filer P.C.B H.I.C.Board CR-C3682-F Microprocessor 400V 3.15A POW-CH3082-B2 250V 25A HIC-CH3072R-C1 - Compressor Type Compressor Model / Nominal Output Compressor Oil ... Amount Pints (cc) Coil Resistance (Ambient Temp. 77 °F (25 °C)) Ohm DC Twin Rotary (Hermetic) C-9RVN273H0H / 2,500W FV68S ... 2.98 (1,400) T - R : 0.169 T - S : 0.169 R - S : 0.
2-3.
7/16 2-5/8 2-5/8 3-3/8 5/16 2-3/4 (3/32) 4-9/16 23/32 1-7/8 2-3/8 9-1/16 (230) 32 5/ 3- 11-13/16 (300) 11-13/16 dia . 16 7-23/32 5-1/2 1-3/32 16-11/32 3-3/4 19-9/16 1-9/32 2-3/4 5-9/16 3-3/4 5-3/16 22-3/8 17-21/32 16-11/32 17-23/32 Narrow tube dia. 3/8" (9.52) Wide tube dia. 5/8" (15.88) 17-5/16 15-1/8 6-7/32 7-25/32 1-27/32 25/32 7-7/8 9-3/32 5-27/32 .3 dia 2 -5/ 3 4-9/16 1-15/32 2-3/32 2-11/16 CS-KS30NKU CS-KS36NKU 1-7/8 2-3/8 Indoor Unit 41-15/16 (1065) 3.
8-5/8 37-1/32 (940) Wiring outlet (knock-out holes dia.1-3/8, 1-3/32, 7/8, 1/2) 4-1/8 1/2 2-17/32 2-5/32 2-3/8 3/4 Refrigerant tubing joint (Gas tube) Flare connection dia.5/8" (15.88) 2-3/8 3-3/8 2-17/32 3/4 31/32 21/32 1-27/32 1-3/16 1-15/16 2-25/32 Wiring outlet (knock-out holes dia.1-3/8, 1-3/32, 7/8, 1/2) 2-ID:1-1/4 holes (holes for drain) Of the 4-ID:1-1/4 holes, use 1 of 2 holes specified for drain use to install the port. Use rubber plugs to seal the remaining 3 holes.
4. REFRIGERANT FLOW DIAGRAM 4-1. Refrigerant Flow Diagram CS-KS30NKU CS-KS36NKU Outdoor Unit CU-KS30NKUA CU-KS36NKUA Outdoor unit Wide tube Wide tube service valve Sub Main Accumulator Accumulator Muffler O.D 5/8" (15.88 mm) Heat exchanger High pressure switch H.P. Compressor Indoor unit Heat exchanger Indoor Unit Narrow tube Electric expansion valve Narrow tube service valve M Cooling cycle O.D. 3/8" (9.
5. PERFORMANCE DATA 5-1. Temperature Charts Indoor Unit CS-KS30NKU Outdoor Unit CU-KS30NKUA Cooling Characteristics (RH : 46%, Indoor fan speed : High fan) (60Hz, 230V) Low pressure at wide tube service valve psig(MPaG) (1) Low pressure performance chart Lo fan Hi Fan 174 (1.2) 0°C) F (3 .86° p m C) ir Te (27° or A Indo 80°F C) (24° 75°F 159 (1.1) 145 (1.0) 131 (0.9) 117 (0.8) 104 (0.
Indoor Unit CS-KS36NKU Outdoor Unit CU-KS36NKUA Cooling Characteristics (RH : 46%, Indoor fan speed : High fan) (60Hz, 230V) Low pressure at wide tube service valve psig(MPaG) (1) Low pressure performance chart Lo fan 174 (1.2) 159 (1.1) Hi Fan ) (30°C .86°F p m e T ) r Air (27°C Indoo 80°F ) (24°C 75°F 145 (1.0) 131 (0.9) 117 (0.8) 104 (0.
5-2. Cooling Capacity Indoor Unit : CS-KS30NKU Outdoor Unit : CU-KS30NKUA Power Supply : 230V Single Phase 60Hz < Cooling Capacity > RATING CAPACITY: 30,600 BTU/h AIR FLOW RATE: INDOOR ENT. TEMP. oF (oC) WB 59 (15.0) 63 (17.2) 67 (19.4) 71 (21.7) 75 (23.9) DB 72 76 80 84 88 72 76 80 84 88 72 76 80 84 88 72 76 80 84 88 76 80 84 88 630 CFM OUTDOOR AMBIENT TEMP. oF (oC) 65 (18.3) 75 (23.9) 85 (29.4) 95 (35.0) 105 (40.6) 115 (46.1) TC CI 26,540 2.07 27,120 2.43 27,710 2.79 27,910 3.
Indoor Unit : Outdoor Unit : CS-KS36NKU CU-KS36NKUA Power supply : 230V Single Phase 60Hz < Cooling Capacity > RATING CAPACITY: 34,000 BTU/h AIR FLOW RATE: INDOOR ENT. TEMP. oF (oC) WB 59 (15.0) 63 (17.2) 67 (19.4) 71 (21.7) 75 (23.9) DB 72 76 80 84 88 72 76 80 84 88 72 76 80 84 88 72 76 80 84 88 76 80 84 88 630 CFM OUTDOOR AMBIENT TEMP. oF (oC) 65 (18.3) 75 (23.9) 85 (29.4) 95 (35.0) 105 (40.6) 115 (46.1) TC CI 27,450 2.61 28,140 3.02 28,840 3.43 29,040 3.67 24,650 3.
5-3. Cooling Capacity (Low Ambient) Indoor Unit : CS-KS30NKU Outdoor Unit : CU-KS30NKUA Power supply : 230V Single Phase 60Hz < Cooling Capacity (Low Ambient) > RATING CAPACITY: 30,600 BTU/h AIR FLOW RATE: INDOOR ENT. TEMP. oF (oC) WB 59 (15.0) 63 (17.2) 67 (19.4) 71 (21.7) 75 (23.9) OUTDOOR AMBIENT TEMP. oF (oC) DB 72 76 80 84 88 72 76 80 84 88 72 76 80 84 88 72 76 80 84 88 76 80 84 88 630 CFM 0 (-17.8) 5 (-15.0) 15 (-9.4) 25 (-3.9) 35 (1.7) 45 (7.2) 55 (12.8) TC CI 30,120 0.
Indoor Unit : CS-KS36NKU Outdoor Unit : CU-KS36NKUA Power supply : 230V Single Phase 60Hz < Cooling Capacity (Low Ambient) > RATING CAPACITY: -1 34,000 BTU/h AIR FLOW RATE: INDOOR ENT. TEMP. oF (oC) WB 59 (15.0) 63 (17.2) 67 (19.4) 71 (21.7) 75 (23.9) OUTDOOR AMBIENT TEMP. oF (oC) DB 72 76 80 84 88 72 76 80 84 88 72 76 80 84 88 72 76 80 84 88 76 80 84 88 630 CFM 0 (-17.8) 5 (-15.0) 15 (-9.4) 25 (-3.9) 35 (1.7) 45 (7.2) 55 (12.8) TC CI 30,900 0.22 30,870 0.36 30,800 0.
5-4. Air Throw Distance Charts Indoor Unit Cooling CS-KS30NKU Room air temp. : 80°F (26.7°C) Fan speed : High Horizontal distance (ft.) 0 5 10 15 20 Axis air velocity (ft./sec.) Vertical distance (ft.
Indoor Unit Cooling CS-KS36NKU Room air temp. : Fan speed : 80°F (26.7°C) High Horizontal distance (ft.) 0 5 10 15 20 25 Axis air velocity (ft./sec.) Vertical distance (ft.
6. ELECTRICAL DATA 6-1. Electrical Characteristics Indoor Unit CS-KS30NKU Outdoor Unit CU-KS30NKUA (1) Voltage:230V < 230V > Cooling Indoor Fan Motor Performance at Rating conditions Rating conditions: Running amp. Power input Indoor air temperature: Outdoor air temperature: A W 0.4 39 UnitOutdoor Unit Fan Motor + Compressor 230V Single-phase 60Hz 16.1 3,251 Complete Unit 16.5 3,290 80 °F (26.7 °C) DB / 67 °F (19.
Indoor Unit CS-KS36NKU Outdoor Unit CU-KS36NKUA (1) Voltage:230V < 230V > Cooling Indoor Fan Motor Performance at Rating conditions Rating conditions: Running amp. Power input Indoor air temperature: Outdoor air temperature: A W 0.4 39 UnitOutdoor Unit Fan Motor + Compressor 230V Single-phase 60Hz 19.6 3,961 Complete Unit 20.0 4,000 80 °F (26.7 °C) DB / 67 °F (19.
6-2.
WHT WHT CRANKCASE HEATER WHT w CH2 w CH1 FAN MOTOR M MAGNETIC COIL M 1 2 3 4 5 1 2 3 4 5 (WHT) MV 1 3 1 3 (RED) FM1 1 2 3 1 2 3 (RED) FM2 1 2 1 2 (GRN) PRY (WHT) TEST/MV 1 2 3 REACTOR + 1 2 1 2 (BLK) COIL 1 2 1 2 (WHT) COMP 1 2 1 2 (YEL) OUTDOOR + + + C1 C2 C1 L4 L3 + L2 + L1 CONTROL P.C.
7. FUNCTIONS 7-1. Operation Functions Emergency operation SENSOR DRY Emergency operation is available when the remote controller malfunctions, has been lost, or otherwise cannot be used. During DRY operation, the system adjusts the room temperature and fan speed according to the conditions in the room, in order to maintain a comfortable room environment. To operate the system, press the OPERATION button, which is also used as the receiver, below the unit display.
HIGH POWER NIGHT SETBACK This function acts to raise the power but keeps the AC system in the same operating mode. This function is set with the HIGH POWER button on the remote controller. (It can be set regardless of the temperature and fan speed settings.) • When NIGHT SETBACK operation is set, the temperature and fan speed settings will be adjusted automatically to allow comfortable sleep. • When NIGHT SETBACK operation is set, " mark" appears on the remote controller.
Noise Reducing Control (Outdoor Unit) The noise reducing control is the function used for silent operation of the air conditioner by means of setting the dip switch on the outdoor unit P.C.Board to control the fan and compressor's motor speed. NOTE When this function is used, the cooling ability is slightly degraded. Therefore, when this function is to be enabled, make sure to receive the approval of the client.
Maximum Current Value Change Function The maximum current value is changed to 14A (for CU-KS30NKUA) or 17A (for CU-KS36NKUA) to prevent power breaker tripping. (It is set to 24A when the unit is delivered from the factory.) NOTE 1. When the high load is given (Outside temperature is high in the cooling operation), the capacity is reduced. When the maximum current value change function is to be enabled, make sure to receive the approval of the client. 2.
7-2. Protective Functions Compressor discharge temperature control Freeze prevention This function controls the operation frequency to prevent the compressor discharge temperature from rising more than a specified temperature. Indoor heat exchanger temperature °F(°C) During COOL or DRY operation, freezing is detected and operation is stopped when the temperature of the indoor heat exchanger matches the conditions below. 1.
8. TROUBLESHOOTING (BEFORE CALLING FOR SERVICE) 8-1. Precautions before Performing Inspection or Repair After checking the self-diagnostics monitor, turn the power OFF before starting inspection or repair. High-capacity electrolytic capacitors are used inside the outdoor unit controller (inverter). They retain an electrical charge (charging voltage DC 310V) even after the power is turned OFF, and some time is required for the charge to dissipate.
(1) Self-diagnostics Lamps INDOOR UNIT (1) OPERATION lamp (2) TIMER lamp OPERATION TIMER (3) ON/OFF Since the indications cover various units, the corresponding parts listed below may not be present in some models. .... OFF INDICATION ON INDOOR UNIT ALARM CODE (3) ... TIMER (2) .. OPERATION ERROE (1) . CODE .... BLINKING DIAGNOSIS CONTENTS .... ON POSSIBLE MALFUNCTION F10 S01 ROOM TEMP. SENSOR TROUBLE (1) OPEN OR SHORT CIRCUIT IN SENSOR F02 HEAT EXCHANGER S02 I/DTEMP.
(2) If the self-diagnostics function fails to operate Check the indoor unit. No indicators illuminate and the indoor fan does not rotate. Check the power voltage. Blown Is the fuse blown? Normal Replace the circuit board or the fuse. Replace the controller.
8-3. Checking the Indoor and Outdoor Units (1) Checking the indoor unit No. 1 Control Use the remote controller to operate the unit in "TEST run" mode. To determine whether the mode is currently in "TEST run" mode, check the 4 indicator lamps on the unit. If all 4 are blinking, the current mode is "TEST run." Check items (unit operation) • The rated voltage must be present between inter-unit wirings 1 and 2. • Connect a 5 k ohm resistor between inter-unit wirings 2 and 3.
(3) Serial Communication Error Identification Procedure If the lamps on the main body show the following conditions after the completion of self-diagnostics, a communication error between the indoor unit and outdoor unit might be considered. In such a case, identify the breakdown section by using the following procedure. NOTE Refer to "Method of Self-Diagnostics" for the self-diagnostics procedure.
( Continued from the previous page A. ) A ( Continued from the previous page B. ) B Is the voltage of about DC22V to 24V given between the terminals 2 and 3 on the indoor unit terminal strip (Serial Communication Line) ? (Fig. 2) Yes No Defect in the indoor unit P.C. board Defect or connection error in the inter-unit cable Outdoor Unit 1. Turn OFF the power and wait until the power lamp (LED) of the outdoor unit controller is turned OFF. 2.
(3-2) Alarm Code : E07/P04/P05/P20/P27 Troubleshooting Serial Communication Outdoor Unit 1 2 3 4 5 6 Power 1. Turn off the power and wait until the power lamp (LED) of the outdoor unit controller is turned OFF. 2. Disconnect the cable from the terminal 3 on the Outdoor unit terminal strip. (Fig. 6) 1 2 3 Indoor Unit Fig. 6 1. Turn ON the power and operate the system using the remote controller or the operation button on the indoor unit. 2.
8-4. Trouble Diagnosis of Fan Motor 8-4-1. Indoor Fan Motor This indoor DC fan motor contains an internal control PCB. Therefore, it is not possible to measure the coil resistance, and the following procedure should be used to check the motor. To perform diagnosis, operate the unit in cooling mode with indoor fan speed "High". Next, make sure that the indoor unit receive the signals from the remote controller when the ON/OFF operation button is pressed.
8-4-2. Outdoor Fan Motor This outdoor DC fan motor contains an internal control PCB. Therefore, it is not possible to measure the coil resistance, and the following procedure should be used to check the motor. Perform the trouble diagnosis by Test Run mode described on Installation Instructions of indoor unit. Important: (A) Turn OFF the power before connecting or disconnecting the motor connectors.
8-5. Noise Malfunction and Electromagnetic Interference An inverter A/C operates using pulse signal control and high frequencies. Therefore, it is susceptible to the effects of external noise, and is likely to cause electromagnetic interference with nearby wireless devices. A noise filter is installed for ordinary use, preventing these problems. However, depending on the installation conditions, these effects may still occur. Please pay attention to the points listed below.
9. CHECKING ELECTRICAL COMPONENTS 9-1. Measurement of Insulation Resistance Ground wire Clip The insulation is in good condition if the resistance exceeds 1M ohm. Probe 9-1-1. Power Supply Cord Insulation tester Clamp the grounding wire of power cord with the lead clip of the insulation resistance tester and measure the resistance by placing a probe on either of the two power wires. (Fig. 1) Then also measure the resistance between the grounding and other power terminals. (Fig. 1) Fig.
9-2. Checking Continuity of Fuse on PCB Ass'y Fuse Remove the PCB Ass'y from the electrical component box. Then pull out the fuse from the PCB Ass'y. (Fig. 5) Check for continuity using a multimeter as shown in Fig. 6. PCB Ass'y Fig. 5 Fuse Fig.
10. REFRIGERANT R410A: SPECIAL PRECAUTIONS WHEN SERVICING UNIT 10-1. Characteristics of New Refrigerant R410A 10-1-1. What is New Refrigerant R410A? R410A is a new refrigerant that contains two types of pseudo-non-azeotropic refrigerant mixture. Its refrigeration capacity and energy efficiency are about the same level as the conventional refrigerant, R22. 10-1-2. Components (mixing proportions) HFC32 (50%) / HFC125 (50%) 10-1-3.
10-2. Checklist before Servicing Use a clutch-type flare tool for R410A or the conventional flare tool. Note that sizes of the resultant flares differ between these two tools. Where a conventional flare tool is used, make sure to observe A Specification (amount of extrusion) by using the flare spacer. Specification A Diameter of tube D Flare tool for R410A Conventional flare tool (for R22) Dia.3/8" (9.52 mm) 0 to 0.0196" 0.0472" Dia.1/2" (12.7 mm) (0 to 0.5 mm) (1.2 mm) Dia.1/4" (6.35 mm) Dia.
10-3. Tools Specifically for R410A For servicing, use the following tools for R410A Tool Distinction Tool Name Gauge manifold Charging hose Gas leak detector Refrigerant cylinder Charging cylinder Refrigerant recovery unit Tools specifically for R410A Vacuum pump with anti-reverse flow (*1) (Solenoid valve-installed type, which prevents oil from flowing back into the unit when the power is off, is recommended.) Vacuum pump (*2)...can be used if the following adapter is attached.
10-5. In Case of Compressor Malfunction CAUTION Should the compressor malfunction, be sure to make the switch to a replacement compressor as quickly as possible. Use only the tools indicated exclusively for R410A. Specifically for R410A." See "10-3. Tools 10-5-1. Procedure for Replacing Compressor (1) Recovering refrigerant Any remaining refrigerant inside the unit should not be released to the atmosphere, but recovered using the refrigerant recovery unit for R410A.
Configuration and characteristics of cylinders (5) Recharging Valve Be sure to charge the specified amount of refrigerant in liquid state using the service port of the wide tube service valve. The proper amount is listed on the unit's nameplate. When the entire amount cannot be charged all at once, charge gradually while operating the unit in Cooling Operation. CAUTION Liquid Never charge a large amount of liquid refrigerant at once to the unit. This may cause damage to the compressor.
10-6. In Case Refrigerant is Leaking CAUTION Never attempt to charge additional refrigerant when refrigerant has been leaking from the unit. Follow the procedure described below to locate points of leaks and carry out repairs, then recharge the refrigerant. (1) Detecting Leaks Use the detector for R410A to locate refrigerant leak points.
10-7. Charging Additional Refrigerant 10-7-1. When Tubes are Extended Observe the proper amount of refrigerant as stated in this service manual or the installation manual that came with the indoor unit. Charge additional refrigerant in liquid state only. CAUTION Never charge additional refrigerant if refrigerant is leaking from the unit. Follow instructions given in "10-6. In Case Refrigerant is Leaking" and completely carry out repairs. Only then should you recharge the refrigerant. 10-8.
