Page 1
TECHNICAL DATA & SERVICE MANUAL
Outdoor Unit Indoor Unit
GR54M2R MCA27RM (X2)
MULTI-SPLIT SYSTEM AIR CONDITIONER
Indoor Unit Outdoor Unit
MCA27RM GR54M2R
0.8180.180.0 03/2001
Page 2
i
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 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.
●
Pay close attention to all warning and caution notices
given in this manual.
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, Get Help
These instructions are all you need for most installation
sites and maintenance conditions. If you require help for
a special problem, contact our sales/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
When Wiring
ELECTRICAL SHOCK CAN CAUSE
SEVERE PERSONAL INJURY OR DEATH.
ONLY A QUALIFIED, EXPERIENCED
ELECTRICIAN SHOULD ATTEMPT TO
WIRE THIS SYSTEM.
• Do not supply power to the unit until all wiring and tubing are completed or reconnected and checked.
• 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 or death.
• Ground the unit following local electrical codes.
• Connect all wiring tightly. Loose wiring may cause
overheating at connection points and a possible fire
hazard.
When Transporting
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 aluminum fins on the air conditioner can cut
your fingers.
When Installing…
…In a Ceiling or Wall
Make sure the ceiling/wall is strong enough to hold the
unit’s weight. It may be necessary to construct a strong
wood or metal frame to provide added support.
…In a Room
Properly insulate any tubing run inside a room to prevent
“sweating” that can cause dripping and water damage to
walls and floors.
…In Moist or Uneven Locations
Use a raised concrete pad or concrete blocks to provide
a solid, level foundation for the outdoor unit. This prevents water damage and abnormal vibration.
…In an Area with High 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
than drifting snow. Provide snow vents.
When Connecting Refrigerant Tubing
• Use the flare method for connecting tubing.
• Apply refrigerant lubricant to the matching surfaces of
the flare and union tubes before connecting them,
then tighten the nut with a torque wrench for a leakfree connection.
• Check carefully for leaks before starting the test run.
When Servicing
• Turn the power OFF at the main power box (mains)
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 you finish, remembering to
check that no metal scraps or bits of wiring have been
left inside the unit being serviced.
Others
• Ventilate any enclosed areas when installing or testing
the refrigeration system. Escaped refrigerant gas, on
contact with fire or heat, can produce dangerously
toxic gas.
• Confirm upon completing installation that no refrigerant gas is leaking. If escaped gas comes in contact
with a stove, gas water heater, electric room heater or
other heat source, it can produce dangerously toxic
gas.
WARNING
WARNING
CAUTION
CAUTION
Page 3
ii
Table of Contents
Page
■
Unit Combination........................................................................................................................ iv
1.OPERATING RANGE................................................................................................................................. 1
2.SPECIFICATIONS
2-1.Unit Specifications.............................................................................................................................. 2
2-2.Major Component Specifications........................................................................................................ 4
2-3.Other Component Specifications........................................................................................................ 6
3.DIMENSIONAL DATA................................................................................................................................. 7
4.COOLING CAPACITY................................................................................................................................. 9
5.HEATING CAPACITY................................................................................................................................. 10
6.AIR THROW DISTANCE CHART............................................................................................................... 11
7.REFRIGERANT FLOW DIAGRAM............................................................................................................. 12
8.ELECTRICAL DATA
8-1.Electrical Characteristics.................................................................................................................... 14
8-2.Electric Wiring Diagram...................................................................................................................... 15
8-3.Performance Charts........................................................................................................................... 17
9.FUNCTION
9-1.Room Temperature Control................................................................................................................ 18
9-2.Dry Operation..................................................................................................................................... 20
9-3.Freeze Prevention.............................................................................................................................. 21
9-4.Overload Prevention........................................................................................................................... 21
9-5.Cold Draft Prevention......................................................................................................................... 22
9-6.Defrosting Operation.......................................................................................................................... 23
10.TROUBLESHOOTING
10-1.Check before and after troubleshooting............................................................................................. 25
10-2.Air conditioner does not operate......................................................................................................... 26
10-3.Some part of air conditioner does not operate................................................................................... 30
10-4.Air conditioner operates, but abnormalities are observed.................................................................. 32
10-5.If a sensor is defective........................................................................................................................ 34
11.ARRANGEMENT OF ELECTRICAL COMPONENTS................................................................................ 35
12.CHECKING ELECTRICAL COMPONENTS
12-1.Measurement of Insulation Resistance.............................................................................................. 36
12-2.Checking Continuity of Fuse on PCB Ass'y........................................................................................ 37
12-3.Checking Motor Capacitor.................................................................................................................. 37
Page 4
iii
■
Unit Combination
Combine indoor and outdoor units only as listed below.
Indoor Unit
Outdoor Unit
A
B
Refer toOutdoor Unit
Symbol of
Indoor Unit
GR54M2R
A
Indoor Unit
MCA27RM
B
Fig.1
MCA27RM
Fig.1
Page 5
1
1. OPERATING RANGE
Temperature Indoor Air Intake Temp. Outdoor Air Intake Temp.
Cooling
Maximum 32°C D.B. / 23°C W.B. 43°C D.B.
Minimum 19°C D.B. / 14°C W.B. 19°C D.B.
Heating
Maximum 27°C D.B. 24°C D.B. /18°C W.B.
Minimum 16°C D.B. –8°C D.B. / –9°C W.B.
Page 6
2.SPECIFICATIONS
2-1.Unit Specifications
DATA SUBJECT TO CHANGE WITHOUT NOTICE.
Remarks:Rating conditions are:
Cooling:Indoor air temperature 27°C D.B./19°C W.B.
Outdoor air temperature 35°C D.B./24°C W.B.
Heating:Indoor air temperature 20°C D.B.
Outdoor air temperature 7°C D.B./6°C W.B.
2
No. of indoor units. 1-unit
Power Source 220 – 240 V ~ 50 Hz
Cooling Heating
Capacity
kW 2.60 / 2.60 / 2.65 3.25 / 3.25 / 3.30
BTU/h 8,900 / 8,900 / 9,000 11,100 / 11,100 / 11,300
Air circulation (High) m
3
/h 470
Moisture removal (High) Liters/h 1.1 —
Voltage rating V 220 / 230 / 240
Available voltage range V 198 to 264
Running amperes A 4.6 / 4.6 / 4.6 4.7 / 4.7 / 4.7
Power input W 990 / 1,010 / 1,040 1,020 / 1,050 / 1,080
Power factor % 98 / 95 / 94 99 / 97 / 96
C.O.P. W/W 2.6 / 2.6 / 2.5 3.2 / 3.1 / 3.1
Compressor locked rotor amperes A 23 / 24 / 25
Controls / Temperature control Microprocessor / I.C. thermostat
Control unit Wireless remote control unit
Timer ON/OFF 24 hours & Daily program, 1-hour OFF
Fan speeds Indoor / Outdoor 3 and Auto / 1(Hi)
Airflow direction (Indoor)
Horizontal Manual
Vertical Auto
Air filter Washable, Anti–Mold
Compressor Rotary (Hermetic)
Refrigerant / Amount charged at shipment g R22 / 1,250
Refrigerant control Capillary tube
Operation sound
Indoor – Hi / Me / LodB-A 38 / 33 / 31
Outdoor – Hi dB-A 53
Refrigerant tubing connections Flare type
Max. allowable tubing length at shipment m 7.5
Refrigerant tube
Narrow tube mm (in.) 6.35 (1/4)
diameter
Wide tube mm (in.) 9.52 (3/8)
Refrigerant tube kit / Accessories Optional / Hanging wall bracket
Indoor Unit Outdoor Unit
Unit dimensions Height mm 270 630
Width mm 805 830
Depth mm 177 305
package dimensions Height mm 243 713
Width mm 855 994
Depth mm 332 413
Weight
Net kg 8.0 61.0
Shipping kg 10.0 66.0
Shipping volume m
3
0.07 0.29
Dimensions & Weight Features Electrical Rating Performance
Indoor Unit MCA27RM (✕1)
Outdoor Unit GR54M2R
Page 7
DATA SUBJECT TO CHANGE WITHOUT NOTICE.
Remarks:Rating conditions are:
Cooling:Indoor air temperature 27°C D.B./19°C W.B.
Outdoor air temperature 35°C D.B./24°C W.B.
Heating:Indoor air temperature 20°C D.B.
Outdoor air temperature 7°C D.B./6°C W.B.
3
No. of indoor units. 2-unit
Power Source 220 – 240 V ~ 50 Hz
Cooling Heating
Capacity
kW 5.00 / 5.00 / 5.10 6.25 / 6.30 / 6.35
BTU/h 17,100 / 17,100 / 17,400 21,300 / 21,500 / 21,700
Air circulation (High) m
3
/h 470 x 2
Moisture removal (High) Liters/h 1.1 x 2 —
Voltage rating V 220 / 230 / 240
Available voltage range V 198 to 264
Running amperes A 9.5 / 9.3 / 9.3 9.2 / 9.0 / 8.9
Power input W 2,040 / 2,080 / 2,120 1,980 / 1,980 / 2,000
Power factor % 98 / 97 / 95 98 / 96 / 94
C.O.P. W/W 2.5 / 2.4 / 2.4 3.2 / 3.2 / 3.2
Compressor locked rotor amperes A 46 / 48 / 50
Controls / Temperature control Microprocessor / I.C. thermostat
Control unit Wireless remote control unit
Timer ON/OFF 24 hours & Daily program, 1-hour OFF
Fan speeds Indoor / Outdoor 3 and Auto / 1(Hi)
Airflow direction (Indoor)
Horizontal Manual
Vertical Auto
Air filter Washable, Anti–Mold
Compressor Rotary (Hermetic)
Refrigerant / Amount charged at shipment g R22 / 1,250 x 2
Refrigerant control Capillary tube
Operation sound
Indoor – Hi / Me / LodB-A 38 / 33 / 31
Outdoor – Hi dB-A 53
Refrigerant tubing connections Flare type
Max. allowable tubing length at shipment m 7.5
Refrigerant tube
Narrow tube mm(in) 6.35 (1/4)
diameter
Wide tube mm(in) 9.52 (3/8)
Refrigerant tube kit / Accessories Optional / Hanging wall bracket
Indoor Unit Outdoor Unit
Unit dimensions Height mm 270 630
Width mm 805 830
Depth mm 177 305
package dimensions Height mm 243 713
Width mm 855 994
Depth mm 332 413
Weight
Net kg 8.0 61.0
Shipping kg 10.0 66.0
Shipping volume m
3
0.07 0.29
Dimensions & Weight Features Electrical Rating Performance
Indoor Unit MCA27RM (✕2)
Outdoor Unit GR54M2R
Page 8
2-2.Major Component Specifications
DATA SUBJECT TO CHANGE WITHOUT NOTICE.
Part No. POW–KM98EH(A), POW–K8EH(B)
Controls Microprocessor
Control circuit fuse 250 V – 3.15 A
Remote Control Unit RCS–8MHPS3E
Type Cross–flow
Q'ty ... Dia. and length mm 1 ... ø95 / L617
Fan motor model ... Q'ty KFV4Q–11H5P–S ... 1
No. of poles ... rpm (230 V, High) 4 ... 1,190
Nominal output W 10
Coil resistance (Ambient temp. 20°C) Ω BRN – WHT :561.8
VLT – WHT :197.4
VLT – ORG :63.4
YEL – ORG :155.7
YEL – PNK :115.9
Safety
Type Internal thermal fuse
devices
Operating temp.
Open °C 145 ±2
Close —
Run capacitor
µF 0.8
VAC 440
Type Stepping motor
Model MP24GA1
Rating DC 12 V
Coil resistance (Ambient temp. 25°C) Ω WHT – BLU (respectively 4 wires) : 380 ±7%
Coil Aluminum plate fin / Copper tube
Rows 2
Fin pitch mm 1.4
Face area m
2
0.130
Heat
Exch. Coil
Flap Motor Fan & Fan Motor
Controller
PCB
4
Indoor Unit MCA27RM
Page 9
5
Controller PCB POW–186CMH
Control circuit fuse 250 V– 3 A
Type Rotary (Hermetic)
Compressor model ... Q'ty C–R95H5K ... 2 / 80696745–S ... 2
Nominal output W 950 x 2
Compressor oil ... Amount cc SUNISO 4GSD–T ... 650 x 2
Coil resistance (Ambient temp. 25°C) Ω C – R : 2.96
C – S : 6.74
Type External (OLR 1, 3) External (OLR 2, 4)
Overload relay ... Q'ty MRA99089–9201 ... 2 CS–7C115 ... 2
Safety
Operating
Open °C 145 ±5 115 ±3
devices
temp.
Close °C 69 ±11 95 ±5
Operating amp.(Ambient temp. 25°C) Trip in 6 to 16 sec. at 16.5 A —
Run capacitor µF 22.5 ... 2
... Q'ty VAC 400 ... 2
Type Propeller
Q'ty ... Dia. mm 1 ... ø400
Fan motor model ... Q'ty SG6–51B5P ... 1
No. of poles ... rpm (230 V,High) 6 ... 910
Nominal output W 50
Coil resistance (Ambient temp. 20°C) Ω WHT – BRN : 92.1
WHT – PNK:196.4
Safety Type Internal protector
devices
Operating
Open °C 130 ±8
temp.
Close Automatic reclosing
Run capacitor
µF 2.0
VAC 460
Coil Aluminum plate fin / Copper tube
Rows 2
Fin pitch mm 1.6
Face area m
2
0.453
External Finish Acrylic baked-on enamel finish
Heat
Exch. Coil
CompressorFan & Fan Motor
DATA SUBJECT TO CHANGE WITHOUT NOTICE.
Outdoor Unit GR54M2R
Page 10
6
2-3.Other Component Specifications
Indoor Unit MCA27RM
Transformer (TR) ATR-J105
Rating Primary AC 230V, 50/60Hz
Secondary 19V, 0.526A
Capacity 10VA
Coil resistance Ω(at 21°C) Primary (WHT – WHT): 205 ±10%
Secondary (BRN – BRN): 2.0 ±10%
Thermal cut-off temp. 150°C
Thermistor (Coil sensor) DTN-TKS131B
Resistance kΩ 0°C 15.0 ±2%
Thermistor (Room sensor) DTN-TKS134B
Resistance kΩ 25°C 5.0 ±3%
Outdoor Unit GR54M2R
Power Relay (PRA, PRB) DFU24D1-F (M)
Coil rating DC 24V
Coil resistance Ω(at 20°C) 650 ±10%
Contact rating AC 250V, 20A
Termistor (Coil sensor) PBC-41E-S15
Resistance kΩ –10°C23.7 ±5% 25°C 5.3 ±5%
0°C15.0 ±5% 30°C 4.4 ±5%
10°C 9.7 ±5% 40°C 3.1 ±5%
20°C 6.5 ±5%
4-way Valve (Solenoid coil) CHV-01Ai038A1 (Coil), CHV-0101 (Valve)
Coil rating AC 230V, 50Hz, 5W
Coil resistance Ω(at 20°C) 1,408 ±7%
Page 11
3.DIMENSIONAL DATA
Indoor Unit
MCA27RM
Page 12
8
Outdoor Unit GR54M2R
5858
95 58
337
307
630
19
Narrow tube service valve
ø6.35(1/4")
1
Wide tube service valve
ø9.52(3/8")
2
305
830
4 – ø12 holes
Air discharge
Air intake
538 146
2
Magnified illustration
3
1
To Indoor Unit B
To Indoor Unit A
3
Check Port
Unit : mm
Page 13
4.COOLING CAPACITY
9
Indoor Unit MCA27RM (×1)
Outdoor Unit GR54M2R
230 V Single phase 50 Hz
RATING CAPACITY 2.60kW
AIR FLOW RATE 470m
3
/h
EVAPORATOR CONDENSER
ENT. TEMP. °C OUTDOOR AMBIENT TEMP. °C
W.B. D.B. 20 25 30 35 40 45
TC 2.62 2.51 2.39 2.28 2.14 1.97
CM 0.68 0.74 0.79 0.85 0.95 1.06
21 SHC 1.81 1.76 1.70 1.64 1.58 1.50
15 23 SHC 2.04 1.99 1.93 1.88 1.81 1.73
25 SHC 2.28 2.22 2.16 2.11 2.04 1.96
27 SHC 2.51 2.45 2.39 2.28 2.14 1.97
29 SHC 2.62 2.51 2.39 2.28 2.14 1.97
31 SHC 2.62 2.51 2.39 2.28 2.14 1.97
TC 2.81 2.69 2.57 2.44 2.30 2.11
CM 0.70 0.76 0.81 0.87 0.97 1.08
21 SHC 1.57 1.52 1.46 1.40 1.34 1.26
17 23 SHC 1.81 1.75 1.69 1.64 1.57 1.49
25 SHC 2.04 1.98 1.93 1.87 1.80 1.72
27 SHC 2.27 2.21 2.16 2.10 2.04 1.96
29 SHC 2.50 2.45 2.39 2.34 2.27 2.11
31 SHC 2.74 2.68 2.57 2.44 2.30 2.11
TC 2.99 2.86 2.73 #2.60 2.44 2.25
CM 0.72 0.78 0.84 0.90 1.00 1.11
21 SHC 1.32 1.27 1.21 1.16 1.09 1.01
19 23 SHC 1.56 1.50 1.44 1.39 1.32 1.24
25 SHC 1.79 1.73 1.68 1.62 1.56 1.48
27 SHC 2.02 1.96 1.91 1.85 1.79 1.71
29 SHC 2.25 2.20 2.14 2.09 2.02 1.94
31 SHC 2.49 2.43 2.37 2.32 2.25 2.17
TC 3.17 3.03 2.89 2.76 2.59 2.38
CM 0.74 0.80 0.86 0.92 1.03 1.14
23 SHC 1.30 1.25 1.19 1.14 1.07 1.00
21 25 SHC 1.54 1.48 1.42 1.37 1.31 1.23
27 SHC 1.77 1.71 1.66 1.60 1.54 1.46
29 SHC 2.00 1.94 1.89 1.84 1.77 1.69
31 SHC 2.23 2.18 2.12 2.07 2.00 1.93
TC 3.36 3.22 3.07 2.89 2.71 2.52
CM 0.76 0.82 0.88 0.95 1.06 1.17
23 25 SHC 1.27 1.21 1.16 1.10 1.03 0.97
27 SHC 1.50 1.45 1.39 1.33 1.26 1.20
29 SHC 1.73 1.68 1.62 1.56 1.50 1.43
31 SHC 1.97 1.91 1.86 1.79 1.73 1.66
TC : Total Cooling Capacity (kW)
SHC :Sensible Heat Capacity (kW)
CM : Compressor Input (kW)
Rating conditions (#Mark) are
Outdoor Ambient Temp. 35°C D.B.
Indoor Unit Entering Air Temp. 27°C D.B. / 19°C W.B.
Page 14
5.HEATING CAPACITY
10
Indoor Unit MCA27RM (×1)
Outdoor Unit GR54M2R
–5 0 5
7
10 15
Outdoor temperature (°C D.B.)
0
10
20
30
40
50
60
70
80
90
100
110
120
Heating capacity ratio (%)
NOTE
1) … Point of Rating condition
Black dot in the chart indicate the following rating condition.
Indoor : 20°C D.B.
Outdoor : 7°C D.B. / 6°C W.B.
2) Above characteristics indicate instantaneous operation, which does not take into
account defrost operation.
3) Fan speed : High
4) Because this air conditioner heats a room by drawing in the heat of the outside
air (heat pump system), the heating efficiency will fall off when the outdoor
temperature is very low. If sufficient heat cannot be obtained with this air
conditioner, use another heating appliance in conjunction with it.
–8
Page 15
6.AIR THROW DISTANCE CHART
11
0
123456789
1
2
3
4
Horizontal distance (m)
Axis air velocity (m/s)
Vertical distance (m)
Axis air velocity
Flap angle
45°
60°
Room air temp.: 20°C
Fan speed : High
Heating
0
123456789
1
2
3
4
Horizontal distance (m)
Axis air velocity (m/s)
Vertical distance (m)
Axis air velocity
Flap angle
0°
30°
Room air temp.: 27°C
Fan speed : High
Cooling
Indoor Unit MCA27RM
Page 16
7.REFRIGERANT FLOW DIAGRAM
12
Indoor Unit MCA27RM (×2)
Outdoor Unit GR54M2R
Heat exchanger
Narrow tube
O. D.
6.35mm
(1/4")
Wide tube
O.D.
9.52mm
(3/8")
Muffler
Accumulator
Compressor A
4–Way
valve
4–Way
valve
Drier
( )
Check valve
Strainer
Heat exchanger
Narrow tube
O.D.
6.35mm
(1/4")
Wide tube
O.D.
9.52mm
(3/8")
Muffler
Accumulator
Compressor B
Wide Tube Service valve
Narrow Tube Service valve
( )
Check valve
Strainer
Heat exchanger
Capillary tube
Check
port
Check
port
Indoor Unit A
Indoor Unit B
Drier
Cooling cycle
Page 17
13
Heat exchanger
Narrow tube
O.D.
6.35mm
(1/4")
Wide tube
O.D.
9.52mm
(3/8")
Muffler
Accumulator
Compressor A
Capillary
tube
( )
Check valve
Strainer
Heat exchanger
Narrow tube
O.D.
6.35mm
(1/4")
Wide tube
O.D.
9.52mm
(3/8")
Muffler
Accumulator
Compressor B
( )
Check valve
Strainer
Heat exchanger
Check
port
Check
port
Indoor Unit A
Indoor Unit B
Wide Tube Service valve
Narrow Tube Service valve
Capillary tube
Drier
Drier
4–Way
valve
4–Way
valve
Insulation of Refrigerant Tubing
To prevent heat loss and wet floors due to dripping of
condensation water, both the wide and narrow tubes
must be well insulated with proper insulation material. The thickness of the insulation should be a min. 8 mm.
After a tube has been insulated,
never try to bend it into a narrow
curve because it can cause the
tube to break or crack.
IMPORTANT
CAUTION
Wide tube
Thickness:
Min. 8 mm
Insulation
Narrow tube
Thickness:
Min. 8 mm
Heating cycle
Page 18
8.ELECTRICAL DATA
8-1.Electrical Characteristics
The values in the table below indicate the sum of indoor and
outdoor units which are in running condition.
14
NOTE
230V Single phase 50 Hz
Indoor Unit MCA27RM
Outdoor Unit GR54M2R
Rating Conditions: Indoor Air Temperature 27°C D.B. / 19°C W.B.
Outdoor Air Temperature 35°C D.B.
Full Load Conditions:Indoor Air Temperature 32°C D.B. / 23°C W.B.
Outdoor Air Temperature 43°C D.B.
Number of indoor unit
1 - Unit 2 - Units
(Either A or B) (Both A and B)
Rating Conditions
Running amp. A 4.6 9.3
Power input kW 1.01 2.08
Full Load Conditions
Running amp. A 5.7 11.8
Power input kW 1.28 2.65
Number of indoor unit
1 - Unit 2 - Units
(Either A or B) (Both A and B)
Rating Conditions
Running amp. A 4.7 9.0
Power input kW 1.05 1.98
Full Load Conditions
Running amp. A 7.1 12.6
Power input kW 1.55 2.75
230V Single phase 50 Hz
Cooling
Heating
Rating Conditions: Indoor Air Temperature 20°C D.B.
Outdoor Air Temperature 7°C D.B. / 6°C W.B.
Full Load Conditions:Indoor Air Temperature 27°C D.B.
Outdoor Air Temperature 24°C D.B. / 18°C W.B.
Cooling
Heating
Page 19
8-2.Electric Wiring Diagram
15
Indoor Unit MCA27RM
Page 20
16
Outdoor Unit GR54M2R
Page 21
8-3. Performance Charts
17
13
12
11
10
9
8
7
6
25 30 35 40 45 50
Outdoor inlet air D.B. temp. (°C)
5
4
3
Indoor inlet air
D.B. temp. (°C)
■ Cooling Characteristics ■ Heating Characteristics
Indoor inlet air
D.B. temp. (°C)
9
8
7
6
5
4
3
2
1
25 30 35 40 45 50
Outdoor inlet air D.B. temp. (°C)
Operating current (A)
10
Indoor inlet air
D.B. temp. (°C)
8
7
6
5
4
3
2
1
–5 0 5 10 15 20
Outdoor inlet air D.B. temp. (°C)
Operating current (A)
25
9
10
30
28
26
24
22
20
18
16
–5 0 5 10 15 20
Outdoor inlet air D.B. temp. (°C)
14
12
10
25
Indoor inlet air
D.B. temp. (°C)
Low pressure at wide tube service valve (kg/cm
2
G)
High pressure at wide tube service valve (kg/cm
2
G)
32
27
21
32
27
21
27
20
15
27
20
15
Overload prevention operates to protect the air conditioner when outdoor ambient temperature reaches extremely
high in heating mode. (Refer to “10-4 Overload Prevention”)
● ...... Points of Rating condition
Black dots in above charts indicate the following rating conditions.
Cooling: Indoor air temperature 27°C D.B./19°C W.B. Heating: Indoor air temperature 20°C D.B.
Outdoor air temperature 35°C D.B./24°C W.B. Outdoor air temperature 7°C D.B./6°C W.B.
NOTE
Indoor Unit MCA27RM (✕1)
Outdoor Unit GR54M2R
Page 22
9.FUNCTION
9-1.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 3 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 after 5 minutes or more 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
18
3 minutes 3 minutes 3 minutes 3 minutes 3 minutes 3 minutes 3 minutes
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.
Signal from remote control unit
Page 23
■ Heating
●
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 3 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 5
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 after 5 minutes or more of compressor
operation.
●
Thermo. ON :When the room temperature is below T – 1°C (T°C is set temperature).
Compressor ➞ON
●
Thermo. OFF :When the room temperature is equal to or above set temperature T°C.
Compressor ➞OFF
✻
1: Refer to 10-5 "Cold Draft Prevention".
19
Set temp.
Signal from remote control unit
Outdoor fan
Compressor
ONON OFF OFF
OFFOFF
T°C
T–1°C
T–2°C
Room temp.
Thermo.
ON
3 minutes 3 minutes 3 minutes 3 minutes 3 minutes 3 minutes
Thermo.
OFF
Thermo.
ON
Thermo.
OFF
ONON
5 minutes
OFF
OFF
ON (Reversing cycle)
OFF
LL LLOFF
OFF
Set speed
30 seconds
LL
30 seconds
LL
*
1
OFF
*
1
ON
OFF
ON
OFF
OFF
Indoor fan
Standby
lamp
Indoor heat
exch. coil
temp. 35°C
Solenoid coil
(4-way valve)
Operation
button
5 minutes
* 1 25°C
20°C
More than
5 minutes
ON
Set speed
ON
NOTE
Page 24
9-2.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 cycle of turning ON
and OFF automatically as shown in the chart below according to the room temperature.
20
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 A1 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.
●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.
Page 25
9-3.Freeze Prevention (Cooling)
●
This function prevents freezing of the indoor heat exchange coil.
●
When the compressor has been running for 10 minutes
*1)
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.
*1)Functionally, compressor running period, or time are of two types, 10 minutes and 6 minutes depending upon
production date.
9-4.Overload Prevention (Heating)
●
This function prevents overheating of the indoor heat exchange coil.
●When the temperature of the indoor heat exchange coil rises above 49°C, and if the indoor fan is L (low speed),
then the fan speed changes from L (low speed) to M (medium speed).
●When the temperature of the indoor heat exchange coil rises above 50°C, the outdoor fan stops.
NOTE
21
ON ON ON ON
OFFOFF
Set speed
More than
10 minutes
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
10 minutes
More than
6 minutes
Set speed
ONON OFF
ON
H or M or L H H H, M H M, L H M
57
54
47
44
Indoor heat
exch. coil
temp. °C
Outdoor fan
Indoor fan
Compressor
Page 26
9-5.Cold Draft Prevention (Heating)
●
This function controls indoor fan speed so a strong draft of cold air will not blow out before the indoor heat
exchange coil have sufficiently warmed up.
●
STANDBY lamp on front of the indoor unit lights up when the indoor fan speed is either LL or OFF.
22
LL = Very low speedInitial start
Indoor heat
exch. coil
temp. °C
ON
Compressor
Indoor fan
Standby lamp
20°C
25°C
35°C
ON ON
LLLL
Set speed
OFF
OFFOFF
Page 27
9-6.Defrosting Operation (Heating)
■Defrosting Flowchart.
23
* Split System A:
(= Cooling cycle)
Split System A (or B)
Heating operation
Defrosting starts.
Defrosting
Cold draft prevention
Defrosting stops.
Split System B (or A)
Temperature in outdoor
heat exchanger
coil drops 1 deg/6 min.
or more and repeats
3 times continuously.
Heating operation
20 minutes masking
6 minutes masking
Temperature in outdoor
heat exchanger coil falls
to –14°C or lower.
Preparation for defrosting
Temperature in outdoor
heat exchanger coil is
26°C or higher.
Defrosting starts.
Cold draft prevention
Defrosting time is over
13.5 minutes.
Indoor unit A
Compressor A
Solenoid coil A
* Split System B:Indoor unit B
Compressor B
Solenoid coil B
Defrosting
Defrosting stops.
**
Page 28
■Defrosting Mode Timing Chart
24
Standby lamp B
Indoor fan B
Indoor heat
exch. coil
temp. 35°C
Light on OFFOFF
OFF
*
1
Light on
Set speed Set speed
Set speed Set speed
*
1
OFF
OFF OFF
30 sec.
ON
ON
ON
5 sec.5 sec.
ON
ON
ON
ON
5 sec.
ON
ON
OFFOFF
OFF
OFF
OFF
1 min.
Defrosting 13.5 min. or
outdoor coil temp. 26°C
65 sec. 65 sec.
ON
Standby lamp A
Indoor fan A
Outdoor fan
4-way valve
A and B
Compressor A
Compressor B
OFF
NOTE
*
1. No LL fan operation during this period.
Release of defrosting
Start of defrosting
Unit A
Unit B
Release of
cold draft prevention
Page 29
10.TROUBLESHOOTING
10-1.Check before and after
troubleshooting
10-1-1.Check power supply wiring.
●
Check that power supply wires are correctly connected to terminals No.1and No.2on the 3p terminal
plate in the outdoor unit.
10-1-2.Check inter-unit wiring.
●
Check that inter-unit wiring is correctly connected to
the indoor unit from the outdoor unit.
10-1-3.Check power supply.
●
Check that voltage is in specified range
(±10% of the rating).
●
Check that power is being supplied.
10-1-4.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.
25
WARNING
Hazardous voltage can cause ELECTRIC
SHOCK or DEATH. Disconnect power or turn
off circuit breaker before you start checking
or servicing.
Outdoor
unit
1
2
3
Ground
Indoor
unit B
4
5
6
8
8
7
1
2
Power supply:
220V–240V~50Hz
Terminal
plate B
1
2
3
4
5
6
7
Inter-unit
power wiring
Inter-unit
control wiring
1
2
3
Indoor
unit A
4
5
6
7
Terminal
plate A
1
2
3
4
5
6
7
Inter-unit
power wiring
Inter-unit
control wiring
Page 30
26
10-2.Air conditioner does not operate.
10-2-1.Circuit breaker trips (or fuse blows).
A. When the circuit breaker is set to ON, it is tripped soon. (Resetting is not possible.)
●
There is a possibility of ground fault.
●
Check insulation resistance.
If resistance value is 2MΩor less, insulation is defective (“NO”).
B. Circuit breaker trips in several minutes after turning the air conditioner on.
●
There is a possibility of short circuit.
Measure insulation
resistance of electrical
parts in outdoor unit.
NO
NO
Set circuit breaker to OFF.
*
Measure insulation
resistance of electrical
parts in indoor unit.
1
Remove both power supply wires
and inter-unit wires from terminal
plate in outdoor unit.
Measure insulation resistance
of outdoor unit.
•
2
Remove inter-unit wires from
terminal plate in indoor unit.
Measure insulation resistance
of indoor unit.
•
•
•
Insulation of
outdoor unit
is defective.
Insulation of
indoor unit
is defective.
Replace with suitable
one (larger capacity).
•
NO
Check capacity of circuit breaker.
Capacity of circuit breaker is
suitable.
•
Measure resistance of compressor
motor winding. (CMA and CMB)
Page 31
27
10-2-2.Neither indoor nor outdoor unit runs.
A. Power is not supplied.
B. Check "OPERATION selector" switch in the indoor unit.
C. Check remote control unit.
NO
•
Check power supply.
Power is being supplied to the
outdoor unit.
Circuit breaker
is tripped.
Power failure
Reset breaker.
Wait for recovery
or contact power
company.
YES
NO
•
OPERATION selector switch is set
in ON position.
Set OPERATION selector switch
to ON.
Switch Ass'y or indoor PCB Ass'y
is defective.
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.
Page 32
28
D. Check fuse on the indoor PCB Ass'y.
E. Check TIMER SELECT button on the remote control unit.
OK
Replace the fuse.
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 or switch Ass'y is
defective.
OK
•
Measure resistance of indoor fan
motor winding.
(FMI)
•
Measure resistance of flap motor
winding. (FLP)
If fuse has been blown,
•
Timer is turned ON. Check to see
if "ON" is displayed on remote
control
YES
Press TIMER ON button to cancell
the timer mode.
Page 33
29
10-2-3.Only outdoor unit does not run.
A. Check setting temperature.
B. Check PCB Ass'y in either indoor or outdoor unit.
10-2-4.Only indoor unit does not run.
OK
NO
Is room temperature too low ?
Try to lower setting temperature by
temperature setting button cooler.
Outdoor unit still does
not run.
Remote control unit is defective.
•
Try to run using another remote
control unit.
COOL
OK
NO
Is room temperature too high ?
Try to raise setting temperature by
temperature setting button warmer.
Outdoor unit still does
not run.
Remote control unit is defective.
•
Try to run using another remote
control unit.
HEAT
•
Indoor PCB Ass'y is defective.
•
Check voltage between terminals
No. 3(+) and No. 4 at terminal plate.
(DC 24V)
No voltage appears.
•
Outdoor PCB Ass'y is defective.
OK
•
Indoor PCB Ass'y is defective.
Page 34
30
10-3.Some part of air conditioner does not operate.
10-3-1.Only indoor fan does not run.
10-3-2.Only flap motor does not run.
10-3-3.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 indoor fan
motor winding.
•
Check fan motor capacitor.
Fan cannot
be turned.
Check fan casing
for foreign matter
on inside.
Check fan rotation.
Turn fan gently once or twice
by hand.
•
Measure resistance of outdoor fan
motor winding.
•
OK
•
Fan motor burnout
or foreign matter
in bearings.
Repair or replace.
Remove foreign
matter or repair.
Check fan motor capacitor. (CF)
•
•
Measure resistance of flap motor
winding.
Page 35
31
10-3-4.Only compressor does not run.
Measure resistance of
compressor motor winding.
•
NO
Check compressor motor
capacitor.
•
YES
YES
YES
Overload relay is working.
Refrigerant gas shortage. Charge refrigerant gas (R22).
Temperature of compressor is
abnormally high.
Rotor may be locked up.
(OLR 1 to 4)(CA,CB)
Measure coil resistance of
power relay. (PRA,PRB)
•
Measure Power supply
voltage.
The voltage is too low.
No
Page 36
32
10-4.Air conditioner operates, but abnormalities are observed.
10-4-1.Operation does not switch from HEAT to COOL (or COOL to HEAT).
•
Indoor PCB Ass'y is defective.
•
Check voltage between terminals
No. 3(+) and No. 5 at terminal plate.
(DC 24V)
No voltage appears.
Outdoor PCB Ass'y is defective.
OK
•
Remote control unit may be defective.
•
Measure resistance of 4–way valve's
winding.
Receiver in switch Ass'y may be
defective.
COOL ➞ HEAT
•
Check voltage between terminals
No. 3(+) and No. 5 at terminal plate.
(0V)
HEAT ➞ COOL
If unit A is stopped, unit B will switch to cooling or drying operation.
(Example) Unit A in heating mode
Unit B in cooling or drying mode
Unit A in heating mode
(Heating operation takes precedence.)
Unit B fan operating
• If the units are operated in different modes (for example, unit A in the heating mode and unit B in the cooling or
drying mode), the results are as follows.
Units A and B cannot be operated in different modes simultaneously (for example,
unit A operating in the heating mode while unit B is operating in the cooling or
drying mode). When operating two units at the same time, set them both to the
same mode. Note however that though technically different modes, unit A can
operate in the cooling mode while B is operating in the drying mode.
CAUTION
Page 37
33
10-4-2.Poor cooling or heating.
10-4-3.Excessive cooling or heating.
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 or warm 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 (R22).
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 or heating
load or replace the air
conditioner with larger
capacity.
NOTE
NO
NO
•
Set temperature is suitable.
Set temperature to higher or
lower 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.
Page 38
34
10-5.If a sensor is defective.
10-5-1.Indoor coil temp. thermistor (TH1) is defective.
Alarm Signal (*)
Operation lamp on the front side of the indoor unit will flash on and off when the indoor coil thermistor is defective.
At the same time the outdoor unit will stop. Indoor unit will operate only for ventilation.
10-5-2.Room temp. thermistor (TH2) is defective.
A. Open
When thermistor opens, the air conditioner will be in the following conditions as the controller tries to detect
extremely low room temperature.
a) In Cooling mode:The air conditioner soon stops and will not start again. (Thermo.OFF)
Neither outdoor fan nor compressor runs.
b) In Heating mode:The air conditioner continues to operate. (Thermo.ON)
Both the outdoor fan and compressor do not stop.
As a result, the room becomes too warm.
B. Short
When thermistor is short, the air conditioner will be in the following conditions as
the controller tries to detect extremely high room temperature.
a) In Cooling mode:The air conditioner continues to operate. (Thermo.ON)
Both the outdoor fan and compressor do not stop.
As a result, the room becomes too cold.
b) In Heating mode:The air conditioner soon stops and will not start again. (Thermo.OFF)
Neither outdoor fan nor compressor runs.
Definition of Open or Short Circuit of Sensor (Thermistor)
Open...A lead wire is broken or disconnected or the circuit inside the temperature sensor is open .
Short...The protective cover of a lead wire has been damaged, and the exposed wire is touching another metal
part, or both lead wires have become exposed and are touching each other. Alternatively, the circuit inside
the temperature sensor is closed.
•
Operation lamp on front side of
indoor unit is flashing on and off. (*)
YES
•
Replace thermistor.
•
Thermistor (TH1 ) is defective.
(That is, sensor is SHORT.)
No
NOTE
NOTE
perature
sor
Lead
wires
Thermistor Structure
Thermistor Structure
Page 39
35
11.ARRANGEMENT OF ELECTRICAL COMPONENT
PCB Ass'y
Compressor motor capacitor (CB)
Varistor (SA1)
Compressor motor capacitor (CA)
Fan motor capacitor (CF)
Overload relay (OLR3)
Overload relay (OLR1)
Power relay B (PRB)
Power relay A (PRA)
Terminal Plate
(To Power supply)
Terminal Plate
(To Indoor Unit B)
Terminal Plate
(To Indoor Unit A)
Varistor (SA2)
Compressor A (CMA)
Compressor B (CMB)
Solenoid coil A (SCA)Solenoid coil B (SCB)
Fan motor
Heat exchenger coil
PCB Ass'y (Controller)
Electric Parts
Parts Layout in Unit
Thermistor
Outdoor Unit GR54M2R
Page 40
36
12-1.Measurement of Insulation
Resistance
●
The insulation is in good condition if the resistance
exceeds 2MΩ.
12-1-1.Power Supply Wires
Clamp the ground wire of the power supply wires with
the lead clip of the insulation resistance tester and measure the resistance by placing a probe on either of the
power wires. (Fig. 1)
Then measure the resistance between the ground wire
and the other power wire. (Fig. 1)
12-1-2.Indoor Unit
Clamp an aluminum plate fin or copper tube with the lead
clip of the insulation resistance tester and measure the
resistance by placing a probe on each terminal screw
except where the ground line is connected on the terminal plate. (Fig. 2)
12-1-3.Outdoor Unit
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 each terminal screw where power
supply lines are connected on the terminal plate. (Fig. 2)
12-1-4.Measurement of Insulation
Resistance for Electrical Parts
Disconnect the lead wires of the desired electric part
from terminal plate, capacitor, etc. Similarly disconnect
the connector. Then measure the insulation resistance.
(Figs. 3 and 4)
Refer to Electric Wiring Diagram.
If the probe cannot enter the poles because the hole is
too narrow then use a probe with a thinner pin.
NOTE
Insulation
tester
Probe
Clip
Ground wire
Fig. 1
Terminal plate
Copper
tube or
metallic part
Clip
Insulation
tester
Probe
Fig. 2
Copper
tube or
metallic part
Clip
Insulation
tester
Probe
Fig. 3
Clip
Insulation
tester
Probe
Metallic
part
From fan motor,
compressor and
other parts
Fig. 4
12.CHECKING ELECTRICAL COMPONENTS
Page 41
37
12-2.Checking continuity of Fuse on
PCB Ass'y
●
Check for continuity using a multimeter as shown in
Fig. 6.
Method Used to Replace Fuse on PCB Ass'y
— Indoor PCB Ass'y —
1.Remove the PCB Ass'y from the electrical component
box
2.Then pull out the fuse from the PCB Ass'y.(Fig.5a)
— Outdoor PCB Ass'y —
1.Remove the PCB Ass’y from the electrical component
box.
2.Pull out the fuse at the metal clasp using pliers while
heating the soldered leads on the back side of the
PCB Ass'y with a soldering iron
(30W or 60W).(Fig.5b)
3.Remove the fuse ends one by one. For replacement
insert a fuse of the same rating and solder it. (Allow
time to radiate heat during soldering so that the fuse
does not melt.)
12-3.Checking Motor Capacitor
Remove the lead wires from the capacitor terminals, and
then place a probe on the capacitor terminals as shown
in Fig. 7. Observe the deflection of the pointer, setting
the resistance measuring range of the multimeter to the
maximum value.
The capacitor is “good” if the pointer bounces to a great
extent and then gradually returns to its original position.
The range of deflection and deflection time differ according to the capacity of the capacitor.
Multimeter
Ω
Compressor motor
capacitor
Fan motor
capacitor
Fuse
PCB Ass’y
Fig. 5a
Fuse
Fig. 6
Fig. 7
Soldering iron
PCB Ass’y
Outdoor
Fuse
Pliers
Fig. 5b
NOTE
Page 42
S.A.C. - olgiate olona - printed in italy
R.D. 28 Reyrieux BP 131 - 01601 Trévoux CEDEX France
Tél. 04.74.00.92.92 - Fax 04.74.00.42.00
R.C.S. Bourg-en-Bresse B 759 200 728
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