TECHNICAL DATA

& SERVICE MANUAL

INDOOR UNIT: KPAF124R5

KPAF185R5

KPAF225R5

SPLIT SYSTEM AIR CONDITIONER

Model No.

KPAF124R5

KPAF185R5

KPAF225R5

Product Code No.

387105949

387005960

387005961

Floor Mounted

Ceiling Mounted

0.8180.41

7.0 06/2005

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.

• Pay close attention to all warning and caution notices given in this manual.

•The unit must be supplied with a dedicated electrical line.

WARNING

This symbol refers to a hazard or unsafe practice which can result in severe personal injury or death.

CAUTION

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 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.

WARNING

When wiring

ELECTRICAL SHOCK CAN CAUSE SEVERE

PERSONAL INJURY OR DEATH. ONLY A 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 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 aluminium 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-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 than drifting snow. Provide snow vents.

When connecting refrigerant tubing

• 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 servicing

• 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 testng 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.

2

Table of Contents

1. SPECIFICATIONS

1-1 Unit specifications

1-2 Major Component specifications

1-3 Other Component specifications

2. DIMENSIONAL DATA

3. ELECTRICAL DATA

3-1 Electric Wiring Diagrams

4. FUNCTION

4-1 Cool Mode Operation

4-2 Heat Mode Operation

4-3 Auto Mode Operation

4-4 Dry Mode Operation

4-5 Fan Mode Operation

4-6 Protections in Cool/Dry Mode

4-7 Protections in Heat Mode

4-8 Sleep Function

4-9 Daily Timer

4-10 I FEEL Function

5. TROUBLESHOOTING

5-1 Check before and after troubleshooting

5-2 Air conditioner does not operate

5-3 Some part of air conditioner does not operate

5-4 Air conditioner operates, but abnormalities are observed

5-5 If a sensor is defective

6. CHECKING ELECTRICAL COMPONENTS

6-1 Measurement of Insulation Resistance

6-2 Checking Continuity of Fuse on PCB Ass'y

6-3 Checking Motor Capacitor

23

23

23

27

29

31

32

32

33

33

Page

12

12

16

17

17

19

13

13

14

15

22

22

22

7

10

4

4

11

3

1. SPECIFICATIONS

1-1 Unit Specifications

KPAF124R5

Power source

Voltage rating

Performance

Capacity

Air circulation

Features

Controls/Temperature controls

Control unit

Timer

Fan speed

Airflow direction

High

Air Filter

Power noise level

Refrigerant tubing connections

Refrigerant tube diameter

Refrigerant

Refrigerant tube kit / Air clean filter

High

Narrow tube

Wide tube

Dimensions & Weight

Unit dimensions

Package dimensions

Weight

Height

Width

Depth

Height

Width

Depth

Net

Shipping

Shipping volume

Horizontal

Vertical dB(A) mm(in.) mm(in.) m³/h

220 - 240 V ~ 50 Hz

230 V

Cooling Heating

See catalogue with the requested matching

700

Microprocessor/ I.C. thermostat

Wireless remote control unit

ON/OFF 24 hours

3 and Auto

Manual

Auto

Washable, Anti-Mold

55

Flare type

6.35 (1/4)

9.52 (3/8)

R410A

Optional / Optional mm mm mm mm mm mm kg kg m

3

680

900

190

770

995

280

23,5

31,5

0,21

DATA SUBJECT TO CHANGE WITHOUT NOTICE

4

KPAF185R5

Power source

Voltage rating

Performance

Capacity

Air circulation

Features

Controls/Temperature controls

Control unit

Timer

Fan speed

Airflow direction

High

Air Filter

Power noise level

Refrigerant tubing connections

Refrigerant tube diameter

Refrigerant

Refrigerant tube kit / Air clean filter

High

Narrow tube

Wide tube

Dimensions & Weight

Unit dimensions

Package dimensions

Weight

Height

Width

Depth

Height

Width

Depth

Net

Shipping

Shipping volume

Horizontal

Vertical dB(A) mm(in.) mm(in.) m³/h

220 - 240 V ~ 50 Hz

230 V

Cooling Heating

See catalogue with the requested matching

800

Microprocessor/ I.C. thermostat

Wireless remote control unit

ON/OFF 24 hours

3 and Auto

Manual

Auto

Washable, Anti-Mold

59

Flare type

6.35 (1/4)

12.7 (1/2)

R410A

Optional / Optional mm mm mm mm mm mm kg kg m

3

680

900

190

770

995

280

23,5

31,5

0,21

DATA SUBJECT TO CHANGE WITHOUT NOTICE

5

KPAF225R5

Power source

Voltage rating

Performance

Capacity

Air circulation

Features

Controls/Temperature controls

Control unit

Timer

Fan speed

Airflow direction

High

Air Filter

Power noise level

Refrigerant tubing connections

Refrigerant tube diameter

Refrigerant

Refrigerant tube kit / Air clean filter

High

Narrow tube

Wide tube

Dimensions & Weight

Unit dimensions

Package dimensions

Weight

Height

Width

Depth

Height

Width

Depth

Net

Shipping

Shipping volume

Horizontal

Vertical dB(A) mm(in.) mm(in.) m³/h

220 - 240 V ~ 50 Hz

230 V

Cooling Heating

See catalogue with the requested matching

800

Microprocessor/ I.C. thermostat

Wireless remote control unit

ON/OFF 24 hours

3 and Auto

Manual

Auto

Washable, Anti-Mold

60

Flare type

9.52 (3/8)

15.88 (5/8)

R410A

Optional / Optional mm mm mm mm mm mm kg kg m

3

680

900

190

770

995

280

23,5

31,5

0,21

DATA SUBJECT TO CHANGE WITHOUT NOTICE

6

1-2 Major Component Specifications

KPAF124R5

Controller PCB

Part No.

Controls

Control circuit fuse

Remote Control Unit

Fan & Fan Motor

Type

Q'ty ……. Dia. and lenght

Fan motor model…Q'ty

No. of poles…rpm (230 V, High)

Nominal output

Running Amps

Power input

Coil resistance (Ambient temp. 25 °C ) mm

W

A

W

Ω

KSA

Microprocessor

250 V - 5 A

RC-2 (RC) - RC-7 (RC)

Cross - flow

2…. Ø 130 / L 180

K48407-M01596…1

4…1160

21

0,29

65

GRY-WHT: 298÷343

WHT-PNK: 421÷485

WHT-VLT: 93,5÷108

VLT-ORG: 93,5÷108

ORG-YEL: 211÷243

Thermal protection

145 ± 5

Automatic

1.5

440

Safety devices

Run capacitor

Type

Operating temp. Open

Close

°C

µF

VAC

Flap Motor

Type

Model

Rating

No. of poles…rpm

Nominal output

Coil resistance (Ambient temp. 25 °C )

Heat Exch. Coil

Coil

Rows

Fin pitch

Face area

W

κΩ

Synchro motor

M2LJ24ZE31

AC 208/230 V ; 50-60 Hz

8…2,5÷3

2,5÷3

16,45±15% mm

Aluminium plate fin / Copper tube

2

1,8

0,192

DATA SUBJECT TO CHANGE WITHOUT NOTICE

7

KPAF185R5

Controller PCB

Part No.

Controls

Control circuit fuse

Remote Control Unit

Fan & Fan Motor

Type

Q'ty ……. Dia. and lenght

Fan motor model…Q'ty

No. of poles…rpm (230 V, High)

Nominal output

Running Amps

Power input

Coil resistance (Ambient temp. 25 °C ) mm

W

A

W

Ω

KSA

Microprocessor

250 V - 5 A

RC-7 (RC)

Cross - flow

2…. Ø 130 / L 180

K48407-M01597…1

4…1140

27

0,33

75

GRY-WHT: 194÷223

WHT-VLT: 80,1÷92,2

VLT-ORG: 80,1÷92,2

ORG-YEL: 200÷230

WHT-PNK: 238÷274

Thermal protection

145 ± 5

Automatic

2

440

Safety devices

Run capacitor

Type

Operating temp. Open

Close

°C

µF

VAC

Flap Motor

Type

Model

Rating

No. of poles…rpm

Nominal output

Coil resistance (Ambient temp. 25 °C )

Heat Exch. Coil

Coil

Rows

Fin pitch

Face area

W

κΩ

Synchro motor

M2LJ24ZE31

AC 208/230 V ; 50-60 Hz

8…2,5÷3

2,5÷3

16,45±15% mm

Aluminium plate fin / Copper tube

2

1,8

0,192

DATA SUBJECT TO CHANGE WITHOUT NOTICE

8

KPAF225R5

Controller PCB

Part No.

Controls

Control circuit fuse

Remote Control Unit

Fan & Fan Motor

Type

Q'ty ……. Dia. and lenght

Fan motor model…Q'ty

No. of poles…rpm (230 V, High)

Nominal output

Running Amps

Power input

Coil resistance (Ambient temp. 25 °C ) mm

W

A

W

Ω

KSA

Microprocessor

250 V - 5 A

RC-7 (RC)

Cross - flow

2…. Ø 130 / L 180

K48407-M01598…1

4…1280

41

0,41

88

GRY-WHT: 124÷144

WHT-VLT: 69,3÷79,8

VLT-ORG: 69,3÷79,8

ORG-YEL: 200÷233

WHT-PNK: 255÷294

Thermal protection

145 ± 5

Automatic

1.5

440

Safety devices

Run capacitor

Type

Operating temp. Open

Close

°C

µF

VAC

Flap Motor

Type

Model

Rating

No. of poles…rpm

Nominal output

Coil resistance (Ambient temp. 25 °C )

Heat Exch. Coil

Coil

Rows

Fin pitch

Face area

W

κΩ

Synchro motor

M2LJ24ZE31

AC 208/230 V ; 50-60 Hz

8…2,5÷3

2,5÷3

16,45±15% mm

Aluminium plate fin / Copper tube

2

1,8

0,192

DATA SUBJECT TO CHANGE WITHOUT NOTICE

9

1-3 Other Component Specifications

Thermistor ( Coil sensor TH1)

Resistance

Thermistor ( Room sensor TH2)

Resistance

ΚΩ

ΚΩ

10 ± 3%

10 ± 5%

10

2. DIMENSIONAL DATA

Unit: mm

Unit: mm

11

3. ELECTRICAL DATA

3-1 Electric Wiring Diagrams

KPAF124R5

KPAF185R5 KPAF225R5

12

4. FUNCTION

4-1 Cool Mode Operation

13

4-2 Heat Mode Operation

14

4-3 Auto (Cool/Heat) Mode Operation

15

4-4 Dry Mode Operation

16

4-5 Fan Mode Operation

4-6 Protection operations in Cool and Dry Mode

1. Indoor Coil Defrost Protection

5 Protection Operations in Cool and Dry Modes

17

2. Outdoor Coil High Pressure Protection

18

4-7 Protection Operations in Heat Mode

1. Outdoor Coil Deice Protection

19

20

2. Indoor Coil High Pressure Protection in Heat Mode

21

4-8 Sleep Function

4-9 Daily Timer Function

4-10 IFEEL Function

22

WARNING

Hazardous voltage can cause ELECTRIC SHOCK or

DEATH. Disconnect power or turn off circuit breaker before you start checking or servicing.

●

Check that power supply wires are correctly connected to terminals L and N on the terminal plate in the indoor unit.

●

Check that inter-unit wiring is correctly connected to the outdoor unit from the indoor unit.

●

Check that voltage is in specified range (±10% of the rating).

●

Check that power is being supplied.

●

Check that coating of lead wires is not damaged.

●

Check that lead wires and connectors are firmly connected.

●

Check that wiring is correct.

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 trip s immediately

. (Resetting is not possible.)

●

There is a possibility of ground fault.

●

Check insulation resistance.

If resistance value is 2M

Ω or less, insulation is defective (“NO”).

WARNING

*

Set circuit breaker to OFF.

1

Remove inter-unit wires from terminal plate in outdoor unit.

•

Measure insulation resistance of outdoor unit.

NO

Insulation of outdoor unit is defective.

•

Measure insulation resistance of electrical parts in outdoor unit.

2

Remove 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.

NO

23

Insulation of indoor unit is defective.

•

Measure insulation resistance of electrical parts in indoor unit.

B. Circuit breaker trips in several minutes after turning the air conditioner on.

●

There is a possibility of short circuit.

•

Check capacity of circuit breaker.

Capacity of circuit breaker is suitable.

NO

Replace with suitable one (larger capacity).

•

Measure resistance of outdoor fan motor winding.

In case of Heating operation :

• Measure resistance of 4-way valve's winding.

• Measure resistance of compressor motor winding.

5-2-2.

A. Power is not supplied.

• Check power supply.

Power is being supplied to the indoor unit.

NO

Circuit breaker is tripped.

Power failure

YES

Reset breaker.

Wait for recovery or contact power company.

Indoor PCB Ass'y is defective.

in ON position.

NO

24

C. Check remote control unit.

• Try to run with another remote control unit.

OK

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.

D. Check fuse on the indoor PCB Ass'y.

• Check fuse on indoor PCB Ass'y for continuity.

(

F01)

OK

If fuse has been blown,

• Check operation lamp to see if light is ON.

Light is OFF

• Measure resistance of primary and secondary winding of transformer.

(TR)

OK

• Indoor PCB Ass'y is defective.

Clean transmitter.

Clean receiver.

Measure resistance of indoor and outdoor fan motor winding.

(FM)

OK

Measure resistance of compressor motor winding.

(CM)

OK

Measure resistance of 4-way valve's windings

OK

Replace the fuse.

E. Check TIMER on the remote control unit.

• Timer is turned ON. Check to see remote control

YES

Cancel the timer mode.

25

A. Check setting temperature.

COOL

Is room temperature too low ?

NO

Try to lower setting temperature by temperature setting button ( button).

Outdoor unit still does not run.

• Try to run using another remote control unit.

OK

Remote control unit is defective.

HEAT

Is room temperature too high ?

NO

Try to raise setting temperature by temperature setting button ( button).

Outdoor unit still does not run.

• Try to run using another remote control unit.

OK

Remote control unit is defective.

• Indoor PCB Ass'y is defective.

26

5

-3. Some part of air conditioner does not operate.

5

-3-1. Only indoor fan does not run.

Fan cannot be turned.

• Check fan casing foreign matter on inside.

• Check fan rotation.

Turn fan gently once or twice by hand.

Fan motor burnout or foreign matter in bearings.

• Measure resistance of indoor fan motor winding.

OK

OK

• Check fan motor capacitor.

5 -3-2. Only flap motor does not run.

• Measure resistance of flap motor winding.

5

-3-3. Only outdoor fan does not run.

Fan cannot be turned.

• Check fan rotation.

Turn fan gently once or twice by hand.

PCB assy is defective.

• Check fan casing foreign matter on inside.

Fan motor burnout or foreign matter in bearings.

• Measure resistance of outdoor fan motor winding.

OK

• Check fan motor capacitor.

Remove foreign matter or repair.

Repair or replace.

Remove foreign matter or repair.

Repair or replace.

27

5-3-3. Only compressor does not run

Check compressor motor capacitor C1

Measure resistance of compressor motor winding

Measure power supply voltage

The voltage is too low

Overload relay is working

(either OLR T or OLR A)

YES

Temperature of compressor is abnormally high

YES

Refrigerant gas shortage

NO

NO

Rotor may be locked up

YES

Charge refrigerant gas

5-3-4. Compressor and outdoor fan do not run

Float switch turned ON

YES

Check if drain pump runs normaly

YES

Verify if drain condensate tube is obstructed

YES

Remove obstruction

NO

Replace the drain pump

28

5-4. Air conditioner operates, but abnormalities are observed

5-4-1. Operation does not switch from HEAT to COOL (or COOL to HEAT)

Remote control unit may be defective

Receiver in lamp ass'y may be defective

Measure resistance of

4-way valve's winding

COOL to HEAT

Check voltage between terminals N and 6 (230V AC)

No voltage appears

Indoor PCB ass'y is defective

OK

Outdoor PCB ass'y is defective

HEAT to COOL

Check voltage between terminals N and 6 (230V AC)

29

• Check position of remote control unit.

• Cool or warm air from air conditioner reaches position directly.

(only with I FEEL feature selected)

YES

Change position of remote control unit.

• Wide and narrow tubes between indoor unit and outdoor unit are insulated.

YES

NO

Temperature difference is small.

• Measure temperature of suction and discharge air of air conditioner.

Possibility of gas shortage.

Temperature difference between suction and discharge air is large enough (approx. 10 deg. or more).

Insulate both wide and narrow tubes separately and then tape together.

Charge refrigerant gas.

Check for clogging of air filter.

Clean filter.

Air filter is clogged.

YES

• Fan speed is set to LOW.

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.

• Set temperature is suitable.

NO

• Remote control unit is placed where it can detect room temperature properly.

NO

30

Set temperature to higher or lower value using temperature setting buttons of the remote control unit.

Change position of remote control unit.

6-5 If a sensor is defective

6-5-1 ICT (indoor coil sensor) OCT(outdoor coil sensor) RAT (room ambient temperature) are defective.

• Stand by lamp on front side of indoor unit is flashing on and off. (*)

YES • Thermistor ICT and OCT and RAT are defective

YES

• Repalce thermistor.

NOTE Allarm signal (*)

Stan by lampoon on the front side of the indoor unit will flash on and off when the thermistor is defective.

At the same time the outdoor unit will stop. Indoor operate only for ventilation.

Temperature sensor

Lead wires

31

6. CHECKING ELECTRICAL COMPONENTS

6-1 Measurement of Insulation

Resistance

power plug

(Local supply)

Ground

The insulation is in good condition if the resistance exceeds 2M

Ω

6-1-1. Power supply wires

Clamp the grounding terminal of the power plug with a lead clip of the insulation resistance tester and measure the resistance by placing a probe on both the two power terminals. (fig.1)

Then, also measure the resistance between the grounding and other power terminals. (fig.1) probe

Insulation tester

NOTE

The shape of the power plug may differ from that of the air conditioner which you are servicing.

Fig. 1

Terminal plate

Probe

6-1-2. Indoor 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)

Copper tube or metallic part

Clip

6-1-3. Outdoor Unit

Clamp an aluminium 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 on the terminal plate. (fig.2)

Note that the ground line terminal should be skipped for the check.

Clip

Copper tube or metallic part

6-1-4. Measurement of Insulation

Resistance for Electrical Parts

Disconnect the lead wires of the desired electric part from terminal plate, capacitor, etc.

Similary disconnect the connector.

Then measure the insulation resistance. (fig.3 and 4)

NOTE: 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.

Metallic part

Clip

Probe

Insulation tester

From fan motor, compressor and other parts

Insulation tester

Probe

Insulation tester

Fig. 2

Fig. 3

Fig. 4

32

6-2 Checking Continuity of Fuse on PCB Ass'y

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

Fuse

PCB Ass’y

Fig. 5

Fuse

Fig. 6

6-3 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

Compressor motor capacitor

Fan motor capacitor

Fig. 7

33

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