PDF – Carrier Split System Air Conditioner Error Codes And

38GVM / 40GVM

Multi---Split High---Wall Ductless Split System

38GVM --- Size 18k, 24k, 30k, 36k and 42k

40GVM --- Size 9k, 12k, and 18k

Service Manual

This Service Manual provides the necessary information to service, repair, and maintain the 38/40GVM.

SAFETY CONSIDERATIONS

TABLE OF CONTENTS

SAFETY CONSIDERATIONS

PAGE

. . . . . . . . . . . . . . . . . . . . . . . . .

MODEL / SERIAL NUMBER NOMENCLATURE

STANDARD FEATURES AND ACCESSORIES

. . . . . . . . .

. . . . . . . . . . .

1

2

3

Improper installation, adjustment, alteration, service, maintenance, or use can cause explosion, fire, electrical shock, or other conditions which may cause death, personal injury, or property damage. Consult a qualified installer, service agency, or your distributor or branch for information or assistance. The qualified installer or agency must use factory--authorized kits or accessories when modifying this product. Refer to the individual instructions packaged with the kits or accessories when installing.

PHYSICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

AHRI CAPACITY RATINGS

AIRTHROW DATA

SOUND RATINGS

. . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

6

6

Follow all safety codes. Wear safety glasses, protective clothing, and work gloves. Use quenching cloth for brazing operations.

Have fire extinguisher available. Read these instructions thoroughly and follow all warnings or cautions included in literature and attached to the unit. Consult local building codes and

National Electrical Code (NEC) for special requirements.

DIMENSIONS -- INDOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

DIMENSIONS -- OUTDOOR

CLEARANCES

ELECTRICAL DATA

CONNECTION DIAGRAM

WIRING DIAGRAMS

. . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SYSTEM OPERATING ENVELOPE . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REFRIGERATION SYSTEM DIAGRAMS . . . . . . . . . . . . . .

SYSTEM EVACUATION AND CHARGING . . . . . . . . . . . . .

REMOTE CONTROL AND FUNCTIONS . . . . . . . . . . . . . . .

8

9

11

12

13

14

19

21

22

Recognize safety information. This is the safety--alert symbol !!

When you see this symbol on the unit and in instructions or manuals, be alert to the potential for personal injury.

Understand these signal words: DANGER, WARNING, and

CAUTION. These words are used with the safety--alert symbol.

DANGER identifies the most serious hazards which will result in severe personal injury or death. WARNING signifies hazards which could result in personal injury or death. CAUTION is used to identify unsafe practices which may result in minor personal injury or product and property damage. NOTE is used to highlight suggestions which will result in enhanced installation, reliability, or operation.

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28

APPENDIX TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44

!

WARNING

UNIT REMOVAL PROCEDURES . . . . . . . . . . . . . . . . . . . . .

47

ELECTRICAL SHOCK HAZARD

!

WARNING

Failure to follow this warning could result in personal injury or death.

Before installing, modifying, or servicing system, main electrical disconnect switch must be in the OFF position.

There may be more than one disconnect switch. Lock out and tag switch with a suitable warning label.

EXPLOSION HAZARD

Failure to follow this warning could result in death, serious personal injury, and/or property damage.

Never use air or gases containing oxygen for leak testing or operating refrigerant compressors. Pressurized mixtures of air or gases containing oxygen can lead to an explosion.

!

CAUTION

EQUIPMENT DAMAGE HAZARD

Failure to follow this caution may result in equipment damage or improper operation.

Do not bury more than 36 in. (914 mm) of refrigerant pipe in the ground. If any section of pipe is buried, there must be a 6 in. (152 mm) vertical rise to the valve connections on the outdoor units. If more than the recommended length is buried, refrigerant may migrate to the cooler buried section during extended periods of system shutdown. This causes refrigerant slugging and could possibly damage the compressor at start--up.

MODEL NUMBER NOMENCLATURE

40 GVM

INDOOR UNIT

009

Fan Coil Unit

Unit Type

GVM --- Multi High Wall

--- --- ---

Nominal Capacity

009 --- 3/4 Ton

012 --- 1 Ton

018 --- 1---1/2 Ton

3

Voltage

3 --- 208/230---1---60

Outdoor Unit

38 GVM

OUTDOOR UNIT

2 18

Unit Type

GVM --- Heat Pump

Number of Ports

2 --- Ports

3 --- Ports

4 --- Ports

5 --- Ports

--- --- ---

Nominal Capacity

18 --- 1---1/2 Tons

24 --- 2 Tons

30 --- 2---1/2 Tons

36 --- 3 Tons

42 --- 3---1/2 Tons

3

Voltage

3 --- 208/230---1---60

Use of the AHRI Certified

TM Mark indicates a manufacturer’s participation in the program For verification of certification for individual products, go to www.ahridirectory.org.

Position Number

Serial Number

Week

Year

Factory Code

Sequential digits unique for each factory

1

5

SERIAL NUMBER NOMENCLATURE

2

2

3

1

4

3

5

V

6

1

2

7

2

8

3

9

4

10

5

STANDARD FEATURES AND ACCESSORIES

Ease of Installation

Mounting Bracket

Low Voltage Controls

Comfort Features

S

S

INDOOR UNITS

Microprocessor Control

Wireless Remote Control

Rapid Cooling and Heating

Automatic Air Sweep

Cold Blow Prevention

Continuous Fan

Auto Restart Function

Auto Changeover

Energy Saving Features

Inverter Driven Compressor

Sleep Mode

24 Hour Stop/Start Timer

Safety And Reliability

Indoor Unit Freeze Protection

3 Minute Compressor Time Delay

High Compressor Discharge Temperature

Low Voltage Protection

Compressor Overload Protection

Compressor Over Current Protection

IPM Module Protection

Ease of Service

Cleanable Filters

Diagnostic LED’s On Outdoor Board

Error Messages Displayed On Front Panel

Application Flexibility

Condensate Pumps

Standard Warranty*

7 Years Compressor limited Warranty

5 year Parts Limited Warranty

Legend

S Standard

A Accessory

* For Residential applications. For Commercial applications, warranty is

1 year for parts and 5 years for compressor.

S

S

S

S

S

S

S

S

S

S

S

S

S

S

S

S

S

S

S

S

S

A

S

S

Fig. 1 – Condensate Pump Accessory

Wire Ties

Wall Mount Bracket

Adhesive

Detection Unit Mounting Bracket

⅝---in Rubber Elbow

Detection Unit

A07892

On high wall fan coils, the condensate pump accessory is recommended when adequate drain line pitch cannot be provided, or when the condensate must move up to exit.

The pump has a lift capability of 12 ft (3.6 m) on the discharge side if the pump is mounted in the fan coil or 6 ft (1.8 m) on the suction side if the pump is remote mounted.

Table 1—Accessory Condensate Pump Kit Contents

Item

16 ft Transparent Suction/Discharge Tubing

Condensate Pump Assembly

Low voltage Power Cord

Transparent Detection Unit Vent Tubing

Power Cable

Qty.

1

1

1

1

1

1

1

6

1

1

1

!

WARNING





3

PHYSICAL DATA -- 38GVM

218 Outdoor Unit 38GVM

System Voltage

Control Voltage

Rated Cooling Capacity (Btuh)

Cooling Cap. Range Min --- Max Btuh

Rated Heating Capacity (Btuh)

Heating Cap. Range Min --- Max Btuh

Operating Weight lb (kg)

Refrigerant Type

Metering Device (At Outdoor Unit)

Charge lb (kg)

Compressor

Type

Model

Outdoor Fan

CFM hi/med/lo

RPM hi/med/lo

Diameter (in)

Watts watts

Outdoor Coil

Face Area (sq. ft)

No. Rows

Fins per inch

Refrigerant Lines

Connection Type

Liquid (Mix Phase) in OD (QTY)

18,000

7,000 --- 21,000

19,000

2,500 --- 22,600

95 (43)

3.0 (1.4)

SNB130FGYMC

1530 / 1354 / 942

830 / 670 / 500

17.5

4.6

1/4” (2)

Vapor Line in OD (QTY) 3/8” (2)

Total Piping ft. (m.)*

Max Piping to Any FCU ft. (m.)

Max Elevation (Between Indoors)

Max Lift (Fan Coil Above) ft

Max Drop (Fan Coil Below) ft

External Finish

*Refer to Long Line Application section

66 (20)

33 (10)

16.4 (5)

16.4 (5)

16.4 (5)

324

26,000

7,500 --- 33,000

29,000

7,500 --- 35,000

135 (61.2)

4.9 (2.2)

430

208/230---1---60

Low Voltage Pulse DC

29,000

7,500 --- 33,000

30,400

7,500 --- 35,000

137 (62.1)

R---410A

EXV

4.9 (2.2)

436

34,400

8,530 --- 34,000

37,200

10,600 --- 40,900

161 (73)

6.4 (2.9)

60

1942 / 1707 / 1413

690 / 600 / 500

20.5

6.3

Inverter Driven Rotary

TNB220FLHMC

2

18

1/4” (3)

3/8” (3)

33 (10)

33 (10)

33 (10)

Flare

1/4” (4)

3/8” (4)

230 (70)

66 (20)

2177 (high)

820 / 640 / 560

21.7

120

7.3

1/4” (3), 3/8” (1)

3/8” (2), 1/2” (1),

5/8”(1)

542

40,000

8,500 --- 46,400

43,000

10,600 --- 47,760

225 (102.3)

10.6 (4.8)

TNB306FPGMC

3237 (high)

860 / 650 / 550

22.4

140

11.6

25 (7.5)

50 (15)

50 (15)

1/4” (4), 3/8” (1)

3/8” (2), 1/2” (2),

5/8”(1)

262 (80)

82 (25)

White

4

PHYSICAL DATA -- 40GVM

Indoor Unit 40GVM

System Voltage

Control Voltage

Electrical Connections

Nominal Cooling Capacity (Btuh)

Nominal Heating Capacity (Btuh)

Operating Weight lb (kg)

Refrigerant Type

Metering Device (At Outdoor Unit)

Moisture Removal Rate (pints/hr)

Indoor Fan

RPM/CFM (Super High) --- Cooling

RPM/CFM (High) --- Cooling

RPM/CFM (Medium) --- Cooling

RPM/CFM (Low) --- Cooling

RPM/CFM (Super High) --- Heating

RPM/CFM (High) --- Heating

RPM/CFM (Medium) --- Heating

RPM/CFM (Low) --- Heating

Motor Watts

Blower Quantity … Size in

Indoor Coil

Face Area (sq. ft)

No. Of Rows

Fins Per Inch

Filters

Quantity

Controls

Wireless Remote

Modes

Fan Mode

Emergency Mode

Defrost Method

Diagnostics

Air Sweep

Soft Start

Rapid Cooling/Heating

Cold Blow Prevention

Sleep Mode

24 Hour Timer

Auto Restart

Freeze Protection On Indoor Unit

Refrigerant Lines

Connection Type

Liquid (Mix Phase) in OD

Vapor Line in OD

Condensate Drain

Size in

External Finish

009

9,000

9,800

1.7

1260 / 330

1100 / 294

950 / 253

750 / 218

1320 / 330

1200 / 294

1100 / 253

750 / 218

18

3/8”

012

208/230---1---60

Low Voltage Pulse DC

Indoor Unit Powered From Outdoor Unit

12,000

13,000

22.0 (10)

R---410A

EXV

2.9

1280 / 341

1100 / 277

950 / 253

750 / 217

1300 / 341

1170 / 277

1050 / 253

950 / 217

20

1 … 3.6 x 25.4

1.85

2

18

2

Integrated Microprocessor

Standard

Cool/Heat/Dry/Auto

High/Medium/Low/Auto

Yes

Demand Defrost

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Flare

1/4”

1/2”

ID = 1/2” OD = 5/8”

White

018

18,000

19,800

29.0 (13)

3.8

1350 / 500

1200 / 459

1050 / 383

900 / 324

1420 / 500

1250 / 459

1150 / 383

1050 / 324

1 … 3.9 x 27.9

2.3

16

5

AHRI* CAPACITY RATINGS

Model Numbers Cooling

High Heating

47° F (8.33° C)

Low Heating

17° F (---8.33° C)

Outdoor Unit

38GVM218--- --- ---3

38GVM224--- --- ---3

38GVM430--- --- ---3

Indoor Unit

2 x 40GVM009--- --- ---3

40GVM009--- --- ---3

+ 40GVM012--- --- ---3

2 x 40GVM009--- --- ---3

+ 40GVM012--- --- ---3

3 x 40GVM009--- --- ---3

40GVM009--- --- ---3 +

2 x 40GVM012--- --- ---3

4 x 40GVM009--- --- ---3

40GVM009--- --- ---3 +

2 x 40GVM012--- --- ---3

+ 40GVM018--- --- ---3

Non---Ducted FCU’s

Capacity

(Btuh)

18,000

18,000

26,000

26,000

26,000

29,000

29,000

EER

10.2

10.2

8.2

8.2

8.2

7.3

7.3

SEER

16.0

16.0

16.0

16.0

16.0

16.0

16.0

Capacity (Btuh)

19,000

19,000

29,000

29,000

29,000

30,400

30,400

HSPF

8.2

8.2

8.2

8.2

8.2

8.2

8.2

Capacity (Btuh)

9,600

9,600

17,000

17,000

17,000

16,500

16,500

38GVM436--- --- ---3 34,400 8.0

16.0

37,200 8.2

22,000

38GVM542--- --- ---3 Non---Ducted FCU’s 40,000 9.3

16.0

43,000 8.0

24,800

*Air Conditioning, Heating & Refrigeration Institute

--- --- = N/A

Legend

EER --- Energy Efficiency Ratio

HSPF --- Heating Seasonal Performance Factor

SEER --- Seasonal Energy Efficiency Ratio

NOTES:

1.

Ratings are net values reflecting the effects of circulating fan heat. Ratings are based on: Cooling Standard: 80_F (26.67_C) db, 67_F (19.44_C) wb air entering indoor unit and 95_F

(35_C) db air entering outdoor unit. High Temperature Heating Standard: 70_F (21.11_C) db air entering indoor unit and 47_F (8.33_C) db, 43_F (6.11_C) wb air entering outdoor unit.

2.

Ratings are based on 25 ft. (7.62 m) of interconnecting refrigerant lines.

3.

All system ratings are based on fan coil units operating at high fan speed. Consult Physical Data tables for air flows at all available fan speeds.

AIR THROW DATA

Model Number

40GVM009--- --- ---3

40GVM012--- --- ---3

40GVM018--- --- ---3

Low

18 (5.5)

19 (5.8)

25 (7.6)

Approximate Air Throw ft. (m)

Medium High

21 (6.4)

21 (6.4)

29 (8.8)

24 (7.3)

24 (7.3)

32 (9.8)

Turbo

27 (8.2)

27 (8.2)

35 (10.7)

SOUND RATINGS

Outdoor Units

Model Number

38GVM218--- --- ---3 (cool/heat)

38GVM324--- --- ---3 (cool/heat)

38GVM430--- --- ---3 (cool/heat)

38GVM436--- --- ---3 (cool/heat)

38GVM542--- --- ---3 (cool/heat)

Sound Power dBA

66/66

66/66

66/66

69/69

68/68

Sound Pressure dBA

56/56

56/56

56/56

59/59

58/58

Indoor Units

Model Number

40GVM009--- --- ---3

40GVM012--- --- ---3

40GVM018--- --- ---3

Sound

Power dBA

36.0

38.0

45.0

Low

Sound

Pressure dBA

26.0

28.0

35.0

Sound

Power dBA

45.0

46.0

50.0

Medium

Sound

Pressure dBA

35.0

36.0

40.0

Sound

Power dBA

47.0

48.0

54.0

NOTES:

1. Sound power ratings are per AHRI 270 and AHRI 350

2. Sound pressure ratings are estimated sound pressure, 3 feet (.91 m) from the unit, based on sound power data.

High

Sound

Pressure dBA

37.0

38.0

44.0

Sound

Power dBA

51.0

52.0

56.0

Turbo

Sound

Pressure dBA

41.0

42.0

46.0

6

DIMENSIONS -- INDOOR

Unit Size

9k

12k

18k

H

W

In. (mm)

33.3 (846)

33.3 (846)

37.0 (940)

W

H

In. (mm)

10.7 (272)

10.7 (272)

11.7 (297)

Fig. 2 – Indoor Unit Dimensions

D

In. (mm)

7.1 (180)

7.1 (180)

7.9 (201)

D

A08289

Net Operating Weight

Lbs. (Kg)

22.0 (10)

22.0 (10)

29.0 (13)

DIMENSIONS -- OUTDOOR

32.1 (815) 12.4 (316)

35.4 (899)

21.7 (550)

14.4 (378)

Unit: in. (mm)

Fig. 3 – 38GVM018

Weight, lb (kg): Gross -- 106 (48) / Net -- 95 (43)

A12552

7

DIMENSIONS -- OUTDOOR

35.1 (892)

13.4 (341)

37.2 (946)

22.0 (560)

15.6 (396)

Unit: in. (mm)

Fig. 4 – 38GVM024/030

024 Weight, lb (kg): Gross -- 146 (66.2) / Net -- 135 (61.2)

030 Weight, lb (kg): Gross -- 148 (67.1) / Net -- 137 (62.1)

39.1 (994)

36.2 (920)

A12553

3.8 (96)

3.0 (76)

7.0 (177)

Unit: in. (mm) 24.0 (610) 6.0

(153)

Fig. 5 – 38GVM036

Weight, lb (kg): Gross -- 172 (78) / Net -- 161 (73)

8

A12554

DIMENSIONS -- OUTDOOR CONTINUED

42.8 (1087)

40.0 (1015)

3.9 (99)

3.0 (76)

4.8 (121)

24.8 (631) 7.5

(191)

Unit: in. (mm)

Fig. 6 – 38GVM042

Weight, lb (kg): Gross -- 247 (112.3) / Net -- 225 (102.3)

CLEARANCES -- INDOOR

5"

(0.13m) min.

CEILING

6" (0.15m) min.

6' (1.8m)

5"

(0.13m) min.

FLOOR

Fig. 7 – Indoor unit clearance

A07891

A12555

9

CLEARANCES -- OUTDOOR

20 (508) minimum space above top of unit

11.8 (300) minimum distance from wall

11.8 (300) minimum space on air inlet side

78 (2000) minimum space in front of air outlet

Fig. 8 – 38GVM018, 024, 030

Unit: in. (mm)

24.0 (610) minimum space on service valve side

A112556

40 (1000) minimum space above top of unit

19.7 (500) minimum space on air inlet side

19.7 (500) minimum distance from wall

78 (2000) minimum space in front of air outlet

Fig. 9 – 38GVM036, 042

Unit: in. (mm)

24.0 (610) minimum space on service valve side

A112557

10

SYSTEM OPERATING ENVELOPE

Model Size

Indoor/Outdoor

Indoor Operating Range (A/C and HP) ° F (° C)

Cooling Ambient Operating Range ° F (° C)

Heating Ambient Operating Range ° F (° C)

9K 12K

Indoor

61 to 86 (16 to 30)

---

---

18K 18K 24K 30K

Outdoor

---

23 to 118 (---5 to 48)

5 to 81 (---15 to 27)

36K 42K

120

110

100

90

86°F

5°F

80

70

60

50

40

-10

61°F

5°F

0 10

23°F

23°F

81°F

81°F

118°F

118°F

86°F

61°F

20 30 40 50 60 70 80

Outdoor Temperature (°F)

90 100 110 120 130 140

Fig. 10 – 18k -- 42k 230V System Operating Envelope

11

ELECTRICAL DATA

Outdoor Units

System Voltage

Unit Size

VOLT---PH---HZ

18 K

24 K

30 K

36 K

42 K

208/230---1---60

Indoor Units

Operating Voltage*

MAX/MIN

253/187

Compressor

RLA

9.6

14.7

19.6

21.0

21.5

LRA

27

45

45

45

67

FLA

0.54

0.59

0.67

1.10

Unit Size

System Voltage

VOLT---PH---HZ

Operating Voltage

MAX/MIN

9 K

12 K

18 K

208/230---1---60

* Permissible limits of the voltage range at which the unit will operate satisfactorily

{

Indoor fan powered from outdoor unit.

LEGEND

FLA --- Full Load Amps

LRA --- Locked Rotor Amps

MCA --- Minimum Circuit Amps

RLA --- Rated Load Amps

MOCP--- Maximum Over Current Protection

253/187

Outdoor Fan

HP

1/12

1/8

1/6

W

60

120

140

MCA

13

20

26

28

29

FLA

Indoor Fan{

0.20

0.32

MAX

FUSE/CB

Amp

(MOCP)

20

30

45

45

50

W

20

WIRING

Power Wiring:

The main power is supplied to the outdoor unit. The field supplied connecting cable from the outdoor unit to indoor unit consists of three (3) wires and provides the power for the indoor unit. Two wires are high voltage AC power and one is a ground wire.

Consult your local building codes and the NEC (National Electrical Code) or CEC (Canadian Electrical Code) for special requirements.

All wires must be sized per NEC or CEC and local codes. Use Electrical Data table MCA (minimum circuit amps) and MOCP (maximum over current protection) to correctly size the wires and the disconnect fuse or breakers respectively.

Per caution note, only copper conductors with a minimum 300 volt rating and 2/64--inch thick insulation must be used.

Control Wiring:

A separate shielded copper conductor only, with a minimum 300 volt rating and 2/64--inch thick insulation, must be used as the communication wire from from the outdoor unit to the indoor unit.

To minimize voltage drop of the control wire, use the following wire size and maximum lengths shown in the chart below.

Wire Size

18 AWG

16 AWG

Length ft (m)

50 ft. (15 m)

50 ft (15) to 100 ft. (30 m)

!

CAUTION



S Wires should be sized based on NEC and local codes.

S Use copper conductors only with a minimum 300 volt .

rating and 2/64 inch thick insulation.

!

CAUTION



S

Be sure to comply with local codes while running wire from indoor unit to outdoor unit.

S

Every wire must be connected firmly. Loose wiring may cause terminal to overheat or result in unit malfunction.

A fire hazard may also exist. Therefore, be sure all wiring is tightly connected.

S No wire should be allowed to touch refrigerant tubing, compressor or any moving parts.

S Disconnecting means must be provided and shall be located within sight and readily accessible from the air conditioner.

S

Connecting cable with conduit shall be routed through hole in the conduit panel.

12

CONNECTION DIAGRAM

Covered conduit connection for size 18k only

Outdoor unit

Terminal Block

Conduit panel

Conduit

38GVM-40GVM 18K - 42K Connection Diagram

This Series of Connections Will be Repeated for Each Indoor Unit (A to A - B to B etc.)

CONNECTING CABLE

OUTDOOR TO INDOOR

L1

Main

Power

Supply

L2

208/230-1-60

GND

Ground

L2 S L1

Power to

Indoor Unit

Control to

Indoor Unit

Power to

Indoor

Unit

208/230 Low V DC 208/230

Unit "A"

Outdoor Unit Terminal Blocks

Power to Outdoor

Unit

Power and Control Signal to

Indoor Units

Two - Five Terminal Blocks

L2 S L1 GND

Power from

Outdoor Unit

Control from

Outdoor Unit

Power from

Outdoor Unit

Ground

208/230 Low V DC

Unit "A"

208/230

Indoor Unit Terminal Block (1)

A12558

Fig. 11 – Field Wiring

13

14

15

16

17

18

REFRIGERATION SYSTEM DIAGRAMS

indoor

A heat exchanger

A3

A

1

filter A2

B heat exchanger

B3

B

1

filter B2

outdoor

filter fan

outdoor heat exchanger

4-way valve

SP high pressure switch

Note: Not available for 18K model

discharge silencer discharge temperature sensor

C heat exchanger

C3 filter

C

1

C2

D heat exchanger

D3 filter

D1

D2 gas -liquid separator

Note: Not available for 18K model

A1:A unit electronic expansion valve B1:B-unit electronic expansion valve

C1:C-unit electronic expansion valve D1:D-unit electronic expansion valve

A3:A unit liquid pipe temperature sensor B3:B-unit liquid pipe temperature sensor

C3:C-unit liquid pipe temperature sensor D3:D-unit liquid pipe temperature sensor

Fig. 17 – Refrigeration System Diagram 18k -- 30k

19

REFRIGERATION SYSTEM DIAGRAMS CONTINUED

M

Heat Exchanger

Liquid Receiver

Outdoor Uint

Electronic Expansion Valve

Indoor Uint

Capillary

Four-way Valve

Oil Separator

Stop Valve

Compressor

Gas/Liquid Separator

Heating

Cooling

Heat Exchanger

Heat Exchanger

Heat Exchanger

Heat Exchanger

Heat Exchanger

Fig. 18 – Refrigeration System Diagram 36k -- 42k

20

SYSTEM EVACUATION AND CHARGING

!

CAUTION

UNIT DAMAGE HAZARD


Deep Vacuum Method

The deep vacuum method requires a vacuum pump capable of pulling a vacuum of 500 microns and a vacuum gage capable of accurately measuring this vacuum depth. The deep vacuum method is the most positive way of assuring a system is free of air and liquid water. (See Fig. 21)

Never use the system compressor as a vacuum pump.

5000

4500

Refrigerant tubes and indoor coil should be evacuated using the recommended deep vacuum method of 500 microns. The alternate triple evacuation method may be used if the procedure outlined below is followed. Always break a vacuum with dry nitrogen.

SYSTEM VACUUM AND CHARGE

Using Vacuum Pump

1. Completely tighten flare nuts A, B, C, D, connect manifold gage charge hose to a charge port of the low side service valve. (See Fig. 19.)

4000

3500

3000

CRONS 2500

2000

1500

1000

500

LEAK IN

SYSTEM

VACUUM TIGHT

TOO WET

TIGHT

DRY SYSTEM

2. Connect charge hose to vacuum pump.

3. Fully open the low side of manifold gage. (See Fig. 20)

4. Start vacuum pump

5. Evacuate using either deep vacuum or triple evacuation method.

6. After evacuation is complete, fully close the low side of manifold gage and stop operation of vacuum pump.

7. The factory charge contained in the outdoor unit is good for up to 25 ft. (8 m) of line length. For refrigerant lines longer than 25 ft (8 m), add 0.1 oz. per foot of extra piping up to total allowable piping length aS listed in physical data.

8. Disconnect charge hose from charge connection of the low side service valve.

9. Fully open service valves B and A.

10. Securely tighten caps of service valves.

Outdoor Unit

A

B

Refrigerant

Low Side

High Side

Indoor Unit

C

D

0 1 2 3 4 5 6 7

MINUTES

Fig. 21 – Deep Vacuum Graph

Triple Evacuation Method

A95424

The triple evacuation method should only be used when vacuum pump is only capable of pumping down to 28 in. of mercury vacuum and system does not contain any liquid water.

Refer to Fig. 22 and proceed as follows:

1. Pump system down to 28 in. of mercury and allow pump to continue operating for an additional 15 minutes.

2. Close service valves and shut off vacuum pump.

3. Connect a nitrogen cylinder and regulator to system and open until system pressure is 2 psig.

4. Close service valve and allow system to stand for 1 hr. During this time, dry nitrogen will be able to diffuse throughout the system absorbing moisture.

5. Repeat this procedure as indicated in Fig. 22. System will then be free of any contaminants and water vapor.

EVACUATE

Service Valve

BREAK VACUUM WITH DRY NITROGEN

A07360

Fig. 19 – Service Valve

WAIT

Manifold Gage

EVACUATE

BREAK VACUUM WITH DRY NITROGEN

WAIT

500 microns

Low side valve

Charge hose

High side valve

Charge hose

Vacuum pump

EVACUATE

CHECK FOR TIGHT, DRY SYSTEM

(IF IT HOLDS DEEP VACUUM)

Low side valve

Fig. 20 – Manifold

A07361

RELEASE CHARGE INTO SYSTEM

A95425

Fig. 22 – Triple Evacuation Method

Final Tubing Check

IMPORTANT: Check to be certain factory tubing on both indoor and outdoor unit has not shifted during shipment.

Ensure tubes are not rubbing against each other or any sheet metal. Pay close attention to feeder tubes, making sure wire ties on feeder tubes are secure and tight.

21

REMOTE CONTROL AND FUNCTIONS

2

4

5

7

9

10

12

1

3

11

14

6

8

1. Remote Control Display

2. ON/OFF Button

3. MODE Button

4. Setpoint Clock, Timer Up (+) and Down (---) Buttons

5. Fan Speed

6. Horizontal Louver Swing Button

7. Clock Button

8. Timer ON Button

9. Dry Coil Button

10. Temperature Button

11. Timer OFF Button

12. Turbo Mode Button

13. Sleep Mode button

14. Light Button to Turn ON or OFF Display on Front Panel

13

A12434

Remote Control 09k -- 18k

______________________________________________________________________________________________________________

Remote Control Display

MODE DISPLAY

3 1

4

AUTO

10

2

11

COOL

6

DRY

FAN

7

9

HEAT

5

8 12 13 14 15 A12435

NOTE: Symbols shown in this manual are for the purpose of demonstration. During actual operation, only the relevant symbols are displayed.

1. TRANSMISSION INDICATOR: Illuminates when remote control transmits signals to the indoor unit.

2. OPER INDICATOR: This symbol appears when the unit is turned on by the remote control, and disappears when the unit is turned off.

3. FAN SPEED DISPLAY: Indicates the set fan speed. AUTO is displayed when unit is running in AUTO mode.

4. MODE DISPLAY: Indicates the current operation mode

“AUTO”, “COOL”, “DRY”, “FAN ONLY”, or “HEAT”

5. SLEEP DISPLAY: Indicates unit is running in SLEEP mode.

6. TEMPERATURE DISPLAY: Temperature setting from 61_F

(16_C) to 86_F (30_C) will be displayed. If FAN mode is selected, there will be no temperature displayed.

7. CLOCK DISPLAY: Indicates the current time (0 to 24 hours).

8. CLOCK INDICATOR: Displayed with time and is not displayed when setting ON/OFF timer.

9. TIMER ON / TIMER OFF DISPLAY: ON is displayed if

TIMER ON is set. OFF is displayed if TIMER OFF is set. ON OFF displayed if both ON and OFF timers are set.

10. TURBO DISPLAY: Indicates unit is running in Turbo Mode.

11. DRY COIL DISPLAY: Indicates unit is running in DRY COIL mode where the fan continues to run after the unit is shut off to dry the coil.

12. TEMPERATURE DISPLAY: Indicates if room temperature or set point temperature is being displayed on the front panel.

13. SWING DISPLAY: Sets louver position or set louvers to continuously move for better air distribution.

14. LIGHT DISPLAY: Indicates if LED display on the front panel is illuminated.

15. LOCK DISPLAY: Indicates if remote control is locked.

22

REMOTE CONTROL AND FUNCTIONS CONTINUED

!

CAUTION


Failure to follow this caution may result in equipment damage.

Handle the control with care and avoid getting the control wet.

NOTE: The remote control is factory set to display

temperatures in _F. If _C is desired, turn the remote off and then press the “MODE” and “--” buttons on the remote simultaneously.

IMPORTANT: The remote control can operate the unit from a distance of up to 25 ft. (7.6 m) as long as there are no obstructions.

This is one way communication only (from remote control to fan coil).

The remote control can perform the following basic functions:

S Turn the system ON and OFF

S Select operating mode

S Adjust room air temperature set point and fan speed

S Adjust airflow direction

Refer to the Remote Control Function section for detailed description of all the capabilities of the remote control.

Setting the Clock

Before you start operating the air conditioner, set the clock on the remote control as outlined below. The clock panel on the remote controller will display the time regardless of whether the air conditioner is in use or not.

Initial Setting of the Clock:

After batteries are inserted in the remote control, the clock panel will display ”12:00”.

1. Push the CLOCK button once will flash.

2. Push the “+” or “--” button. Each time you press the button, the time moves forward or backward by one minute depending on which button you press.

If you push the “+” or “--” button continuously, the time adjusts in increments of 10 minutes.

3. When the right time is achieved, press the CLOCK button once to set the time. The will stop flashing.

4. To readjust the Clock, Press the CLOCK button on the remote. The will flash. Repeat steps 1 through 3.

NOTE: The time of the CLOCK must be set before the

AUTO--TIMER function will operate.

!

CAUTION

UNIT OPERATION HAZARD

Battery Installation

Two AAA 1.5 v alkaline batteries (included) are required for operation of the remote control.

To install or replace batteries :

1. Slide the back cover off the control to open the battery compartment.

2. Remove old batteries if you are replacing the batteries.

3. Insert batteries. Follow the polarity markings inside the battery compartment.

4. Replace battery compartment cover.


Static electricity or other factors (voltage fluctuations) can cause the remote control clock to reset. If your remote control is reset

(the time of ”12:00” flashing), set the clock before starting the unit.

A08299

NOTE:

1. When replacing batteries, do not use old batteries or a different type battery. This may cause the remote control to malfunction.

2. If the remote is not going to be used for several weeks, remove the batteries. Otherwise battery leakage may damage the remote control.

3. The average battery life under normal use is about 6 months.

4. Replace the batteries when there is no audible beep from the indoor unit or if the Transmission Indicator fails to light.

23

Remote Control Operation -- Quick Start

NOTE: When transmitting a command from the remote control to the unit, be sure to point the control toward the LED display on the front panel of the unit. The unit will confirm receipt of a command by sounding an audible beep.

1. Turn the unit on by pushing the ON/OFF button.

2. Select the desired mode by pushing the mode button.

(Only for heating and cooling units)

A08301

3. Select the temperature set point by pointing the control toward the unit and pressing the “+” or “--” temperature set point buttons until the desired temperature appears on screen. In AUTO mode, the setpoint temperature is not adjustable.

4. Select the desired fan speed by pressing the FAN button to select desired fan speed.

NOTE: If unit is operating in Dry mode (X--FAN), low fan speed will be displayed and the fan speed cannot be changed.

5. Set the airflow direction. When the unit is turned on, the louvers default to the cooling or heating position. The user can adjust the default louver position by pushing the

“SWING” buttons. For details on operating the SWING louvers, refer to the Remote Control Functions section.

Emergency Operation

If the remote control is lost, damaged, or the batteries are exhausted, the AUTO button on the unit can be used to temporarily operate the unit.

Open the front cover panel and press the AUTO button once briefly when the system is off.

To stop emergency operation, push the AUTO button once. The emergency operation can also be stopped by pushing the

“ON/OFF” button on the remote control.

AUTO/STOP

Manual Switch

FUNCTIONS

The remote control is the interface between the user and the high--wall systems. Commands are entered by the user to control the system. Any command that has been entered with the remote control will remain in the memory until it is changed by the user or the batteries are replaced.

NOTE: When entering commands, point the remote control in the direction of the LED display on the front panel. The

OPER will appear for a short period of time on the remote control when the command is entered. The unit will only emit an audible beep when the signals are received correctly.

Locking Function:

Settings can be locked by pushing the “+” and “--” buttons simultaneously. When the remote is locked, no commands can be entered.

To unlock the remote, press “+” and “--” buttons simultaneously again.

ON/OFF:

When the air conditioner is not in operation, the remote control will display the last set point and time.

S

Press the On/Off button to start the unit.

-- The unit will start in the last operating mode and set point.

The “OPER” indicator will appear. The “RUN” indicator on the display panel turns green.

S Press button On/Off to stop the unit.

-- The “RUN” indicator light on the display panel will turn red and the remote control will display the setpoint and time.

“OPER” will disappear.

NOTE: If the On/Off button is pressed too soon after a stop, the compressor will not start for 3 minutes due to the inherent protection against frequent compressor cycling.

When turning the unit ON and OFF, the Timer and Sleep functions will be canceled.

SELECTING THE OPERATING MODE:

Use the MODE button to select available modes. The selected mode will be displayed on the remote control and the appropriate light will illuminate on the unit’s display panel.

The following occurs when the AUTO button is pushed:

S No temperature will be displayed on display panel.

A12433

S Unit will run in FAN ONLY mode if return air temperature is between 68_F (20_C) and 77_F (25_C).

S Unit will run in HEATING if return air temperature is less than 68_F (20_C).

S Unit will run in COOLING if return air temperature is greater than 77_F (25_C).

S Fan speed will be set to AUTO

S SWING will be on.

(Only for heating and cooling units)

A09641 /A09628b

Mode Descriptions

AUTO MODE

AUTO mode is the default setting at start--up. In AUTO mode, the set temperature will not be displayed on the LCD, and the unit will automatically select the suitable operation mode to provide comfort based on parameters set from the factory.

24

FUNCTION AND CONTROLS CONTINUED

COOL & HEAT MODES

Press the “+” and “--” buttons to select the temperature. The unit will confirm signal receipt with a beep and the value of the set temperature is displayed on the remote and on the front panel display.

The temperature can be set between 61_F (16_C) and 86_F

(30_C).

NOTE: In Cooling mode, if the temperature selected is higher than the room temperature, the unit will not start. The same applies for the Heating mode if the selected temperature is lower than the room temperature.

DRY MODE

Displaying Setpoint or Room Temperatures on Front Panel

The setpoint temperature or room temperature can be displayed on the front panel. Only setpoint temperature is displayed on the remote.

:

ºF

ºC

HOUR

ON/OFF

Room

Temperature

Icon

This is a dehumidification mode of operation. The system will dry the filter and slightly cool the room air temperature. This mode does not take the place of a dehumidifier.

In DRY mode, the indoor fan will operate continuously in low speed. The fan speed is not adjustable.

FAN MODE

This mode filters and circulates room air at the selected fan speed.

See figure below for selecting fan speed.

Low / Med / High indicator

AUTO

A09638

When the “TEMP” button is pushed once, the temperature indicator (without thermometer) is displayed. This indicates that the setpoint temperature is displayed on the front panel.

When the “TEMP” button is pushed a second time, a thermometer is displayed inside the temperature indicator. This indicates that the room temperature is displayed on the front panel.

NOTE: If any other button is pushed on remote control, the temperature will return to the set point temperature. Outdoor air temperature is not available.

AUTO

FAN

OPER

Using Dry Coil Function (X--Fan):

:

ºF

ºC

HOUR

ON/OFF

When operating in humid areas, hi--wall units have a DRY COIL function that will allow the indoor fan to run for a pre--determined amount of time (10 minutes) after the unit is turned off (cooling

or dry modes) to ensure that additional moisture is removed from coil. Push the “X--FAN” button to enable this feature. This will be displayed on remote control.

A09649

The fan speed is selected by pressing the FAN button. This button is used to set the fan speed in the following sequence:

OPER

ºF

Remote

Dry Coil

Icon

ºC

:

HOUR

ON/OFF

Fan Speeds: Low Medium High

NOTE: When the unit is on, the fan will run continuously in cooling or heating. When in heating, there might be situations where the fan will slow down or shut off to prevent cold blow.

TURBO MODE

The desired setpoint, either in heating or cooling, can be achieved faster if TURBO mode is used. After selecting the “HEAT” or

“COOL” mode button, push the “TURBO” button. This will force the unit to run at super high speed. When the setpoint is satisfied, push the “TURBO” button again. The unit will run at the selected fan speed.

When TURBO mode is running, the following is displayed on the remote control:

Turbo

Icon

:

OPER

ºF

ºC

HOUR

ON/OFF

A09636

A09637

To deactivate this feature, push the “X--FAN” button again.

Selecting the Horizontal Direction Louver Position

When the unit is turned on, the louvers default to the cooling or heating position.

If the louver position is not providing adequate comfort due to room layout or where people are gathered, two options are available to correct the situation:

Setting the louvers in a stationary position

(other than default for heating and cooling):

The stationary position can be one of five (5) default positions.

To change the louver position, press the “SWING“ button once. The icon is displayed on the remote.

:

OPER

ºF

ºC

HOUR

ON/OFF

Swing Icon

A09640

25


Timer ON only

When the is displayed, the louver will swing continuously between positions 1 and 5 as shown below.

0 1 2 3 4

:

OPER

ºF

ºC

HOUR

ON

Only ON is displayed.

OFF

8 7 6 5

A09634

If the “SWING” button is pushed again,the louver will move to position 1. If position 2 through 5 is desired, push the button repeatedly until the desired position (2 through 5) is displayed on remote control.

Setting the louvers to move continuously:

This setting allows the louvers to move continuously between either positions 1 through 5, or between positions 6, 7, and 8.

Push the button once to have louvers swinging between positions 1 and 5. If position 6, 7, or 8 is desired, push the button repeatedly until the desired position is displayed on the remote.

NOTE: Always use the remote control to adjust the horizontal louver position otherwise, abnormal operation may occur. If this occurs, turn the unit off and then on again.

Sometimes, in the heating mode, when the ”SWING” button is pushed, the louvers will not start moving right away.

This is due to the fact that the fan will not start running until the coil temperature is warm enough to prevent discomfort to the user by blowing cold air.

Sleep Mode

This mode is used to conserve energy and can be used when the unit is in the COOL, HEAT or DRY mode only.

For Cooling Mode:

S Push the SLEEP button. The SLEEP display will appear on the remote control.

:

OPER

ºF

ºC

HOUR

ON/OFF

A09644

S After 1 hour the set point will be raised by 1.8_F (1_C).

S After another hour, the set point will be raised by another

1.8_F (1_C) and the fan will run in low speed.

S The SLEEP mode will be cancelled when the SLEEP button is pushed again.

For Heating Mode:

S Same as cooling mode but set points will be lowered by

1.8_F (1_C) and the HEAT icon will disappear from the display panel.

Timer Function

TIMER ON (to start the unit) and TIMER OFF (to stop the unit) can be used separately or together. The clock on the remote control must be set before using this function.

A09639

This function will allow the unit to start automatically at the set time. The TIMER ON can be set while the unit is on or off.

To set the TIMER ON function, perform the following:

1. Push the “TIMER ON” button once.

2. The clock indicator and time will not be displayed on the remote control. The default “TIMER ON” time (first time function is used) or the last time setting will be displayed and “ON” will flash.

3. Push the “--” or “+” within 5 seconds until the desired on time is displayed.

NOTE: Pressing the “--” or “+” will decrease or increase the time in 1 minute increments.

Pressing the “--” or “+” continuously will decrease or increase the time in 10 minute increments.

4. Push the “TIMER ON” again. The “ON” icon will stop blinking and the time at which the unit will start is set. The clock indicator and the time will be displayed again.

The “TIMER ON” time will be stored in memory indefinitely until it is cancelled by the user by pushing the “TIMER ON” button or the remote control batteries are replaced.

If the unit is running and the “TIMER ON” set time is reached, the unit will continue operating normally.

NOTE: When the unit is shut off by the user using the

“ON/OFF” button, and if the “TIMER ON” is set, the following will be displayed on the remote control.

-- Set Point

-- Time

-- Clock indicator next to time indicates TIMER ON is set.

On the display panel, the operation light will turn red.

When the “TIMER ON” set time is reached, the display on the remote does not change, but the unit will run as indicated by the operation light on the front cover turning green. To get display on the remote, push the “ON/OFF” button once.

Timer OFF only

This function will allow the unit to stop automatically at the set time. The timer can be set while the unit is on or while it is off.

To set the “TIMER OFF” function, perform the following:

1. Push the “TIMER OFF” button once.

2. The clock indicator

“OFF” will be flashing.

and time will not be displayed.

3. Push the “--” or “+” button within 5 seconds until the desired ON time is displayed.

NOTE: Pressing the “ --” or “+” will decrease or increase the time in 1 minute increments.

Pressing the “--” or “+” continuously, will decrease or increase the time in 10 minute increments.

4. Push the “TIMER OFF” button again, the “OFF” icon will stop blinking and the time at which the unit will turn off is set. The clock indicator and the time will be displayed again.

26


The “TIMER OFF” time will be stored in memory indefinitely until is is cancelled by pushing the the “TIMER OFF” button or the batteries are replaced in the remote control.

Time Delay

If the On/Off button is pressed too soon after a stop, the compressor will not start for 3 minutes due to the inherent protection against frequent compressor cycling. The unit will only emit an audible beep when the signals are received correctly.

If the unit is running and the “TIMER OFF” set time is reached, the unit will turn off and the operation indicator light on the front panel will turn red. The display on the remote control will remain the same as when the unit was running. To turn the unit on again, push the “ON/OFF” button twice. The operation indicator light on the front panel will turn green.

Timer ON and Timer OFF

Heating Features

If the unit is in the heating mode, there will be a delay when the fan starts. The fan will start only after the coil is warmed up to prevent cold blow.

Defrost Operation

:

OPER

ºF

ºC

HOUR

ON/OFF

ON/OFF will be displayed

A09643

Use both functions as described in “TIMER ON” and “TIMER

OFF” sections to program the unit to turn on and shut off at specified times. Times will be stored in memory until cancelled by user or the remote control batteries are replaced.

Light Function

This function will allow the user to Turn ON or OFF the display on the front panel.

Press the light icon to turn the indoor unit front panel ON or

OFF. The remote control will display the Light Icon as shown below.

In heating mode, if the outdoor coil is frosted, the indoor fan and outdoor fan will turn off while system removes the frost on the outdoor coil. “H1” will be displayed on the display panel on the front cover of the unit.

The system will automatically revert to normal operation when frost is removed from the outdoor unit, and “H1” will disappear.

Auto Start

If the power fails while the unit is operating, the unit stores the operating condition, and it will start operation automatically under those conditions when the power is restored.

Light Icon

A12435

27

TROUBLESHOOTING

Precautions for Performing Inspections and Repairs

Be cautious during installation and maintenance. Follow all rules and regulations to avoid electric shock and to prevent injury or damage.

!

WARNING





Static Maintenance

Static Maintenance is maintenance during de--energization of the air conditioner.

For static maintenance, make sure that the unit is de--energized and the plug is disconnected.

Dynamic Maintenance

Dynamic maintenance is the maintenance during energization of the unit.

Before dynamic maintenance, check the electricity and ensure that there is a good ground. Check if there is electricity on the case and copper pipe of the air conditioner with a voltage tester.

!

WARNING



A large--capacity electrolytic capacitor is used in the outdoor unit controller (inverter). When the power supply is turned off, charge (charging voltage DC280V to 380V) remains and takes a long time to discharge.

Do Not open the outdoor unit for 20 minutes after power has been turned OFF.

Take sufficient care to avoid directly touching any of the circuit parts without first turning off the power.

At times, such as when the circuit board is to be replaced, place the circuit board assembly in a vertical position.

Diagnose troubles according to the trouble diagnosis procedure as described below.

Also refer to the check points in servicing written on the wiring diagrams attached to the indoor/outdoor units.

No.

1

2

3

Trouble Shooting Procedure

Confirmation

Code displays interpretation of error codes.

Basic System Check

Confirmation

:

1. Confirmation of Power Supply: Confirm that the power breaker operates normally and provides power

2. Confirmation Voltage: Confirm that voltage is AC

220--240 10%. If voltage is not in this range, the unit may not operate normally.

28

TROUBLESHOOTING CONTINUED

PROBLEM

Indoor unit emits a bad odor on start--up

You hear water flowing noise when the unit is running

Indoor unit produces a mist when the air conditioner is running

Wireless remote control does not work

Water leaks into room from

Indoor unit

Unit/System Does Not Work

Cooling is Not Working

Properly

Heating is Not Working

Properly

Unit Stops During Operation

Basic Troubleshooting

POSSIBLE CAUSE

 Air filter dirty

 Output air still has odor after cleaning filter.

 This is normal and is the refrigerant flowing through the system.

 This is normal cooling and is caused by high humidity and temperature in the room.

 Batteries are dead.

 Unit needs to be reset.

 Condensing water has overflowed

 To protect the unit upon an immediate restart after a stop, the system controller will delay the unit for 3 minutes before allowing the unit to start back up.

 The circuit breaker has tripped or a fuse has blown.

 Power failure.

 Error codes displayed

 Voltage is too low.

 The filter is blocked with dust.

 Temperature is not set properly.

 A window or door is open.

 The outdoor unit is obstructed.

 The fan speed is too low.

 The operation mode is in Fan instead of

Cool.

 The filter is blocked with dust.

 Temperature is set too low.

 A window or door is open.

 The outdoor unit is obstructed.

 The Off timer is not operating correctly.

 Error codes displayed

SOLUTION

 Clean the air filter

 Contact your service representative.

 No maintenance required

 No maintenance required. Mist should stop as room is cooled down and the humidity is removed.

 See battery replacement section in this manual and replace batteries.

 Turn off power to indoor unit. Remove plug from wall and then reinsert plug. Restart unit.

 Check indoor condensing drain or call your representative.

 After turning unit off, wait at least 3 minutes before trying to restart.

 Reset the circuit breaker or replace the fuse with the specified replacement fuse.

 Restart operation when the power is restored.

 Call your service representative.


 Clean the air filter.

 Check the temperature and reset if necessary.

 Close the window or door.

 Remove the obstruction.

 Change the fan speed selection.

 Change the operating mode to Cool or reset the unit.

 Clean the air filter.

 Check the temperature and reset if necessary.

 Close the window or door.

 Remove the obstruction.

 Restart the operating mode.


29

18, 24, and 30K

NA

NA

Inlet tube temperature sensor malfunction

Outlet tube temperature sensor malfunction

Low charge or refrigeration system blockage

Indoor return air temperature sensor malfunction

Indoor tube temperature sensor malfunction

Outdoor ambient temperature sensor malfunction

NA

Outdoor discharge air temperature sensor

Cooling oil return cycle

System high pressure protection

Indoor freeze protection

System low pressure protection

Compressor discharge high temperature protection

Communication error between indoor and outdoor

Mode conflict

System overload protection

Cold Blow Protection

Test mode

Pump down mode

IPM Rest

Compressor current protection

NA

Heat sink temperature sensor malfunction

IPM over temperature protection

NA

Current sensor malfunction

NA

Input current protection

NA

Low voltage protection

High voltage protection

NA

Capacitor charging malfunction

Defrost or heating oil return cycle

NA

Compressor overheat protection

IPM Protection

Compressor speed reduction

PFC board protection

Compressor high voltage protection

Compressor start---up failure

Compressor phase loss protection

NA

NA

NA

NA

Memory card error

Frequency limitation for module circuit protection

Frequency limitation for module temperature protection

Frequency limitation for overload protection

Frequency limitation for system circuit protection

Frequency limitation for module circuit protection

Frequency limitation for freeze protection

Compressor demagnetizing protection

Indoor and outdoor units mismatch

Compressor phase detection malfunction

Low DC bus voltage

Communication error between main board and EXV


38GVM Diagnostic Codes

36 and 42K

Defrost Mode 1

Defrost Mode 2

Inlet tube temperature sensor malfunction

Outlet tube temperature sensor malfunction

NA


Indoor tube temperature sensor malfunction

Outdoor ambient temperature sensor malfunction

Outdoor mid---coil temperature sensor malfunction

Outdoor discharge air temperature sensor

Cooling oil return cycle

System high pressure protection

Indoor freeze protection

System low pressure protection

Compressor discharge high temperature protection

Communication error between indoor and outdoor

Mode conflict

System overload protection

NA

Test mode

Pump down mode

IPM Rest

Compressor current protection

Communication error between the inverter drive and main board

Heat sink temperature sensor malfunction

IPM over temperature protection

Open Contactor

Current sensor malfunction

Current sensor mis---wiring protection

Input current protection

Inverter board ambient temperature sensor malfunction

Low voltage protection

High voltage protection

Abnormal input AC voltage

Capacitor charging malfunction

Heating oil return cycle

Forced defrost

Compressor overheat protection

IPM Protection

Compressor speed reduction

PFC board protection

NA

Compressor start---up failure

Compressor phase loss protection

Compressor stalling

Compressor over---speed protection

Condenser coil inlet temp sensor malfunction

Condenser outlet temperature sensor malfunction

NA

NA

NA

NA

NA

NA

NA

NA

NA

NA

NA

Communication error between main board and EXV

EU

F6

F8

F9

FH

HE

LP

U1

U3 dn

H3

H5

H7

Hc

L9

Lc

Ld

LE

LF

A5

PL

PH

PP

PU

H1

H1

A7

EE

En

P7

P8

P9

Pc

Pd

PA

PF

E6

E7

E8

E9 dd

Fo

P0

P5

P6

Indoor Unit

Display

08

0A

See Error Code Table


F0



F3

F4

F5

F7

E1

E2

E3

E4

Indoor and/or

Outdoor Unit

Error

Outdoor

Outdoor

Indoor

Indoor

Outdoor

Indoor

Indoor

Outdoor

Outdoor

Outdoor

Outdoor

Outdoor

Indoor

Outdoor

Outdoor

Indoor and outdoor

Indoor

Outdoor

Indoor

Outdoor

Outdoor

Outdoor

Outdoor

Outdoor

Outdoor

Outdoor

Outdoor

Outdoor

Outdoor

Outdoor

Outdoor

Outdoor

Outdoor

Outdoor

Outdoor

Outdoor

Outdoor

Outdoor

Outdoor

Outdoor

Outdoor

Outdoor

Outdoor

Outdoor

Outdoor

Outdoor

Outdoor

Outdoor

Outdoor

Outdoor

Outdoor

Outdoor

Outdoor

Outdoor

Outdoor

Outdoor and Indoor

Outdoor

Outdoor

Outdoor

30


Error Code Table

Error

Code

13

14

15

16

17

41

Error Description

Unit A indoor pipe outlet temperature sensor malfunction

Unit A indoor pipe inlet temperature sensor malfunction

Unit A Indoor return air sensor malfunction

Unit A mode conflict

Unit A freeze protection

Unit D communication error

Error

Code

23

24

25

26

27

46


Unit B indoor pipe outlet temperature sensor malfunction

Unit B indoor pipe inlet temperature sensor malfunction

Unit B Indoor return air sensor malfunction

Unit B mode conflict

Unit B freeze protection

Unit D mode conflict

42

43

44

45


Unit D indoor pipe outlet temperature sensor malfunction

Unit D indoor pipe inlet temperature sensor malfunction

Unit D Indoor return air temperature sensor malfunction

47

51

52

53

Unit D freeze protection

Unit E communication error

Unit E indoor pipe midway temperature sensor malfunction

Unit E indoor pipe outlet temperature sensor malfunction

Note: Refer to Appendix Tables 1 --- 3 on pages 44 --- for sensor code information.

55

56

35

36

37

54

Error

Code

33

34

57

C5


Unit C indoor unit pipe outlet temperature sensor malfunction

Unit C indoor unit pipe inlet temperature sensor malfunction

Unit C Indoor unit return air sensor malfunction

Unit C mode conflict

Unit C freeze protection

Unit E indoor pipe inlet temperature sensor malfunction

Unit E Indoor return air temperature sensor malfunction

Unit E mode conflict

Unit E freeze protection

Jumper missing on replacement indoor board

31


Malfunction Indicator

Note:

○

: off

●

: on : blink

When several malfunctions occur at the same time, they will be displayed in circulation and every malfunction is displayed for 5s.

0 Normal stop operation

1 Normal compressor operation

2 Compressor overload protection

4 Outdoor unit overload protection

5 High pressure protection

8 IPM over heating protection

9 PFC protection (including PFC overheating protection)

11 High voltage protection

12 Low voltage protection

15 Compressor phase-drop protection

16 Compressor phase detection malfunction

18 DC power supply short circuit

19 Normal defrost operation

20 Normal oil return operation

21 Complete unit frequency reduction protection

22 Complete unit frequency reduction protection

23 Unit A frequency restriction or frequency reduction protection

24 Unit B frequency restriction or frequency reduction protection

25 Unit C frequency restriction or frequency reduction protection

26 Unit D frequency restriction or frequency reduction protection

27 Outdoor ambient temperature sensor malfunction

28 Outdoor tube temperature sensor malfunction

29 Discharge temperature sensor malfunction

30 IPM thermal resistance malfunction

31 Unit A liquid pipe temperature sensor malfunction

32 Unit A gas pipe temperature sensor malfunction

33 Unit B liquid pipe temperature sensor malfunction

34 Unit B gas pipe temperature sensor malfunction

35 Unit C liquid pipe temperature sensor malfunction

36 Unit C gas pipe temperature sensor malfunction

37 Unit D liquid pipe temperature sensor malfunction

38 Unit D gas pipe temperature sensor malfunction

39 Unit A mode conflict

40 Unit B mode conflict

41 Unit C mode conflict

42 Unit D mode conflict

LED1 LED2 LED3 LED4

○ ○ ○ ○

● ○

○

○

●

●

●

●

○

●

○

○

○

○

○

○

○

○

○

○

○

○

○

○

○

○

○

●

○

●

○

●

○

○

○

●

●

●

●

●

●

●

●

●

●

●

●

○

●

○

●

○

●

○

○

○

●

●

●

○

○

○

○

○

○

○

○

○

○

○

○

○

○

○

○

○

●

○

●

○

●

○

●

○

●

○

○

○

○

●

●

●

○

○

○

●

●

●

○

○

○

○

○

○

○

○

○

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

○

○

●

●

●

32


43 Communication failure with Unit A

44 Communication failure with Unit B

45 Communication failure with Unit C

46 Communication failure with Unit D

47 Unit A freeze protection

48 Unit B freeze protection

49 Unit C freeze protection

50 Unit D freeze protection

overheating prevention protection overheating prevention protection overheating prevention protection overheating prevention protection

55 Unit A communication wire misconnection or expansion valve malfunction

56 Unit B communication wire misconnection or expansion valve malfunction

57 Unit C communication wire misconnection or expansion valve malfunction

58 Unit D communication wire misconnection or expansion valve malfunction

○

●

○

●

●

○

●

○

●

○

●

○

○

○

●

●

●

○

○

○

●

●

●

●

○

○

○

○

○

●

●

●

●

●

●

●

●

●

●

●

Malfunction Checking and Elimination

NOTE: Discharge power capacities at positions shown below. Voltage should be less than 20v (measured with a meter) prior to initiating service work.

18k 24/30k

(1) IPM protection malfunction:

Main checking point:

S

Is the input voltage of the unit within the acceptable range?

S

Is the compressor connected correctly?

S

Is the compressor winding resistance correct?

S Are the heat exchangers clean / unblocked?

S Is the refrigerant charge correct?

Flow chart:

33


2. if the indoor and outdoor fans are running normally;

Energize the unit

Please check:

1. if the indoor or outdoor heat exchangers are dirty, if there is blockage to affect the airflow;

3. if the system pressure is too high;

4. if the system is overcharged;

Is the compressor wiring connected?

yes

Test the resistance of the compressor windings

Is the resistance is normal?

yes

Check the compressor windings to ground no no yes

If any of these causes exist no

Correct according to the service

manual and then recharge the system

Reconnect the compressor wiring according to the

wiring diagram yes

Is the resistance is above 500M ?

no

Replace the compressor

Malfunction is eliminated no

Replace the outdoor

mainboard yes

End

34


(2) PFC protection malfunction

Main checking points:

● Is the power supply correct?;

● Is the reactor broken or mis-wired?

Flow chart:

Start

;

Verify that the power supply is correct yes

Turn the system on after the power supply error is cleared no

Check if the outdoor reactor is broken or mis-wired

The reactor is broken or mis-wired no

Replace the outdoor mainboard yes

Replace the reactor or correct the wiring no

Malfunction is eliminated yes

End

35


(3) Capacity charging malfunction


● Is the wiring of the reactor connected correctly or is the reactor broken;

● Is the mainboard broken;

Flow chart:

Energize the unit and wait for 1min

Check the capacitor voltage with a voltmeter on the DC scale

Is the voltage above 100V DC no

Check if the reactor wiring is loose or if the reactor is broke yes The detection circuit of the outdoor mainboard has malfunction no yes

Replace the reactor or reconnect the loose wire

Replace the outdoor mainboard

Malfunction is eliminated no yes


End

36


(4) Anti-high temperature and overload malfunction


● Is the outdoor ambient temperature above the operating limit ;

● Is the outdoor fan running normally;

● Are the indoor and outdoor heat exchangers dirty or blocked;

Flow chart:

Start

Is the outdoor ambient temperature above 125°F yes no

Is the indoor or outdoor heat exchanger dirty or blocked yes no

Is the outdoor fan working correctly no yes

Replace outdoor mainboard

The system is not designed to operate above 125°F - this is normal system protection

Correct the heat exchanger problem

Is the outdoor fan motor connected correctly yes

Replace fan capacitor yes

Replace outdoor fan motor

End

37


(5) Temperature sensor malfunction


Is the terminal of the temperature sensor loose or not connected correctly;

Is the mainboard broken ;

Flow chart:

Start

Check whether the wiring connection between the temperature sensor and the outdoor main board is loose or not connected yes no

Check whether the temperature sensor to the resistance table is operating properly yes

Replace the outdoor main board with the same model no

Correct the wiring problem

Eliminate the malfunction yes no

Replace the temperature sensor with the same model no

Eliminate the malfunction yes

End

38


(6) Start failure malfunction


Is the compressor connected properly

Is the stop duration of the compressor is correct

Is the compressor broken

Flow chart:

Energize and

start the unit

The stop duration of the unit is not enough, the high and low pressure of the system have not equalized, restart after 3 minutes.

no

Is the stop duration of the compressor

3 minutes or longer yes

Is the compressor connect correctly yes no

Is the refrigerant charge

amount too great yes

Reclaim and charge the refrigerant according to the Service Manual



Eliminate the malfunction no

Replace the compressor yes

End no

Reconnect the compressor according to the wiring diagram no


39


(7) Communication malfunction


Is the connection wire between the indoor unit and outdoor unit connected correctly at both ends

Is the indoor mainboard or outdoor main board broken

Flow chart:

Communication malfunction of some indoor units

De-energize and make sure all connections at both ends are correct and tight no

Connected correctly yes

De-energize, exchange the signal wire of a bad unit with one from a good unit. Wait 3 minutes for restart.

Reconnect according to the wiring diagram


The bad indoor unit resumes normal function yes

Replace outdoor mainboard no

Replace the mainboard of the bad indoor unit

End

40


All the indoor units show communication malfunction

De-energize, check all signal and power wiring connections

Connected correctly?

yes

De-energize, check the wiring between the outdoor main board and the filter board.

no Reconnect according to the wiring diagram


Connected correctly?

yes

Is the wiring broken?

no

Check power supply to outdoor main board no Reconnect according to the wiring diagram yes

Replace the wire



Is the power supply correct?

yes

Replace the outdoor mainboard no Replace the filter board of

the outdoor unit

Resume communication?

yes

End no Replace indoor

mainboard


41


(8) Compressor overload, diacharge protection malfunction


Is the eletronic expansion valve connected correctly or broken

Is there a refrigerant leak

Is the overload protector broken

Flow chart:

Start

Replace the overload protector no

Is the overload protector connected correctly?

yes

Check the resistance across the overload protector? Is it less than 1k ohms?

yes

Is the electronic expansion valve connected correctly?

no no

Check the coil of the electronic valve, replace it if broken. yes


Check for refrigerant leak, recharge according to the Service Manual after the leak is corrected.


Replace outdoor

mainboard

End

Note: All 5 segments of the electronic expansion coil should measure within 100 ohm.

Reconnect according to the wiring diagram

42


(9) Compressor desynchronizing malfunction


Is the system pressure too high

Is the eletronic expansion valve working correctly or is it broken;

Are the system heat exchangers functioning correctly

Flow chart:

The system starts then stops immediately after being energized

Is stop duration of the compressor

3 minutes or less?

yes

Is the compressor connected correctly?

no yes no

Reconnect the compressor correctly per the wiring diagram


Is the eletronic expansion valve broken?

no

Replace the outdoor main board yes

Replace the elctronic expansion valve


Replace the compressor yes no


End

43


Appendix 1: Resistance Table of Ambient Temperature Sensor for Indoor and Outdoor Units (15K)

6

7

8

3

4

1

2

5

-5

-4

-3

-2

-1

0

TEMP (_C)

-19

-18

-17

-16

-15

-14

-13

-12

-11

-10

-9

-8

-7

-6

15

16

17

18

19

12

13

14

9

10

11

45

46

47

40

41

42

43

44

34

35

36

37

38

39

TEMP (_C)

20

21

22

23

24

25

26

27

28

29

30

31

32

33

54

55

56

57

58

51

52

53

48

49

50

46.6

44.31

42.14

40.09

38.15

36.32

34.58

32.94

31.38

29.9

28.51

27.18

25.92

24.73

23.6

22.53

21.51

20.54

19.63

Resistance(kΩ)

138.1

128.6

121.6

115

108.7

102.9

97.4

92.22

87.35

82.75

78.43

74.35

70.5

66.88

63.46

60.23

57.18

54.31

51.59

49.02

7.967

7.653

7.352

7.065

6.791

6.529

6.278

6.038

5.809

5.589

5.379

5.197

4.986

4.802

4.625

4.456

4.294

4.139

3.99

Resistance(kΩ)

18.75

17.93

17.14

16.39

15.68

15

14.36

13.74

13.16

12.6

12.07

11.57

11.09

10.63

10.2

9.779

9.382

9.003

8.642

8.297

1.933

1.871

1.811

1.754

1.699

1.645

1.594

1.544

1.497

1.451

1.408

1.363

1.322

1.282

1.244

1.207

1.171

1.136

1.103

Resistance(kΩ)

3.848

3.711

3.579

3.454

3.333

3.217

3.105

2.998

2.896

2.797

2.702

2.611

2.523

2.439

2.358

2.28

2.206

2.133

2.064

1.997

84

85

86

79

80

81

82

83

73

74

75

76

77

78

67

68

69

70

71

72

TEMP (_C)

59

60

61

62

63

64

65

66

93

94

95

96

97

90

91

92

87

88

89

0.608

0.592

0.577

0.561

0.547

0.532

0.519

0.505

0.492

0.48

0.467

0.456

0.444

0.433

0.422

0.412

0.401

0.391

0.382

Resistance(kΩ)

1.071

1.039

1.009

0.98

0.952

0.925

0.898

0.873

0.848

0.825

0.802

0.779

0.758

0.737

0.717

0.697

0.678

0.66

0.642

0.625

118

119

120

121

122

123

124

125

112

113

114

115

116

117

TEMP (_C)

98

99

100

101

102

103

104

105

106

107

108

109

110

111

132

133

134

135

136

126

127

128

129

130

131

44


Appendix 2: Resistance Table of Outdoor and Indoor Tube Temperature Sensors (20K)

6

7

8

3

4

1

2

5

-5

-4

-3

-2

-1

0

TEMP (_C)

-19

-18

-17

-16

-15

-14

-13

-12

-11

-10

-9

-8

-7

-6

15

16

17

18

19

12

13

14

9

10

11

45

46

47

40

41

42

43

44

34

35

36

37

38

39

TEMP (_C)

20

21

22

23

24

25

26

27

28

29

30

31

32

33

54

55

56

57

58

51

52

53

48

49

50

62.13

59.08

56.19

53.46

50.87

48.42

46.11

43.92

41.84

39.87

38.01

36.24

34.57

32.98

31.47

30.04

28.68

27.39

26.17

Resistance(kΩ)

181.4

171.4

162.1

153.3

145

137.2

129.9

123

116.5

110.3

104.6

99.13

94

89.17

84.61

80.31

76.24

72.41

68.79

65.37

10.62

10.2

9.803

9.42

9.054

8.705

8.37

8.051

7.745

7.453

7.173

6.905

6.648

6.403

6.167

5.942

5.726

5.519

5.32

Resistance(kΩ)

25.01

23.9

22.85

21.85

20.9

20

19.14

18.13

17.55

16.8

16.1

15.43

14.79

14.18

13.59

13.04

12.51

12

11.52

11.06

84

85

86

79

80

81

82

83

73

74

75

76

77

78

67

68

69

70

71

72

TEMP (_C)

59

60

61

62

63

64

65

66

93

94

95

96

97

90

91

92

87

88

89

2.577

2.495

2.415

2.339

2.265

2.194

2.125

2.059

1.996

1.934

1.875

1.818

1.736

1.71

1.658

1.609

1.561

1.515

1.47

Resistance(kΩ)

5.13

4.948

4.773

4.605

4.443

4.289

4.14

3.998

3.861

3.729

3.603

3.481

3.364

3.252

3.144

3.04

2.94

2.844

2.752

2.663

0.811

0.77

0.769

0.746

0.729

0.71

0.692

0.674

0.658

0.64

0.623

0.607

0.592

0.577

0.563

0.549

0.535

0.521

0.509

Resistance(kΩ)

1.427

1.386

1.346

1.307

1.269

1.233

1.198

1.164

1.131

1.099

1.069

1.039

1.01

0.983

0.956

0.93

0.904

0.88

0.856

0.833

118

119

120

121

122

123

124

125

112

113

114

115

116

117

TEMP (_C)

98

99

100

101

102

103

104

105

106

107

108

109

110

111

132

133

134

135

136

126

127

128

129

130

131

45


Appendix 3: Resistance Table for Outdoor Discharge Temperature Sensor (50K)

-4

-3

-2

-9

-8

-7

-6

-5

-15

-14

-13

-12

-11

-10

TEMP (_C)

-29

-28

-27

-26

-25

-24

-23

-22

-21

-20

-19

-18

-17

-16

5

6

7

8

9

2

3

4

-1

0

1

35

36

37

30

31

32

33

34

24

25

26

27

28

29

TEMP (_C)

10

11

12

13

14

15

16

17

18

19

20

21

22

23

44

45

46

47

48

41

42

43

38

39

40

259.3

245.6

232.6

220.5

209

198.3

199.1

178.5

169.5

161

153

145.4

138.3

131.5

125.1

119.1

113.4

108

102.8

Resistance(kΩ)

853.5

799.8

750

703.8

660.8

620.8

580.6

548.9

516.6

486.5

458.3

432

407.4

384.5

362.9

342.8

323.9

306.2

289.6

274

39.61

37.96

36.38

34.88

33.45

32.09

30.79

29.54

28.36

27.23

26.15

25.11

24.13

23.19

22.29

21.43

20.6

19.81

19.06

Resistance(kΩ)

98

93.42

89.07

84.95

81.05

77.35

73.83

70.5

67.34

64.33

61.48

58.77

56.19

53.74

51.41

49.19

47.08

45.07

43.16

41.34

74

75

76

69

70

71

72

73

63

64

65

66

67

68

TEMP (_C)

49

50

51

52

53

54

55

56

57

58

59

60

61

62

83

84

85

86

87

80

81

82

77

78

79

NOTE: The information above is for reference only.

6.76

6.54

6.33

6.13

5.93

5.75

8.85

8.56

8.27

7.99

7.73

7.47

7.22

7.00

5.57

5.39

5.22

5.06

4.90

Resistance(kΩ)

18.34

17.65

16.99

16.36

15.75

15.17

14.62

14.09

13.58

13.09

12.62

12.17

11.74

11.32

10.93

10.54

10.18

9.83

9.49

9.17

2.12

2.07

2.02

1.96

1.91

1.86

2.64

2.57

2.50

2.43

2.37

2.30

2.24

2.18

1.82

1.77

1.73

1.68

1.64

Resistance(kΩ)

4.75

4.61

4.47

4.33

4.20

4.08

3.96

3.84

3.13

3.04

2.96

2.87

2.79

2.72

3.73

3.62

3.51

3.41

3.32

3.22

108

109

110

111

112

113

114

115

102

103

104

105

106

107

TEMP (_C)

88

89

90

91

92

93

94

95

96

97

98

99

100

101

122

123

124

125

126

116

117

118

119

120

121

46

REMOVAL PROCEDURE OF OUTDOOR UNIT -- 18K

Steps Procedure

1. Remove top cover and wiring cover

1 Before disassembly

2 Remove screws retaining the wiring cover, lift the cover upward to remove it.

Wiring Cover

Top Panel

3 Remove screws retaining the top cover, lift the top cover upward to remove it.

47

Steps

2.Remove front grille and front panel

1

Procedure

Remove the screws retaining the front grille to the front panel. Remove the front grille.

Front grille

2 Remove the screws retaining the panel, lift it upward to loosen the clasp on the right side, rotate it to the left and then remove the front panel.

3.Remove right and left side panels

1 Remove the screws retaining the right side panel to the chassis, the valve support and the electric box, then remove the right side panel.

Front panel

2 Remove the screws retaining the left side panel to the chassis, then remove the left side panel.

Left Side Panel

Right Side

Panel

48

Steps

4.Remove the fan blade

Procedure

1 Remove the nut retaining the blade to the motor shaft, then remove the fan blade.

Fan Blade

2 Remove the four (4) screws retaining the motor; disconnect the motor wiring, then remove the motor.

Remove the two (2) screws retaining the motor support; then lift the motor support upwards to remove it.

Fan Motor

Support

5.Remove control box assembly

Remove the screws retaining the control box sub-assembly; loosen the wire bundle; remove the wiring terminals and then lift the control box upwards to remove it.

Fan Motor

Control Box

49

Steps

6. Remove sound shield

Carefully remove the sound shield from around the compressor.

Procedure

7. Remove reactor

Remove screws holding the reactor to the compressor partition; then remove the reactor.

8. Remove 4-way valve

Reclaim system refrigerant charge.

Cut all lines connected to 4-way valve; disconnect solenoid coil wiring and remove

4-way valve from unit.

Sound Shield

Reactor

4-Way

Valve

50

Steps Procedure

9. Remove electronic expansion valves and shut-off valves

Remove the solenoid coils from the electronic expansion vlaves. Cut all lines connecting the valves to the system and remove the valves.

Electronic Expansion Valves

Shut-off Valves

10. Remove the service valve support assembly

Remove the screws retaining the valve support to the chassis; then remove the valve support assembly.

Service Valve

Support Assembly

11. Remove compressor partition

Remove screws retaining the partition and then remove the partition.

Compressor

Partiition

51

Steps

12. Remove compressor

Procedure

Remove three (3) nuts from compressor mounting bolts, then lift compressor from base pan.

Compressor

13. Remove condenser

1 Remove the screws retaining the support and condenser assembly. Then remove the support.

2 Remove the condenser from the base pan.

Support

Condenser

Base Pan

52

REMOVAL PROCEDURE OF OUTDOOR UNIT -- 24K / 30K

Steps

Procedure

1.Remove wiring connection cover and conduit connection plate

Before disassembly

Remove the screws retaining the wiring connection cover to the right side panel and remove cover.

Wiring

Connection Cover

Remove the screws retaining the conduit connection plate to the right side panel and remove the plate.

Conduit Connection

Plate

53

Steps

8.Remove condenser support

Remove the screws retaining the condenser support to the base pan and remove the condenser support.

Procedure

Condenser

Support

9.Remove fan blade

Remove the nut retaining the fan blade to the fan motor shaft and remove the fan blade.

10.Remove motor and motor support

Disconnect the fan motor wiring and remove the screws retaining the motor. Remove the motor.

Remove the screws retaining the motor support to the base pan and remove the support.

Motor

Fan Blade

Motor Support

54

Steps

11.Remove control box assembly

Disconnect all wiring, remove screws retaining control box to compressor partition and lift control box out of unit.

Procedure

Control Box Assembly

12.Remove reactor

Remove the screws retaining the reactor to the compressor partition and remove the reactor.

13.Remove 4-way valve

Reclaim all refrigerant charg in system.

Cut all line connections to 4-way valve and remove from unit.

Reactor

4-Way Valve

55

Steps

14.Remove suction pipe assembly

Cut the suction pipe at the receiver and the compressor. Remove suction pipe from unit.

Procedure

15.Remove liquid receiver

Remove the screws retaining the liquid receiver to the compressor partition and remove the reciever from the unit.

16.Remove the compressor partition

Remove the screws retaining the compressor partition to the condenser tube sheet and the base pan. Remove partition.

Compressor

Partition

Suction Pipe

Liquid Receiver

Compressor

Tube Sheet

Compressor

Partition

Base Pan

56

Steps

17.Remove compressor

Remove nuts from compressor mounting bolts and lift compressor from base pan.

Procedure

18.Remove service valve support

Remove the screws retaining the service valve support to the base pan and remove the support.

Base Pan

Base Pan

19.Remove electronic expansion valves

Cut all lines to the electronic expansion valves and remove the valves from the service valve support.

Compressor

Service Valve

Support

Service Valve

Support

Electronic

Expansion Valves

57


Procedure Steps

1. Before disassembly

2.Remove top panel

Remove the 3 screws connecting the top panel with the front panel and the right side plate, and then remove the top panel.

3.Remove front side plate

Remove the 1 screw connecting the front sideplate and the panel,and then remove the front side plate.

Front side

plate

Top panel

58

Steps

4.Remove guard grille plate to remove guard grille.

Procedure

Guard grille

5. Remove right side plate

Remove the screws connecting the right side plate with the chassis, the valve support and the electric box, and then remove the right side plate assy .

6. remove the grille

Remove the 4 screws connecting the grille and the

Cabinet, and then remove the grille.

Cabinet

Right side plate

Grille

59

Steps

7.

Remove cabinet

Remove the screws connecting the panel with the chassis,the motor support and Clapboard Assy then remove the cabinet.

Procedure

Cabinet

8.Remove control box assy

Control box assy

Remove the grounding wire screw on the control box assy and then remove the grounding wire.

D i s c o n n e c t t h e w i r i n g t e r m i n a l s o f r e a c t o r, c o m p r e s s o r, h i g h a n d l o w p r e s s u r e s w i t c h , compressor overload protector, temperature sensor, outdoor fan motor and 4-way valve.

Note: keep pressing the circlip when disconnecting the wiring terminal of reactor; keep pressing the retainer when disconnecting other wiring terminals.

Remove the wire inside the wiring groove.

Remove the 2 screws retaining the control box assy and then lift the control box assy upwards to remove it.

9.Remove fan blade, motor, motor support and reactor

Remove the nut retaining the fan blade and then remove the fan blade.

Remove the screws retaining the motor and then remove the motor.

Remove the screws retaining the motor support and then remove the motor support.

Remove the 4 screws connecting the reactor and isolation plate, and then remove the reactor.

Reactor

Motor

Fan Blade

60

Motor Support

Steps

10.Remove 4-way valve

Reclaim all refrigerant charge in system.


Procedure

4-way valve

11.Remove Service Valve Support


Cut all line connections to the service valve support; remove the 2 bolts retaining the liquid valve; remove the service valve support.

12.Remove Connection Pipe Sub-assy

Cut all line connections to the connection pipe sub-assy; then remove connection pipe sub-assy.

Service Valve Support

Connection Pipe

Sub-assy

61

Steps

13.Remove Gas-liquid Separator

Unsolder the spot weld of Gas-liquid Separator, and Remove the screws connecting the Gas-liquid

Separator and Clapboard Sub-Assy, then remove

Gas-liquid Separator

Procedure

14.Remove Clapboard Sub-Assy

Remove the screws connecting Clapboard Sub-

Assy with the chassis, and Condenser Support Plate then remove the cabinet.

Gas-liquid Separator

Clapboard

Condenser

Support Plate

15.Remove left side plate assy

Remove the screws connecting the left side plate and the chassis, then remove the left side plat assy.

Condenser Support Plate left side plate

62

Steps

16.Remove compressor the compressor upwards to remove the compressor.

Note: Keep the ports of discharge pipe and suction pipe from foreign objects.

Procedure

Compressor

17.Remove condenser sub-assy

Remove the screws retaining the condenser sub-assy and chassis, then lift the condenser s u b - a s s y upwards to remove.

Condenser Sub-Assy

18.Remove Compressor Mounting Plate Sub-Assy

Lift the Compressor Mounting Plate Sub-Assy upwards to remove it.

Condenser Support Plate chassis

Compressor Mounting Plate Sub-Assy

63


Procedure Steps

1. Disassemble the cover plate

① Remove the fixed screws on the cover plate by

using a screwdriver.

② Remove the cover plate.

2. Disassemble the front panel

① Remove the fixed screws on the front panel by


② Remove the front panel.

3. Disassemble the panel on the right side

① Remove the fixed screws on the panel by using

a screwdriver.

② Remove the panel on the right side.

64

Steps

4. Dismount the grille

① Remove the fixed screws on the grille by using

a screwdriver.

② Remove the grille.

Procedure

5. Disassemble the outer casing

① Remove the fixed screws on the outer casing by


② Remove the outer casing.

6. Disassemble the fan blades

① Remove the fixed screws on the fan blades by

using a spanner.

② Remove the fan blades.

65

Steps

7 Assemble the disassembled main parts as per the reverse

disassembly order mentioned above

Procedure

Assemble the disassembled main parts as per the reverse disassembly order mentioned above and energize the unit for trial test.

Disassembly and Assembly of Compressor

Remark: Make sure that there is no refrigerant in pipe system and the power supply is cut off before disassembling the compress or.

Procedure Steps

1. Disconnect the power cord

① Remove the fixed screws on the power cord by


② Draw out the power cord;

Note:

Please note the color of each power cord and also the corresponding terminal number when removing the power cord in case of misconnection.

Note the color of each power cord and also the corresponding terminal

2. Disassemble the pipeline connected with compressor

Disconnect the pipeline connected with compressor.

66

Steps

3. Remove the bad compressor

Procedure

① Remove the bolts retaining the compressor.

② Remove the bad compressor from the bottom plate

4. Place the new compressor on the bottom plate and connect the

suction inlet and discharge outlet with the pipe system

① Place the compressor on the bottom plate.

② Tighten the nuts .

Disassembly and Assembly of 4-way Valve

Steps

1. Remove the 4-way valve coil

Procedure

① Remove the screws on the fixed coil by using a screwdriver.

② Remove the 4-way valve coil.

67

Steps

2. Remove 4-way valve



.

Procedure

3. Replace the 4-way valve

① Place the new 4-way valve in the right place.

② Reweld the new 4-way valve with the pipeline.

4. Install the 4-way valve coil

① Replace the 4-way valve coil in place

② Tighten the screws with a screwdriver.

68

Disassembly and Assembly of Electronic Expansion Valve

Steps Procedure

1. Remove the electronic expansion valve coil

Remove the electronic expansion valve coil by rotating it until the lock is unfixed.

2 Remove the electronic expansion valve

Cut all lines to the electronic expansion valves then remove.

3. Replace the electronic expansion valve

Place the new electronic expansion valve in the right place.

4. Reconnect the electronic expansion valve with the pipeline

Reconnect the electronic expansion valve with the pipeline by welding.

5. Install the electronic expansion valve coil

Set the electronic expansion valve coil on the valve body and adjust the lock to the right place.

69

Disassembly and Assembly of Vapor Liquid Separator

Steps

1. Disconnect the liquid separator and the connected pipeline

Procedure

Disconnect the liquid separator and the connected pipeline.

2. Remove the liquid separator

① Remove the bolt retaining the liquid separator

② Remove the liquid separator from the middle baffle.

3. Fix the new liquid separator and connect it with the pipeline

① Place the new liquid separator on the middle baffle

② Tighten the bolt and reconnect the new

liquid separator with the pipeline by welding.

Copyright 2013 Carrier Corp. S 7310 W. Morris St. S Indianapolis, IN 46231 Edition Date: 03/13

Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

70

Catalog No.38---40GVM---1SM

Replaces: New

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