Technibel Climatisation CAV92C5TA Series Manual

TECHNICAL DATA
& SERVICE MANUAL
INDOOR UNIT: CAV92C5TA
-
CAV122C5TA-
SPLIT SYSTEM AIR CONDITIONER
CAV122C5TA- 387106937
0.8180.254.0 05/2002
Model No. Product Code No.
CAV92C5TA- 387106936

IMPORTANT!
Please read before installation
This air conditioning system meets strict safety and operating
standards.
For the installer or service person, it is important to install or
service the system so that it operates safely and efficiently.
For safe installation and trouble-free operation, you must:
• Carefully read this instruction booklet before beginning.
• Follow each installation or repair step exactly as shown.
• Observe all local, state and national electrical codes.
• ay close attention to all warning and caution notices given in
this manual.
•The unit must be supplied with a dedicated electrical line.
This symbol refers to a hazard or unsafe practice which can result
in severe personal injury or death.
This symbol refers to a hazard or unsafe practice which can result
in personal injury or product or property damage.
If necessary, et help
These instructions are all you need for most installation sites and
maintenance conditions.
If you require help for a special problem, contact our sale/service
outlet or your certified dealer for additional instructions.
In case of improper installation
The manufacturer shall in no way be responsible for improper
installation or maintenance service, including failure to follow the
instructions in this document.
SPECIAL PRECAUTIONS
• During installation, connect before the refrigerant system and
then the wiring one; proceed in the reverse orden when removing
the units.
When wirin
ELECTRICAL SHOCK CAN CAUSE SEVERE
PERSONAL INJURY OR DEATH. ONLY QUALIFIED,
EXPERIENCED ELECTRICIANS SHOULD ATTEMPT
TO WIRE THIS SYSTEM.
• Do not supply power to the unit until all wiring and tubing are
completed or reconnected and checked, to ensure the grounding.
• Highly dangerous electrical voltages are used in this system.
Carefully refer to the wiring diagram and these instructions when
wiring.
Improper connections and inadequate grounding can cause
accidental injury and death.
•Ground the unit following local electrical codes.
• The Yellow/Green wire cannot be used for any connection
different from the ground connection.
• Connect all wiring tightly. Loose wiring may cause overheating
at connection points and a possible fire hazard.
• Do not allow wiring to touch the refrigerant tubing, compressor,
or any moving parts of the fan.
• Do not use multi-core cable when wiring the power supply and
control lines. Use separate cables for each type of line.
When transportin
Be careful when picking up and moving the indoor and outdoor
units. Get a partner to help, and bend your knees when lifting to
reduce strain on your back. Sharp edges or thin aluminium fins on
the air conditioner can cut your fingers.
When installin ...
• Keep all tubing runs as short as possible.
• Use the flare method for connecting tubing.
• Apply refrigerant lubricant to the matching surfaces of the flare
and union tubes before connecting them; screw by hand and
then tighten the nut with a torque wrench for a leak-free
connection.
• Check carefully for leaks before starting the test run.
NOTE:
Depending on the system type, liquid and gas lines may be either
narrow or wide. Therefore, to avoid confusion, the refrigerant
tubing for your particular model is specified as narrow tube for
liquid, wide tube for gas.
When servicin
• Turn the power OFF at the main power board before opening
the unit to check or repair electrical parts and wiring.
• Keep your fingers and clothing away from any moving parts.
• Clean up the site after the work, remembering to check that no
metal scraps or bits of wiring have been left inside the unit being
serviced.
• Ventilate the room during the installation or testing the refrigeration
system; make sure that, after the installation, no gas leaks are
present, because this could produce toxic gas and dangerous
if in contact with flames or heat-sources.
WARNING
CAUTION
WARNING
… In a ceiling
Make sure the ceiling is strong enough to hold the unit-weight.
It may be necessary to build a strong wooden or metal frame to
provide added support.
… In a room
Properly insulate any tubing run inside a room to prevent
"sweating", which can cause dripping and water damage to
walls and floors.
... In moist or uneven locations
Use a raised concrete base to provide a solid level foundation
for the outdoor unit. This prevents damage and abnormal
vibrations.
... In area with strong winds
Securely anchor the outdoor unit down with bolts and a metal
frame. Provide a suitable air baffle.
... In a snowy area (for heat pump-type systems)
Install the outdoor unit on a raised platform that is higher then
drifting snow. Provide snow vents.
When connecting refrigerant tubing
2

Pa
g
e
1. SPECIFICATIONS 4
1-1 Unit specifications 4
1-2 Major Component specifications 6
1-3 Other Component specifications 8
2. DIMENSIONAL DATA 9
3. ELECTRICAL DATA 10
3-1 Electric Wiring Diagrams 10
4. FUNCTION 11
4-1 Room Temperature Control 11
4-2 Dry Operation (Dehumidification) 12
4-3 Freeze Prevention (Cooling and Dry) 12
4-4 Drain Pump and Float Switch 13
5. TROUBLESHOOTING 14
5-1 Check before and after troubleshooting 14
5-2 Air conditioner does not operate 14
5-3 Some part of air conditioner does not operate 18
5-4 Air conditioner operates, but abnormalities are observed 20
5-5 If a sensor is defective 21
6. CHECKING ELECTRICAL COMPONENTS 22
6-1 Measurement of Insulation Resistance 22
6-2 Checkin
g
Continuit
y
of Fuse on PCB Ass'
y
23
6-3 Checking Motor Capacitor 23
7. MAINTENANCE 24
7-1 Changing Address of Remote Control Unit in Indoor Unit 24
Table of Contents
3

1. SPECIFICATIONS
1-1 Unit Specifications
CAV92C5TA-
Power source
V
olta
g
e ratin
g
Performance
Capacity
Air circulation (High/Med/Low) m³/h
Features
Controls/Temperature controls
Control unit
Timer
Fan speed
Airflow direction Vertical
Air Filter
Power noise level Hi/Me/Lo dB-A
Refrigerant tubing connections
Refrigerant Narrow tube mm(in.)
tube diameter Wide tube mm(in.)
Refrigerant
Refrigerant tube kit / Air clean filter
Dimensions & Wei
g
ht
Dimensions Unit Height mm
Width mm
Depth mm
Ceiling panel Height mm
Width mm
Depth mm
Package dimensions Unit Height mm
Width mm
Depth mm
Volume m3
Ceiling panel Height mm
Width mm
Depth mm
Volume m3
Weight Unit Net kg
Shipping kg
Ceiling panel Net kg
Shipping kg
DATA SUBJECT TO CHANGE WITHOUT NOTICE
4,70
0,07
16,5
21
2,50
0,18
110
800
800
650
220 - 240V ~ 50H
z
230V
730
730
380
744
6,35 (1/4)
575
575
64
Microprocessor/ I.C. thermostat
Wireless remote control unit
3 and Auto /1(Hi)
ON/OFF 24 hours & Daily program, 1-hour OFF
273
A
uto
9,52 (3/8)
Optional / ------
See catalogue with the requested matching
500/450/400
R407C
Flare type
Washable, Anti-Mold
45/42/38
4

CAV122C5TA-
Power source
V
olta
g
e ratin
g
Performance
Capacity
Air circulation (High/Med/Low) m³/h
Features
Controls/Temperature controls
Control unit
Timer
Fan speed
Airflow direction Vertical
Air Filter
Power noise level Hi/Me/Lo dB-A
Refrigerant tubing connections
Refrigerant Narrow tube mm(in.)
tube diameter Wide tube mm(in.)
Refrigerant
Refrigerant tube kit / Air clean filter
Dimensions & Wei
g
ht
Dimensions Unit Height mm
Width mm
Depth mm
Ceiling panel Height mm
Width mm
Depth mm
Package dimensions Unit Height mm
Width mm
Depth mm
Volume m3
Ceiling panel Height mm
Width mm
Depth mm
Volume m3
Weight Unit Net kg
Shipping kg
Ceiling panel Net kg
Shipping kg
DATA SUBJECT TO CHANGE WITHOUT NOTICE
2,50
800
0,07
16,5
21
0,18
110
800
575
64
730
730
380
744
650
ON/OFF 24 hours & Daily program, 1-hour OFF
3 and Auto /1(Hi)
A
uto
Flare type
6,35 (1/4)
273
12,7 (1/2)
220 - 240V ~ 50H
z
230V
4,70
Wireless remote control unit
See catalogue with the requested matching
Microprocessor/ I.C. thermostat
500/450/400
R407C
Optional / ------
575
Washable, Anti-Mold
45/42/38
5

1-2 Major Component Specifications
CAV92C5TA-
Controller PCB
Part No.
Controls
Control circuit fuse
Remote Control Unit
Fan & Fan Motor
Type
Q'ty ……. Dia. and lenght mm
Fan motor model…Q'ty
No. Of poles…rpm (230 V)
Running Amps A
Power input W
Coil resistance (Ambient temp. 20 °C ) ΩBLU-BLK: 463,5
BLK-GRY: 33,5
GRY-RED: 38,5
RED-WHT: 143,5
WHT-BLU: 80,0
Safety devices Type
Operating temp. Open °C
Close °C
Run capacitor µF
VAC
Flap Motor
Type
Model
Rating
No of poles …rpm
Nominal output W
Coil resistance (Ambient temp. 20 °C ) kΩ
Heat Exch. Coil
Coil
Rows
Fin pitch mm
face area m2
DATA SUBJECT TO CHANGE WITHOUT NOTICE
1,3
0,258
A
C 208/230V 50/60H
z
8 …. 2,5/3,0
A
luminium plate fin / Copper tube
1
Internal thermal protector
130 ± 15K
1,5
450
0,18
41
XR99/129E
RCS-6PN4E-G
Centrifugal fan
R4E280-AK43-13 …1
4… 620/560/490/240
1…. Ø 280 / L 175
Synchro moto
r
3/2,5
16,45 ± 15%
160 ± 10K
M2LJ24ZE31
Microprocessor
250 V - 3,15
A
6

CAV122C5TA-
Controller PCB
Part No.
Controls
Control circuit fuse
Remote Control Unit
Fan & Fan Motor
Type
Q'ty ……. Dia. and lenght mm
Fan motor model…Q'ty
No. Of poles…rpm (230 V, Cool-Heat)
Running Amps A
Power input W
Coil resistance (Ambient temp. 20 °C ) ΩBLU-BLK: 463,5
BLK-GRY: 33,5
GRY-RED: 38,5
RED-WHT: 143,5
WHT-BLU: 80,0
Safety devices Type
Operating temp. Open °C
Close °C
Run capacitor µF
VAC
Flap Motor
Type
Model
Rating
No of poles …rpm
Nominal output W
Coil resistance (Ambient temp. 20 °C ) kΩ
Heat Exch. Coil
Coil
Rows
Fin pitch mm
face area m2
DATA SUBJECT TO CHANGE WITHOUT NOTICE
1…. Ø 280 / L 175
1,3
0,258
A
C 208/230V 50/60H
z
8 …. 2,5/3,0
A
luminium plate fin / Copper tube
1
3/2,5
16,45 ± 15%
R4E280-AK43-13 …1
250 V - 3,15
A
RCS-6PN4E-G
Centrifugal fan
XR99/129E
Microprocessor
4… 620/560/490/240
0,18
Internal thermal protector
41
160 ± 10K
130 ± 15K
1,5
450
Synchro moto
r
M2LJ24ZE31
7

1-3 Other Component Specifications CAV92C5TA-
CAV122C5TA-
Trasformer
Rating Primary
Secondary
Capacity
Coil resistance Ω
(
at 21°C
)
Thermal cut-off temp.
Thermistor
(
Coil sensor TH1
)
Resistance ΚΩ
Thermistor
(
Room sensor TH2
)
Resistance ΚΩ
Drain pump
Model
Rating Voltage
Input
Total head capacity
Safet
y
float switch
Model
Contact rating
BI 1300 2725
230V AC/DC - 0,5
A
PC 309564003
220/240V - 50H
z
14W
0,4 l/min
0 °C 15,3 ± 5%
DTN-TKS134B
25 °C 5,0 ± 3%
Primary (WHT-WHT): 205 ± 10%
Secondary (BRN-BRN): 2,0 ± 10%
150°C
PBC-41E-S14
A
TR-J105
A
C 230V, 50/60H
z
19V - 0.526
A
10 V
A
8

2. DIMENSIONAL DATA
9

3. ELECTRICAL DATA
3-1 Electric Wiring Diagrams
10

4. FUNCTION
4-1. Room Temperature Control
■Cooling
●Room temperature control is obtained by cycling the compressor ON and OFF under control of the room
temperature sensor in the remote control unit.
●The room temperature (and other information) is transmitted every 5 minutes by the remote control unit to the
controller in the indoor unit.
●The control circuit will not attempt to turn the compressor ON until the compressor has been OFF for at least
3 minutes. To protect the compressor from stalling out when trying to start against the high side refrigerant
pressure, the control circuit has a built-in automatic time delay to allow the internal pressure to equalize.
●As a protective measure, the control circuit switches the compressor OFF not before than 5 minutes
of compressor operation.
●Thermo. ON : When the room temperature is above T + 1°C (T°C is set temperature).
Compressor ➞ON
●Thermo. OFF : When the room temperature is equal to or below set temperature T°C.
Compressor ➞OFF
3 minutes5 minutes
ON OFF ON OFF ON OFFCompressor
ON OFF ON OFF ON OFF
More than
5 minutes
Outdoor fan
Indoor fan Set speed
T+1 °C
T°Cset temp.
Thermo.
OFF Thermo. OFF Thermo. ON Thermo. OFF
Thermo.
ON
Thermo.
ON
Thermo.
ON
Room temp.
5 minutes 5 minutes 5 minutes 5 minutes 5 minutes 5 minutes 5 minutes
Signal from remote control unit
3 seconds3 seconds3 seconds 3 seconds
11

4-2. Dry Operation (Dehumidification)
●Dry operation uses the ability of the cooling cycle to remove moisture from the air, but by running at low level to
dehumidify without greatly reducing the room temperature. The air conditioner repeats the ON/OFF cycle
automatically as shown in the chart below according to the room temperature.
●Intermittent ventilation occurs by switching the indoor fan speed between L ↔LL.
●Dry operation does not occur when the room temperature is under 15°C, which is the monitor zone.
●When the compressor stops, the indoor fan stops as well.
NOTE
Room temp.
Cooling operation
T+2 °C
Set temp. T °C
T–1°C
Monitor zone
Both the indoor and outdoor units stop.
Room temp. 15 °C
*Dry A zone
Compressor :
FMI (indoor fan) : Continuous operation L (low speed) / LL (very low speed) intermittent ventilation
only while the compressor is ON.
*Dry B zone
Compressor :
FMI (indoor fan) : Intermittent operation (ON for 3 minutes and OFF for 9 minutes) L (low speed) / LL (very low speed) intermittent ventilation
only while the compressor is ON.
4-3. Freeze Prevention (Cooling and Dry)
●This function prevents freezing of the indoor heat exchange coil.
●When the compressor has been running for 6minutes or more and the temperature of the indoor heat
exchange coil falls below –1°C, the control circuit stops the compressor for at least 6 minutes. The compressor
does not start again until the temperature rises above 8°C or 6 minutes has elapsed.
ON ON ON ON
OFFOFF
Set speed
More than
6minutes
6 minutes
T+1 °C
Indoor heat exch.
coil temp. –1°C
Compressor
Indoor fan
Room temp. Thermo. OFF
Thermo. ON
Set temp. T °C
More than
6minutes
More than
6 minutes
Set speed
12

4-4 Drain Pump and Float Switch
Compressor
Drain Pump OFF
Float Switch
NOTE:
Either in Heating or another mode or the unit is stopped, when the float switch is turned ON,
the drain pump operates for 20 minutes minimum
OFF OFF
OFF OFF OFF
OFF
ON ON
ON ON ON ON
ON ON
ON
20'min. 20'min.
3'min
13

6. TROUBLESHOOTING
6-1. Check before and after troubleshooting
6-1-1. Check power supply wiring.
●Check that power supply wires are correctly connected to terminals Land Non the terminal plate in the indoor
unit.
6-1-2. Check inter-unit wiring.
●Check that inter-unit wiring is correctly connected to the outdoor unit from the indoor unit.
6-1-3. Check power supply.
●Check that voltage is in specified range (±10% of the rating).
●Check that power is being supplied.
6-1-4. Check lead wires and connectors in indoor and outdoor units.
●Check that coating of lead wires is not damaged.
●Check that lead wires and connectors are firmly connected.
●Check that wiring is correct.
WARNING
Hazardous voltage can cause ELECTRIC SHOCK or
DEATH. Disconnect power or turn off circuit breaker
before you start checking or servicing.
5-2. Air conditioner does not operate.
5-2-1. Circuit breaker trips (or fuse blows).
A. When the circuit breaker is set to ON, it trips immediately. (Resetting is not possible.)
●There is a possibility of ground fault.
●Check insulation resistance.
If resistance value is 2MΩor less, insulation is defective (“NO”).
NO
Measure insulation
resistance of electrical
parts in outdoor unit.
NO
Set circuit breaker to OFF.
*
Measure insulation
resistance of electrical
parts in indoor unit.
1Remove inter-unit wires from
terminal plate in outdoor unit.
Measure insulation resistance
of outdoor unit.
•
2Remove inter-unit wires from
terminal plate in indoor unit.
Then, pull the power plug out of
the wall outlet
Measure insulation resistance
of indoor unit.
•
•
•
Insulation of
outdoor unit
is defective.
Insulation of
indoor unit
is defective.
WARNING
5.
5-1.
5-1-1.
5-1-2.
5-1-3.
5-1-4.
14

B. Circuit breaker trips in several minutes after turning the air conditioner on.
●There is a possibility of short circuit.
6-2-2. Neither indoor nor outdoor unit runs.
A. Power is not supplied.
B. Check "OPERATION selector" switch in the indoor unit.
YES
NO
•OPERATION selector switch is set
in ON position.
Set OPERATION selector switch
to ON.
Indoor PCB Ass'y is defective.
NO
•Check power supply.
Power is being supplied to the
indoor unit.
Circuit breaker
is tripped.
Power failure
Reset breaker.
Wait for recovery
or contact power
company.
Replace with suitable
one (larger capacity).
•
•
•
NO
Check capacity of circuit breaker.
Capacity of circuit breaker is
suitable.
Measure resistance of outdoor fan
motor winding.
Measure resistance of compressor
motor winding.
5-2-2.
15

C. Check remote control unit.
D. Check fuse on the indoor PCB Ass'y.
E. Check TIMER on the remote control unit.
•Timer is turned ON. Check to see
if or is displayed on
remote control
YES Cancel the timer mode.
ON
OK
OK
•Check fuse on indoor PCB Ass'y
for continuity. (F)
•Check operation lamp to see
if light is ON.
Light is OFF
•Measure resistance of primary and
secondary winding of transformer.
(TR)
•Indoor PCB Ass'y is defective.
OK
•Measure resistance of indoor and
outdoor fan motor winding.
(FM)
•Measure resistance of compressor
motor winding. (CM)
OK
If fuse has been blown,
OK
•Try to run with another remote
control unit.
First remote control unit is defective.
•Check for residue buildup on
transmitter of remote control unit.
•Check for residue buildup on remote
control receiver on front of indoor
unit.
Clean transmitter.
Clean receiver.
•Replace the fuse.
16

6-2-3. Only outdoor unit does not run.
A. Check setting temperature.
6-2-4. Only Indoor unit does not run.
•Indoor PCB Ass'y is defective.
OK
NO
Is room temperature too low ?
Try to lower setting temperature by
temperature setting button ( button).
Outdoor unit still does
not run.
Remote control unit is defective.
•Try to run using another remote
control unit.
COOL
5-2-3.
5-2-4.
17

5-3. Some part of air conditioner does not operate.
5-3-1. Only indoor fan does not run.
5-3-2. Only flap motor does not run.
5-3-3. Only outdoor fan does not run.
Fan cannot
be turned.
OK
•Check fan rotation.
Turn fan gently once or twice by
hand.
•Check fan casing
foreign matter on
inside.
Fan motor burnout
or foreign matter in
bearings.
Remove foreign
matter or repair.
Repair or replace.
•Measure resistance of outdoor fan
motor winding.
•Check fan motor capacitor.
•Measure resistance of flap motor
winding.
Fan cannot
be turned.
OK
•Check fan rotation.
Turn fan gently once or twice by
hand.
•Check fan casing
foreign matter on
inside.
Fan motor burnout
or foreign matter in
bearings.
Remove foreign
matter or repair.
Repair or replace.
•Measure resistance of indoor fan
motor winding.
•Check fan motor capacitor.
PCB assy is defective.
OK
18

5-3-4. Only compressor does not run
Check compressor motor Overload relay is working
capacitor C1 (either OLR T or OLR A)
Measure resistance of Temperature of compressor
compressor motor winding is abnormally high
Refrigerant gas shortage Charge refrigerant gas
Measure power supply voltage Rotor may be locked up
The voltage is too low
5-3-5. Compressor and outdoor fan do not run
Float switch turned ON
Check if drain pump Replace the drain pump
runs normaly
Verify if drain condensate tube
is obstructed
Remove obstruction
YES
YES
YES
NO
NO
YES
YES
NO
YES
19

6-4-1. Poor cooling.
6-4-2. Excessive cooling.
NO
NO
•Set temperature is suitable. Set temperature to higher
value using temperature
setting buttons of the remote
control unit.
•Remote control unit is placed where
it can detect room temperature
properly.
Change position of remote
control unit.
Air filter is clogged.
NO
YES
Temperature
difference
is small.
YES
Temperature difference between
suction and discharge air is
large enough (approx. 10 deg. or more).
Possibility of
gas shortage.
YES
•Check position of remote control unit.
Cool air from air conditioner
reaches position directly.
•Change position of remote
control unit.
•Wide and narrow tubes between
indoor unit and outdoor unit are
insulated.
Insulate both wide and narrow
tubes separately and then
tape together.
•Measure temperature of suction and
discharge air of air conditioner. Charge refrigerant
gas.
Check for clogging of air filter.
•Fan speed is set to LOW.
Clean filter.
Set fan speed to either
HIGH or MEDIUM.
•Review cooling load estimate,
if performance of air conditioner is
normal.
Reduce cooling
load or replace the air
conditioner with larger
capacity.
6-4. Air conditioner operates, but abnormalities are observed.
5-4.
5-4-1.
5-4-2.
20