Service manual Portable air conditioners 51AKA 006 51AKB 006G 51AKM 006G 51AKB 008G RTB 165G RTE 165G RTB 205C VTB 075C Contents page 1. ASSEMBLY DRAWINGS .......................................................................................... 3 2. PARTS DESCRIPTION .......................................................................................... 4/5 2.1 Control panel .................................................................................................. 6/7 2.2 Accessories supplied ........................................................................................ 8 2.3 Dimensions and weight .................................................................................... 8 3. TECHNICAL DATA .................................................................................................... 8 4. PERFORMANCE DIAGRAMS ............................................................................. 9/10 5. WIRING DIAGRAMS .......................................................................................... 11/13 6. REFRIGERANT CIRCUIT PRINCIPLE OF OPERATION ..................................... 14 7. R-407c REFRIGERANT .......................................................................................... 14 7.1 General ............................................................................................................ 14 7.2 Main differences between R-407c and R22 refrigerant ........................... 15/16 8. MICROPROCESSOR CONTROL .......................................................................... 17 8.1 Special functions of the buttons ..................................................................... 17 8.2 Logic connection diagram .............................................................................. 17 8.3 Flow charts ................................................................................................. 18/20 8.4 Resistance values of room temperature sensor ........................................... 21 9. UNIT DISASSEMBLY ......................................................................................... 21/24 10. TROUBLESHOOTING ....................................................................................... 25/28 10.1 Component testing procedure ........................................................................ 29 11. OPTIONAL ACCESSORIES .............................................................................. 30/31 2 1 ASSEMBLY DRAWINGS mod. 51AKB 006G 51AKB 008G RTB 165G RTB 205C mod. VTB 075C mod. 51AKA 006 mod. 51AKM 006G RTE 165G 3 2 PARTS DESCRIPTION Exhaust air outlet Flexible duct Air outlet Control panel Air outlet (for ventilation, dehumidification and heating only) Supply cable with plug Air inlet 4 2 PARTS DESCRIPTION Air filters Condensate collection tank Condensate drain tube 5 2.1 Control panel mod. 51AKB 006 RTB 165F mod. 51AKB 06G RTB 165G 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. OFF position Mode selector TURBO cooling SILENT cooling Dehumidification Low fan speed High fan speed Ventilation function indicator light Cooling indicator light Dehumidification indicator light Full water tank alarm indicator light Thermostat mod. VTB 075F VTB 075G 1. 2. 3. 4. 5. 6. ON - OFF push button Cooling - fan only push button Thermostat ON and alarm indicator light Dehumidification push button High - low speed fan push button 6 2.1 Control panel mod. 51AKM 006 51AKM 06G RTE 165F RTE 165G 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. ON-OFF button Mode selector Temperature setting button Fan speed setting button Operation on timer Operation off timer Low fan speed LED High fan speed LED ON timer LED OFF timer LED Display of set temperature and programmed operating times Set temperature LED Heating LED Dehumidification LED Cooling LED Fan only LED mod. VTE 075F VTE 075G 7 2.2 Accessories supplied 2.3 Dimensions and weight kg 1. Air outlet vent 2. Flexible hose 3. Fastening strap with suction cup 27.5 3 TECHNICAL DATA Model 51AKB 006 / 51AKB 06G RTB 165F / RTB 165G VTB 075F / VTB 075G W (Btu/h) W (Btu/h) W 750 --640 A A 3.3 --2.9 l/h 1.1 0.8 1.1 0.8 3.3 4,35 + 4,35 2.9 16 750 1000 + 1000 640 16 1830 6300 ----51AKM 006 / 51AKM 06G RTE 165F / RTE 165G VTE 075F / VTE 075G 1830 6300 1000 + 1000 3410 + 3410 Cooling capacity Heating capacity Power input ­ cooling ­ heating ­ dehumidification Locked rotor amps Operating current ­ cooling ­ heating ­ dehumidification Dehumidification rate ­ cooling ­ dehumidification Air flow (fan speed) l/s - rpm ­ high-speed cooling ­ low-speed cooling ­ high-speed heating ­ low-speed heating ­ high-speed dehumidification ­ low-speed dehumidification Recommended fuse size Supply voltage 88.9 - 1320 72.2 - 1100 ------111.1 - 1100 A 16 230V - 1 - 50Hz 8 88.9 - 1320 72.2 - 1100 88.9 - 1320 72.2 - 1100 138.9 - 1320 111.1 - 1100 16 4 PERFORMANCE DIAGRAMS Cooling capacity, Watt Cooling capacity, Btu/h 80% (1) 60% (1) 40% (1) Cooling capacity, Btu/h Cooling capacity, Watt 80% (1) 60% (1) 40% (1) Indoor dry bulb temperature °C Indoor dry bulb temperature °C (1) Relative humidity The cooling capacity diagram is based on the room dry bulb temperature for three different relative humidity values. Power input, Watt 80% (1) 60% (1) 40% (1) Power input, Watt Indoor dry bulb temperature °C (1) Relative humidity The power input diagram is based on the room dry bulb temperature for three different relative humidity values. 9 4 PERFORMANCE DIAGRAMS Suction temperature °C 80% (1) Suction temperature °C 60% (1) Discharge air temperature °C Discharge air temperature °C 80% (1) 60% (1) 40% (1) 40% (1) Indoor dry bulb temperature °C Indoor dry bulb temperature °C (1) Relative humidity The air discharge temperature diagram is based on the room dry bulb temperature and relative humidity. Due to the temperature differences of the air at the outlet, the thermometer must be placed exactly in the position shown in the sketch. Discharge air temperature measuring point 10 5 WIRING DIAGRAMS mod. 51AKB 006 / 51AKB 06G mod. RTB 165F / RTB 165G Legend "RS" CONTACT POSITIONS POSITION CONTACT CPS WS CM CC IFM IFC TAF CDP TA CWT RS X1 C1 C2 C4 C5 Power supply cable Full tank switch Compressor Compressor capacitor Indoor fan motor Indoor fan capacitor Antifreeze thermostat Condensate drain pump Room thermostat Compressor overload protector Rotary switch Terminal block Indoor fan connector Pump connector Top panel connector Compressor connector Wire colours O A B R C W G Y-G Orange Brown Blue Red Black White Grey Yellow-Green Note: The connection sequence does not represent the physical layout. 11 5 WIRING DIAGRAMS mod. VTB 075F / VTB 075G Legend CC CDP CM CPS CWT C1 C2 C3 C4 C6 IFC IFM Compressor capacitor Condensate drain pump Compressor Power supply cable Compressor overload protector Indoor fan connector Pump connector Compressor connector Heater connector Lamp board connector Indoor fan capacitor Indoor fan motor LB TA WS X1 SW1 SW2 SW3 SW4 HTR ST F1 TAF Lamp board Room thermostat Full tank switch Terminal block On-off switch Fan speed change switch Heat-cool switch Dehumidifier switch Electric heater Safety thermostat Thermal fuse Antifreeze thermostat Note: The connection sequence does not represent the physical layout. Wire colours A B G R W Y-G Bk Brown Blue Grey Red White Yellow-Green Black / Nero 12 5 WIRING DIAGRAMS mod. 51AKM 006 / 51AKM 06G mod. RTE 165F / RTE 165G mod. VTE 075F / VTE 075G Legend CPS TAF HTR CC IFM WS CWT HTP IFC CDP X1 CM Power suppply cable Antifreeze thermostat Electric heater Compressor capacitor Indoor fan motor Full tank switch Compressor overload protector Heater thermal protector Indoor fan capacitor Condensate drain pump Terminal block Compressor NTC CB PB C1 C2 C4 C5 C6 C7 C8 C9 Air sensor Control board Power board Compressor connector Pump connector PB connector Indoor fan connector Heater connector CB connector CB connector CB connector Note: The connection sequence does not represent the physical layout. Wire colours A B R O C W G V Y-G Brown Blue Red Orange Black White Grey Violet Yellow-Green 13 6 REFRIGERANT CIRCUIT PRINCIPLE OF OPERATION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Compressor Condenser Fan Filter Capillary tube Evaporator Gas discharge Liquid Liquid/gas Gas suction 7 R-407c REFRIGERANT 7.1 General 51AKB06G, 51AKM06G, RTB165G, RTE165G, VTB075G and VTE075G units use the new refrigerant R-407c. R-407c is a blend of three basic constituents: R32, R125, R-134a with respectively weight composition 23%, 25%, 52%. R-407c is an HFC refrigerant that does not destroy ozone layer. General behaviour of R-407c systems is very similar to standard R22 one; system differences linked to R-407c are below: Since R-407c is a zeotropic blend, during phase change, liquid composition is different from vapour one; for this reason in case of leakage in zones with biphase, residual refrigerant composition could be changed. R-407c phase changes are not at constant temperature as in R22 case, but with increasing temperature during evaporation and with decreasing temperature during condensation (Glide effect). In case of refrigerant recharge, in order to assure correct composition two following steps will have to be followed: · Residual refrigerant in the system will have to be pulled out and stored in a disposal cylinder (do not ventilate in ambient). · Refrigerant charge will have to be done only with liquid phase in order to guarantee proper refrigerant composition inside the system; this can be done or using dedicated cylinders with two valves (one for liquid, the other for vapour) or in case of one valve cylinder, put cylinder in up side down position. · In case of too much refrigerant charged, it is dangerous to remove partially the charge; this could change refrigerant composition inside the sistem; in such case it is suggested to remove completely the refrigerant charge, pull vacuum again and recharge the sistem with proper amount of refrigerant. Leak detection will have to be carryed-out only with HFC sensitive leak detector. Even if R-407c refrigerant is ozone friendly, do not ventilate it in the ambient because its warming effect is not zero. For all other technical details see standard rooles for R22. 14 7.2 Main differences between R-407c and R22 refrigerant R-407c Refrigerant charging procedure R22 Refrigerant charging procedure Refrigerant composition Refrigerant composition Partial refrigerant charge: Partial refrigerant charge: NOT PERMITTED! Complete refrigerant charge only. Leak detector YES! Partial refrigerant charge allowed. Leak detector Use HFC detector only. Use HCFC detector only. 15 7.2 Differences between R-407c and R22 units R-407c Temperature trend in evaporator R22 Temperature trend in evaporator Temperature trend in condenser Temperature trend in condenser 16 8 MICROPROCESSOR CONTROL 8.1 Special functions of the buttons Pressing two buttons at the same time it is possible to activate some functions which are NOT described in the Instruction Manual. Self-Test If the and "fan speed" buttons are pressed simultaneously the sequence outlined in the table 1 will start. Press any button to leave the Self-Test mode. At this point the unit will automatically enter the maximum cooling mode. 1 electric heater + LOW SPEED fan (only for models with electric heaters) LOW SPEED fan HI SPEED fan compressor + HI SPEED fan (dehumidification) compressor + HI SPEED fan condensate drain pump (maximum cooling WITHOUT thermostat) Table 1 Test Activated function Duration 7 seconds 2 7 seconds Reset If the Timer On and Timer Off buttons are pressed simultaneously the unit will return to the same condition it was in just after the first time the plug was connected to the socket: cooling mode, hi-speed fan and 22 °C room temperature set point. Provided the pressure difference between discharge and suction is acceptable (because the compressor worked for few seconds), it is possible to restart the unit in this way even if three minutes have not yet elapsed from the previous stop. 3 7 seconds 4 7 seconds 5 continuous 8.2 Logic connection diagram Low speed LED High speed LED Timer ON LED Timer OFF LED Temperature LED Heating LED Dehumidification LED Cooling LED Fan only LED Tank micro switch TR1 Pump TRIAC TR3 High speed TRIAC TR4 Low speed TRIAC Air sensor Feed back TRIAC DISPLAY MICROPROCESSOR Pump Control circuit TRIAC Fan speed button Timer ON button Timer OFF button Temperature set button Operating mode button ON / OFF button Fan DC + 5V RELAY CONTROL CIRCUIT CONTROL PCB DC +12 V DC +12 / +5V AC + 12V RELAY 3 compressor RELAY 2 heater 2 RELAY 1 heater 1+2 POWER PCB TRANSFORMER Compressor Heater 2 Heater 1+2 NEUTRAL LIVE POWER SUPPLY 17 8.3 Flow charts POWER PLUG CONNECTED ON/OFF ON/OFF BUTTON IS PRESSED PLUG CONNECTED NO ...