Replacing a faulty (wired) aircon controller - Pyrex, Vulcan, Bonaire

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Downunder35m
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Replacing a faulty (wired) aircon controller - Pyrex, Vulcan, Bonaire

Post by Downunder35m »

I was tasked with the repair of the controller for a Pyrox Comfort Control aircon system.
Whenever there is a slight power fault, like during bad weather, the controller would freeze up and become unresponsive.
For the wireless controller you can do a simple reset by holding the power and up bottom for about 10 seconds - until CODE appears on the display.
For the wired model the offical fix for a freeze or otherwise unresponsive controller it turn turn the power for entire aircon off for about a minute.
Thing is that the fix more often then not fails and the controller stays unresponsive.

A technician, several years ago (unit is from 2002), stated it was a common fault of Pyrex, Vulcan and Bonaire wired controllers.
The working fix would be to disconnect the controller and then to push the connector back in.
Problem is, back then, they used solid wires, like the strands in ethernet cables.
No surprise then that these wires broke off one day.....
The guys then got the not so smart idea to remove the connector and to "secure" the wires directly on the pins - by cutting the top cover of the on board connector off and using sticky tape.
Not knowing where any of the wires had to go meant the controller got fried.

I got lucky when asked to fix the problem that I found a picture for the connector on the cable showing the correct colors and placement.
If you have the controller in front of you, with the back cover removed, the pins for the on board connector are:
From the left: Not connected, Brown, Red, Orange, Yellow.
Replacing the entire cable was out of the question, but a suitable connector couldn't be found either.
It is a 2.15mm pitch with a non standard shape, at least I could not find it anywhere.
At first I pondered with the idea of taking the crimp connectors out of the plug.
But it is a one way system and bending down those retaining clips ended with finding out I can#t push them out again.
Ok the possible solutions:
Exploring the works of the old inventors, mixng them up with a modern touch.
To tinker and create means to be alive.
Bringing the long lost back means history comes alive again.
Downunder35m
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Posts: 983
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Re: Replacing a faulty (wired) aircon controller - Pyrex, Vulcan, Bonaire

Post by Downunder35m »

Be it Pyrex, Vulcan, Bonaire - or probably lost of other brands as well:
If it runs on 24V you can exchange the controllers as they systems are identical.
If it is NOT a"Confort Control" system you still might have a good chance to just use any 24V aircon controller for your unit.

Assuming the installer used a genuine cable the wire colors are basically fixed.
You have RED for the +24V.
Brown or Black for 0V, Ground.
Yellow - Cooling on.
Green - (indoor) fan ON.
White (if applicable) - Heating ON.
Orange - RV ON in COOL.
Blue - RV ON in COOL.

Ok .... I see you are confused already ;)
Let's assume your system only cools.
RED and BLACK are clear.
Green is required to turn the fan on.
No green wire means your unit turns it on automatically.
Yellow is for the signal from the controller that the room temp is too high and the system has to run.
Orange is the return signal to show on the controller's display that the compressor is running and the system is cooling.

If you have a reverse cycle system we have to add a few colors.
White for the signal from the controller that it is too cold in the room and Blue to for the signal from the Aircon to the display that the system is now in heating mode and heating.

If your connector on the CABLE fits the order from post 1 chances are you can just replace the controller with any of the three brands.
On the other hand you might not like that type of controller at all or found a dirt cheap one somewhere ....
Your only problem is finding the correct assignments for the pins to connect your cable.
So if you go to some scrap yard or such then look out for controllers that had the cable cut off but still connected ;)
This way you will have a very high chance to find matching colors ...
The other option is to go with a "generic" controller you can buy for cheap online.
Or in lame terms: A temperature controller that runs on 24V.
Search for "w3002 24V" and you can find them for under 10 bucks.
Before you go this route though please double check what functions your remote had!
Let me try to explain:
If it is NOT a "Comfort Control" remote for the above brands that you currently have then you might have to find a remote from a different brand.

Dangers and downsides:
Exploring the works of the old inventors, mixng them up with a modern touch.
To tinker and create means to be alive.
Bringing the long lost back means history comes alive again.
Downunder35m
Laser-sculpter
Posts: 983
Joined: Sun Aug 16, 2020 5:32 am
Location: Australia
Contact:

Re: Replacing a faulty (wired) aircon controller - Pyrex, Vulcan, Bonaire

Post by Downunder35m »

If you can't find a matching remote you might have a hard time getting things to work and might even damage the controller for the main unit on the roof.
The remote often has more features than what fits the above wiring code and colors.
Like "boost mode" and "flush"for evaporative coolers or a "silent" mode - the later especially for inverter models.
Quite often though the corresponding buttons won't do anything, won't change anything on the display either...
You know your remote - I don't!

Anything made paste around the year 2000 is likely use some sort of communication protocol between remote and main unit.
Especially reverse cycle systems.
With a bit of luck you can find a service manual for your model online.
While it might not have anything dedicated to the remote functions it should have a section showing the wire connection from main unit to remote.
Usually you also find a color code with it, or through the part number for the cable a picture online where you see the wire colors.
For the connector on the main unit you should find some information in the service manual that indicates what the pins are for.
E.g.: "4V, GND,ON,Cool/heat,FAN".
If you find something indicating a data connection you might see "24V,IN,OUT,GND".
For a serial data connection you should only use a matching remote as a replacement.
For those that show on the main unit specs the direct functions like on, off heat, cool, fan and so on you can use any remote model that matches what you unit is capable of providing.

Your best option is to use the same brand and model.
Second best is to use a compatible model, like in the Vulcan, Bonaire, Pyrex "Comfort Control" case.
Last resort option would be digital temperature controller.
If you can't find a genuine replacement remote online call a local aircon installer - they are often able to tell you if there is other brands or models that fit.
Exploring the works of the old inventors, mixng them up with a modern touch.
To tinker and create means to be alive.
Bringing the long lost back means history comes alive again.
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