CHUNLAN FRD35-B Service manual

Structure & Features

Air duct Type Air Conditioner

Service Manual

JIANGSU CHUNLAN REFRIGERATING EQUIPMENT Co., Ltd.

AUGUST 2004


Contents

Chapter I Structure & features ........................................................................................... 1

Chapter II Exploded views & dismantling sequence of parts............................................. 4

Chapter III Main technical parameters............................................................................... 34

Chapter IV Performance curve ........................................................................................... 40

Chapter V Circuit diagrams............................................................................................... 41

Chapter VI List of main parts and wear parts..................................................................... 59

Chapter VII Type selection .................................................................................................. 65

Chapter VIII Installation ....................................................................................................... 66

Chapter IX Air duct design & noise reduction ................................................................... 83

Chapter X Method of operation ........................................................................................ 89

Chapter XI Maintenance..................................................................................................... 94

Chapter XII Troubleshooting ............................................................................................... 95

Chapter XIII Typical case analysis...................................................................................... 109 i


Chapter I Structure & features

I. Brief introduction

This air duct type air conditioner is our latest home (commercial) centralized air conditioning product. This product features high efficiency, energy saving, mild and silent operation, computerized intelligent control and healthy fresh air etc. In addition, wire and wireless controls are provided for easy operation. The product can be widely used in large area, multi-room composite compartment/houses, villa, and medium and small restaurants, bars, leisure and recreation sites.

II. Indoor unit

1. Indoor unit of low static pressure series air duct type air conditioner

Mounting hole

Fan

Return air box (optional)

Wire controller

Remote controller

Water outlet

Air exhaust

PTC aux. electric heating

Fresh air port

Return air port

FRD23-B, FRD35-B & FRD50-B indoor unit outline

Mounting hole

Air exhaust

Evaporator

Wire controller

Electric box

Remote controller

FR(D)71-B & FR(D)100-B indoor unit outline

- 1 -


2. Indoor unit of medium static pressure series air duct type air conditioner

Electric box

Wire controller

Remote controller

Air exhaust

Lifting lug mounting position

FR95-C & FR125-C/S indoor unit outline

3. Indoor unit of high static pressure series air duct type air conditioner

Mounting strip

Wire controller

Air exhaust

Electric box

Remote controller

FR(D)95 & FR(D)125/S indoor unit outline

Mounting strip

Wire controller

Air exhaust

Electric box

Remote controller

FR(D)180/S & FR(D)260/S indoor unit outline

- 2 -


III Outdoor units

FRD23-B, FRD35-B, FRD50-B outdoor unit FRD71-B, FR71-B outdoor unit

Air intake

Air exhaust

FR(D)95, FR(D)125/S, FR95-C, FR125-C/S, FR(D)100-B outdoor unit outline

Air intake

Air exhaust

Air exhaust

Air intake

FR(D)180/S outdoor unit outline FR(D)260/S outdoor unit outline

- 3 -

Exploded view & dismantling sequence of parts

Chapter II Exploded views & dismantling sequence of parts

I. Exploded view & dismantling sequence of indoor unit of FRD23-B, FRD35-B and

FRD50-B

1. Exploded view of FRD23-B, FRD35-B and FRD50-B indoor unit

Exploded view of indoor unit of FRD23-B, FRD35-B & FRD50-B

- 4 -


2. Exploded view schedule for FRD23-B, FRD35-B and FRD50-B in door unit

No. Description

4 Right side plate assembly

8 Fan section left side plate assembly

9 Impeller

10 Motor

11 Fan section top plate

13 Spiral casing

Optional

Optional

Optional

Optional

Optional

Remark

- 5 -


3. Dismantling sequence of indoor unit of FRD23-B, FRD35-B and FRD50-B

(1) Remove 18

(2) Remove 17, 19

(3) Remove 12

(4) Remove 11

(5) Remove 16

(6) Remove 14, 8

(7) Remove 9, 13

(8) Remove 10

(9) Remove 15

(10) Remove 7, 6

(11) Remove 20

(12) Remove 21, 4

(13) Remove 5

(14) Remove 3, 1

(15) Remove 2.

Annex: Dismantling sequence of typical parts

Indoor capacitor

(1) Remove 12

(2) Remove capacitor.

Indoors motor:

(1) Remove fan section rear plate 12

(2) Remove fan section top plate 11

(3) Remove spiral casing 13 and impeller 9

(4) Remove connecting plug from control board in electric box

(5) Remove motor 10 and capacitor.

Note: Return air box of FRD23-B, FRD35-B or FRD50-B indoor unit is optional. There are two modes of air return (lower air return and rear air return) and two modes of water discharge (left and right). This exploded view and dismantling sequence is based on lower air return and left water discharge.

- 6 -


II. Exploded view and dismantling sequence for outdoor unit of FRD23-B, FRD35-B &

FRD50-B

1. Exploded view of outdoor unit of FRD23-B, FRD35-B and FRD50-B

Exploded view of outdoor unit of FRD23-B, FRD35-B and FRD50-B

- 7 -


2. Exploded view schedule of outdoor unit of FRD23-B, FRD35-B and FRD50-B

No. Description

2 Small shutoff valve

3 Large shutoff valve

4 Compressor

5 Axial flow fan

6 Motor

7 Reversing valve assembly

Remark

10 Outdoor electric assembly

11 Top cover assembly

12 Capillary assembly

14 Right rear plate

- 8 -


3. Dismantling sequence of outdoor unit of RD23-B, FRD35-B and FRD50-B

(1) Remove 11

(2) Remove 8, 9

(3) Remove 14

(4) Remove 1

(5) Remove 10

(6) Remove 5, 6

(7) Remove 16

(8) Remove 2, 3

(9) Remove 15

(10) Remove 7

(11) Remove 12, 13

(12) Remove 4

(13) Remove 17


Outdoor electric assembly:

(1) Remove top cover assembly 11

(2) Remove handle assembly 9

(3) Remove left rear plate assembly 8

(4) Remove outdoor electric assembly 10.

Outdoors motor:


(2) Remote handle assembly 9

(3) Remove front plate assembly 1

(4) Remove fan 5

(5) Remove connecting plug from motor 6 and remove the motor.

Outdoors compressor


(2) Remove handle assembly 9 and left rear plate assembly 8


(4) Remove large and small shutoff valves 3 and 2, and remove reversing valve 7

(5) Remove compressor cable and the compressor.

- 9 -


III. Exploded view and dismantling sequence of indoor unit of FR(D)71-B and

FR(D)100-B

1. Exploded view of indoor unit of FR(D)71-B and FR(D)100-B

Indoor unit

Exploded view of indoor unit of FR(D)71-B and FR(D)100-B

- 10 -


2. Exploded view schedule of indoor unit of FR(D)71-B and FR(D)100-B

No. Description Remark

2 Top plate assembly

4 PTC electric heater Only for FRD71-B & FRD100-B

5 Spiral casing

6 Impeller

8 Evaporator assembly

10 Bottom plate assembly I

11 Bottom plate assembly II

12 Motor

13 Fan support plate

14 Manger board assembly

15 Right support


17 Right small hole cover plate

18 Electric box assembly

- 11 -


3. Dismantling sequence of indoor unit of FR(D)71-B and FR(D)100-B

(1) Remove 18

(2) Remove 17

(3) Remove 4, 3, 15

(4) Remove 2

(5) Remove 1

(6) Remove 5, 6

(7) Remove 12

(8) Remove 14

(9) Remove 13

(10) Remove 8

(11) Remove 9

(12) Remove 16, 17

(13) Remove 10, 11


Indoor capacitor

(1) Remove 1


Indoors motor:

(1) Remove electric box 18

(2) Remove plug of indoor motor from control board in electric box.

(3) Remove air intake plate 1

(4) Remove top plate assembly 2 with 3, 4 and 15



Note: FR(D)71-B and FR(D)100-B have two air return modes: lower air return and rear air return. This exploded view and dismantling sequence is based on rear air return.

- 12 -


IV. Exploded view and dismantling sequence of outdoor unit of FR(D)71-B

1. FR(D)71-B outdoor unit exploded view

FR(D)71-B outdoor unit exploded view

- 13 -


2. Exploded view schedule for FR(D)71-B outdoor unit

No. Description

2 Axial flow fan

3 Motor

5 Condenser

Remark


10 Right panel assembly

11 Handle


18 Fixing strip

20 Capillary assembly

22 4-way pipe assembly

- 14 -


3. FR(D)71-B outdoor unit dismantling sequence

(1) Remove 7

(2) Remove 11, 13

(3) Remove 1

(4) Remove 10

(5) Remove 8, 6

(6) Remove 18

(7) Remove 2, 3

(8) Remove 4

(9) Remove 12

(10) Remove 14, 15

(11) Remove 16

(12) Remove 9

(13) Remove 20, 21, 22

(14) Remove 19

(15) Remove17





(3) Remove right panel assembly 10, 13

(4) Remove electric assembly 12.

Outdoors motor:



(3) Remove fan 2

(4) Unplug motor 3 and remove the motor.

Outdoors compressor:



(3) Remove right side plate assembly 10

(4) Remove reversing valve assembly 14 and air suction pipe 15

(5) Remove compressor cable and take out the compressor.

- 15 -


V. Exploded view and dismantling sequence of indoor unit of FR95-C, FR125-C/S

1. Exploded view of indoor unit of FR95-C and FR125-C/S

- 16 -


2. Exploded view schedule of indoor unit of FR95-C and FR125-C/S



3 Lifting hook

7 Fixing support assembly

8 Fixing support cover plate assembly

9 Spiral casing assembly

10 Centrifugal impeller

12 Motor

14 Strainer

18 Right support plate

19 Connecting plate assembly


- 17 -


3. Dismantling sequence of indoor unit of FR95-C and FR125-C/S

(1) Remove 1

(2) Remove 11, 14

(3) Remove 2

(4) Remove 4, 3

(5) Remove 21

(6) Remove 9, 10

(7) Remove 12, 13

(8) Remove 8

(9) Remove 7

(10) Remove 22

(11) Remove 19

(12) Remove 20

(13) Remove 5, 18, 17

(14) Remove 15


Indoor capacitor:

(1) Remove 1

(2) Remove 11, 14


Indoors motor:

(1) Remove electric box 4

(2) Remove cover plate 2 and strainer frame 11

(3) Remove plug of indoor motor from control board in electric box

(4) Remove fan mounting plate 21


(6) Remove motor support 13


- 18 -


VI. Exploded view and dismantling sequence of indoor unit of FR(D)95 and FR(D)125/S

1. Exploded view of indoor unit of FR(D)95 and FR(D)125/S

Exploded view of indoor unit of FR(D)95 and FR(D)125/S

- 19 -


2. Exploded view schedule of indoor unit of FR(D)95 and FR(D)125/S

No. Description



8 Fixing block

9 Left small hole cover plate

10 Square hole cover plate assembly

13 Impeller

14 Spiral casing assembly

15 Tapping screw ST4X12

17 Motor

20 Capacitor clip

21 Capacitor


23 Right small hole cover plate assembly

24 Mounting strip

25 Bolt with two washers

26 Retainer

Remark

- 20 -


3. Dismantling sequence of indoor unit of FR(D)95 and FR(D)125/S

(1) Remove 1;

(2) Remove 2;

(3) Remove 8, 4;

(4) Remove 14, 16;

(5) Remove 23;

(6) Remove 7;

(7) Remove 3;

(8) Remove 5;

(9) Remove 22


Indoor capacitor:

(1) Loosen tapping screws on retainer 26, rotate retainer 26;

(2) Remove right small hole cover plate assembly 10;

(3) Remove capacitor clip 20

Indoor motor:

(1) Loosen tapping screws on retainer 26, rotate retainer 26;

(2) Remove left and right small square hole cover plate assemblies 10 respectively;

(3) Remove left air intake 11, remove impeller 13;

(4) Remove plugs of motor 17 and capacitor 21 from control board;

(5) Remove connecting bolt between motor fixing block 19 and fan spiral casing 14;

(6) Remove motor.

- 21 -


VII. Exploded view and dismantling sequence of auxiliary electric heating box of FRD95 and FRD125/S

Exploded view of auxiliary electric heating box of FRD95 and FRD125/S

Exploded view schedule of auxiliary electric heating box of FRD95 and FRD125/S


3 Left side plate assembly

4 Bottom plate assembly II

5 Bottom plate assembly I

6 PTC electric heater


Dismantling sequence of aux. electric heating box PTC of FRD95 and FRD125/S

(1) Remove electric box cover 8 and remove PTC electric heating wire

(2) Remove bottom plate assembly I (part 5)

(3) Remove side frame assembly 3

(4) Remove PTC electric heating wire

- 22 -


VIII. Exploded view and dismantling sequence of outdoor unit of FR(D)95, FR(D)125/S,

FR(D)100-B, FR95-C and FR125-C/S

1. Exploded view of outdoor unit of FR(D)95, FR(D)125/S, FR(D)100-B, FR95-C &

FR125-C/S

Exploded view of outdoor unit of FR(D)95, FR(D)100-B, FR(D)125/S, FR95-C,

FR125-C/S (example of FR(D)95)

- 23 -


2. Exploded view schedule of outdoor unit of FR(D)95, FR(D)125/S, FR(D)100-B, FR95-C &

FR125-C/S



2 Air intake mesh assembly

5 Condenser

11 Spring washer 5

12 Motor

14 Axial flow fan

16 Handle


24 Compressor junction box cover

25

Dg13(FR(D)95, FR95-C, FR(D)100-B), Dg16 (FR(D)125/S,

FR125-C/S)

26 Compressor

- 24 -


3. Dismantling sequence of outdoor unit of FR(D)95, FR(D)125/S, FR(D)100-B, FR95-C、&

FR125-C/S

(1) Remove 1;

(2) Remove 2;

(3) Remove 3 and 4 respectively;

(4) Remove 15;


(6) Remove 17;

(7) Remove 5 and 18 respectively

(8) Remove 20 and 26.



(1) Remove top cover 1;

(2) Remove right panel assembly 4;

(3) Remove cover plate on electric assembly 17.

Outdoor motor:

(1) Remove top cover assembly 1;

(2) Remove left panel assembly 3 and right panel assembly 4 respectively;

(3) Remove front panel assembly 15;

(4) Remove fan 14;

(5) Unplug motor 12 and remove motor.

Outdoor compressor:



(3) Remove electric assembly 17;

(4) Remove reversing valve assembly 20;

(5) Remove compressor.

- 25 -


IX. Exploded view and dismantling sequence of indoor unit of FR(D)180/S and

FR(D)260/S

1. Exploded view of indoor unit of FR(D)180/S and FR(D)260/S

Exploded view of indoor unit of FR(D)180/S and FR(D)260/S

- 26 -


2. Exploded view schedule of indoor unit of FR(D)180/S and FR(D)260/S



5 Water tray assembly

6 Strainer retaining strip

7 Left side plate assembly

9 Left small hole cover plate

10 Square hole cover plate assembly

12 Bottom plate assembly

13 Impeller

15

17 Motor

19

Tapping screw ST4X12

Motor fixing block

21 Capacitor


23 Right small hole cover plate assembly

25 Bolt with two washers

26 Retainer

- 27 -


3. Dismantling sequence of indoor unit of FR(D)180/S and FR(D)260/S

(1) Remove 1;

(2) Remove 2;

(3) Remove 8, 4;

(4) Remove 14, 16

(5) Remove 23;

(6) Remove 7;

(7) Remove 3;

(8) Remove 5;

(9) Remove 22.


Indoors right motor capacitor (seen from air exhaust):

(1) Loosen tapping screw on retainer 26, rotate retainer 26;

(2) Remove right small hole cover plate assembly 10

(3) Remove capacitor clip 20.

Indoors left motor capacitor (seen from air exhaust):

(1) Remove 1;

(2) Remove capacitor clip 20.

Indoor motor:

(1) Remove 1;

(2) Remove 14;

(3) Same method as for motor removal for FR(D)95 and FR(D)125/S.

Note: FRD180/S auxiliary electric heating box outline is the same as FRD95 auxiliary electric heating box; two such boxes are provided. FRD260/S auxiliary electric heating box outline is the same as FRD125/S auxiliary electric heating box; two such boxes are provided. Method of dismantling is the same as for FRD95 and FRD125/S auxiliary electric heating box.

- 28 -


X. Exploded view and dismantling sequence of outdoor unit of FR(D)180/S

1. FR(D)180/S outdoor unit exploded view

FR(D)180/S outdoor unit exploded view

- 29 -


2. FR(D)180/S outdoor unit exploded view schedule



2 Air intake mesh assembly

3 Left panel assembly

5 Condenser

11 Spring washer 5

12 Motor

14 Axial flow fan

16 Handle


25 Compressor junction box cover

27 Compressor

- 30 -


3. FR(D)180/S outdoor unit dismantling sequence

(1) Remove 1;

(2) Remove 2;


(4) Remove 15;




(8) Remove 20 and 27.


A. Outdoor electric assembly

(1) Remove top cover 1;


(3) Remove cover plate 18 on electric assembly 17.

B. 室外电机


(2) Remove left panel assembly 3 and right panel assembly 4 respectively;

(3) Remove front panel assembly 15;

(4) Remove fan 14;

(5) Unplug motor 12 and remove the motor.

C. Outdoor compressor



(3) Remove electric assembly 17;

(4) Remove reversing valve assembly 20;

(5) Remove compressor.

- 31 -


XI. FR(D)260/S outdoor unit exploded view and dismantling sequence

1. FR(D)260/S outdoor unit exploded view and dismantling sequence

FR(D)260/S outdoor unit exploded view

- 32 -


2. FR(D)260/S outdoor unit schedule

No. Description QTY No. Description QTY

1

3 Tapping screw

1

5 Left air intake assembly 1

6 Left air exhaust pipe ASSY 1

1

8 HP valve assembly

9 LP valve assembly

1

1

10 Bolt M8×30

11 Washer 8

12 Spring washer

13 Nut

8

8

12

12

14 Air hood assembly

15 Axial flow fan

16 Motor 2

1

2

2

18 Support assembly 1

1

20 Support strip assembly 1

3. FR(D)260/S outdoor unit dismantling sequence

(1) Remove 14, 1 and 39;

21 Support plate assembly


23 One-way valve assembly

24 ------

25 Air pipe assembly

26 Electric heating band

27 Right condenser

28 Right air intake pipe assembly

29 Right air exhaust pipe assembly 1

1

1

1

2

30 Connector assembly


1

1

1

--

1

1

32

36

37

38

39

40

Air/water separator

33 Compressor

34

Bolt M8×50

35 Washer 8

Liner

Damper

Chassis

Enclosing plate

Fixing plate

1

1

4

4

1

4

4

1

1

(2) Remove 2, 31, 21, 20, 19;

(3) Remove fan assembly (15, 16, 17);

(4) Remove 4, 27, 18, 8;

(5) Remove 10, 22, 23, 25;

(6) Remove 33, 32 respectively.

- 33 -

Main technical parameters

Chapter III Main technical parameters

I. Main technical parameters of FRD23-B, FRD35-B and FRD50-B

Model FRD23－B FRD35－B FRD50－B

Rated cooling capacity

W

Rated heating capacity

W

Power supply

2300 3500 5000

2300(850) 3500(1200) 5000(1500)

220V～50Hz

Rated input Cooling W/A 890/4.1 1340/6.2 1950/8.9

Power/Curr Heating W/A

790(850)/3.6(4.0) 1320(1200)/6.0(5.5) 1850(1500)/8.4(6.8)

Air flow (indoor unit) m

3

/h 420 600 800

Static exhaust air pressure Pa

Indoor unit kg

Mass

Outdoor unit kg

24

28

20

25.5

35

28

52

Noise

Indoor unit dB(A)

Outdoor unit dB(A)

≤

38

≤

50

R22/0.71

≤

44

≤

52

R22/1.24

≤

48

≤

56

R22/1.6 Refrigerant kg

Connecting pipe size

Liquid pipe mm

Air pipe mm ф

10 ф

6 ф

12

Air exhaust size mm

Return air port size mm

Fresh air port size mm

128×722 128×922

170×680 170×880

100×100

Outline Indoor unit mm

L×W×H Outdoor unit mm

Notes: 1. Experimental conditions:

888×466×234 1088×466×234

650×250×551 800×252×646

(1) Length of connecting pipe for test: 5m;

(2) Refrigeration conditions (normal): indoor dry bulb 27℃, wet bulb 19℃; Outdoor dry bulb

35℃, wet bulb 24℃;

(3) Heating conditions (normal): indoor dry bulb 20℃, wet bulb 15℃; outdoor dry bulb 7℃, wet bulb 6℃;

(4) Static pressure is 20Pa

2. Operating environment (T):

- 34 -


Cooling: 15℃＜T＜32℃ (indoor) Heating: 12℃＜T＜27℃ (indoor)

18℃＜T＜43℃ (outdoor) -7℃＜T＜24℃ (outdoor)

3. Value in “( )” is nominal value of auxiliary electric heating;

4. Return air port size based on optional return air box size.

II. Main technical parameters for FR(D)71-B and FR(D)100-B

Rated cooling capacity

Rated heating capacity 7500W

7100W

7500（2300）W 10500W

10000W

10500（2300）

W

Power supply 220V～50Hz

Rated input power

Cooling 2760W

Heating 2420W

3900W

3100W

Rated input current

Cooling 13.4A

Heating

Air circulation flow

11.8 A 11.8(10.5) A 14.2 A

17.8A

14.2(10.5) A

1500 m

3

/h 2000

30Pa Air exhaust static pressure

Indoor unit noise

Outdoor unit noise

54dB(A)

60 dB(A)

56dB(A)

62dB(A)

Indoor unit

Mass

Outdoor unit

Filling of refrigerant

Conn. pipe size (user)

Liquid pipe

Steam pipe

44 Kg

78 Kg

46 Kg

R22/2.7 Kg

60 Kg

Liquid pipe φ10×1

85 Kg

62 Kg

R22/3.3 Kg

Outline Ind. unit mm

W×D×H

Outd Unit mm

1260×555×226 mm

950×370×746 mm

Notes:

(1) Length of connecting pipe for test: 7.5m

(2) Operating environment (T):

Cooling: 15℃＜T＜32℃ (indoor)

Steam pipe φ16×1

1880×555×226 mm

950×420×853 mm

18℃＜T＜43℃ (outdoor)

Heating: 12℃＜T＜27℃ (indoor)

-7℃＜T＜24℃ (outdoor)

- 35 -

(3) Value in “( )” is nominal value for auxiliary electric heating.


- 36 -


III. Main technical parameters of FR95-C and FR125-C/S

Cooling capacity

Heating capacity

Power supply

9500W

11000W

12500W

15000W

Rated input power

Cooling 3700W

Heating 3500W

4600W

4200W

Cooling 18.1A 8.1A

Rated input current

Heating 17.2A

Air circulation (indoor unit)

7.4A

2000m

3

/h 2200m

3

/h

Exhaust air static pressure 50Pa

Indoor unit noise 52dB(A)

Outdoor unit noise

R22 filling amount

62dB(A)

50Pa

54dB (A)

64dB(A)

2.95Kg 3.2Kg

Climate type

Remote control

Mass

Indoor unit

Outdoor unit

47Kg

85Kg

T1

Yes

52Kg

95Kg

Size of ID/OD connecting pipe (user supplied)

Connecting nut

Outline Indoor unit mm

W×D×H

Outdoor unit

LP M16×1.5m SP M22×1.5

1150×750×285mm

950×360×853mm

Notes:







LP M16×1.5 SP M27×2

1150×750×285mm

950×360×853mm

- 37 -


IV. Main technical parameters of FR(D)95 and FR(D)125/S

Cooling capacity

Heating capacity

Power supply

11000W

9500W

11000(3000)W

12500W

15000W 15000(4500)W

Rated input power

Cooling 3950W 4900W

Heating 3500W 3500(3000)W 4500W 4500(4500)W

Cooling 18.2A 8.6A

Rated input current

Heating 16A 16(13.7A) 8A 8(6.9A)

Air circulation (indoor unit) 1900m

3

/h 2700m

3

/h

Exhaust air static pressure 76Pa 127Pa

Indoor unit noise 61dB(A) 64dB(A)

Outdoor unit noise

R22 filling amount

62dB(A) 64dB(A)

2.95Kg 3.2Kg

Climate type

Remote control

Mass

Indoor unit

Outdoor unit

35Kg

85Kg

T1

Yes

43Kg

95Kg

Size of ID/OD connecting pipe

(user supplied)

Connecting nut LP M16×1.5 SP M22×1.5 LP M16×1.5 SP M27×2

Outline Indoor unit mm 655×618×400mm 865×618×400mm

W×D×H

Outdoor unit 950×360×853mm

Notes:



Cooling: 15℃＜T＜32℃ (indoor )




(3) Value in “( )” is nominal value for auxiliary electric heating.

950×360×853mm

- 38 -


V. Main technical parameters of FR(D)180/S and FR(D)260/S

Cooling capacity 18000W 26000W

Power supply

Operating voltage range

380V 3N～50Hz

380V 3N-50Hz

342-418V

11000W power

18.9A current

Heating 11A 11(9)A

Air circulation (indoor U)

16.4A 16.4(13.6)A

3700m

3

/h 4600m

3

/h

Exhaust air static pressure 76Pa

Indoor unit noise 63dB(A)

127Pa

66dB(A)

Outdoor unit noise

R22 filling amount

Climate type

Remote control

65dB(A)

5.8Kg

T1

Yes

68dB(A)

11.5Kg

Mass

Indoor unit

Outdoor unit

Size of ID/OD connecting pipe (user supplied)

Connecting nut

Outline Ind. unit mm

W×D×H OD unit mm

65Kg

46

150Kg

LP M18×1 SP M30×2

1309×618×400mm

950×392×1160mm

85Kg

62

190Kg

LP M22×1.5 SP M36×2

1800×618×400mm

1450×750×964mm

Notes:







(3) Value in “( )” is nominal value for auxiliary electric heating

- 39 -

Performance curve

Chapter IV Performance curve

I. Air flow static pressure performance curve

1. Air flow static pressure performance curve for FR(D)71-B, FR(D)100-B, FR(D)95 and

FR(D)125/S

Air flow

2. Air flow static pressure performance curve of FR(D)180/S and FR(D)260/S

Air flow

- 40 -

I. Circuit diagrams

Chapter V Circuit diagrams

- 41 -

Circuit diagrams

- 42 -

Circuit diagrams

Circuit diagrams

- 43 -

Circuit diagrams

- 44 -

Circuit diagrams

- 45 -

Circuit diagrams

- 46 -

Circuit diagrams

- 47 -

Circuit diagrams

- 48 -

Circuit diagrams

- 49 -

Circuit diagrams

- 50 -

Circuit diagrams

- 51 -

Circuit diagrams

- 52 -

Circuit diagrams

- 53 -

Circuit diagrams

- 54 -

Circuit diagrams

II. Numbers and meanings of each signal line & terminal

1. Signal line terminals for FRD23-B and FRD35-B

(1) Brown Compressor

(2) Blue Power supply line N

(3) Yellow/green Earthing line

(4) Black Outdoor motor

(5) White Reversing valve coil

2. FRD50-B signal line terminals

(1) Brow Compressor

(2) Blue Power supply line N

(3) Yellow/green Earthing line

(4) Black Outdoor motor

(5) Red Reversing valve coil

3. FR71-B signal line terminals

(1) Black Outdoor fan motor

(2) Purple Outdoor fan motor

(3) Red Outdoor fan motor

(4) Gray Reversing valve coil

(5) White Compressor AC contactor coil

L: Phase line feedline of power cable (user supplied)

N: Zero line feedline of power cable (user supplied)

L’: Phase line of indoor-outdoor connecting cable of power connecting cable (user supplied)

N’: Zero line of indoor-outdoor connecting cable of power connecting cable (user supplied)


(1) Indoor-outdoor connecting cable (user supplied) for outdoor fan motor

(2) Indoor-outdoor connecting cable (user supplied) for outdoor fan motor

(3) Indoor-outdoor connecting cable (user supplied) for reversing valve coil

(4) Indoor-outdoor connecting cable (user supplied) for compressor AC contactor coil

L: Indoor-outdoor connecting cable (user supplied) power supply phase line

N: Indoor-outdoor connecting cable (user supplied) power supply zero line

- 55 -

Circuit diagrams

5. FR100-B signal line terminals

(1) Black Outdoors fan motor high speed

(2) Purple Outdoors fan motor medium speed

(3) Red Outdoors fan motor low speed

(4) Gray Reversing valve coil

(5) White Compressor AC contactor coil

L: Power supply connecting cable (user supplied) power phase line feedline

N: Power supply connecting cable (user supplied) power zero line feedline

L’: Power supply connecting cable (user supplied) indoor-outdoor connecting line power phase line

N’: Power supply connecting cable (user supplied) indoor-outdoor connecting line power zero line


(1) Indoor-outdoor connecting cable (user supplied) outdoor fan motor high speed

(2) Indoor-outdoor connecting cable (user supplied) outdoor fan motor medium speed

(3) Indoor-outdoor connecting cable (user supplied) reversing valve coil

(4) Indoor-outdoor connecting cable (user supplied) compressor AC contactor coil

L: Indoor-outdoor connecting cable (user supplied) power phase line

N: Indoor-outdoor connecting cable (user supplied) power zero line

7. FR95 signal line terminals

(1) Outdoor fan motor (high speed)

(2) Power supply phase line

(3) Reversing valve coil

(4) Outdoor fan motor (medium speed)

(5) Outdoor fan motor (low speed)

(6) Power supply zero line

(7) Compressor AC contactor coil

8. FR95-C and FRD95 signal line terminals





- 56 -

L: Power supply phase line

N: Power supply zero line

9. FR125/S signal line terminals


(2) 3-phase power supply phase A



(5) Outdoor fan motor (low speed)

(6) Power supply zero line


(8) 3-phase power supply phase B

(9) 3-phase power supply phase C

10. FR125-C/S and FRD125/S signal line terminals





N: Power supply zero line

L1: 3-phase power supply phase A

L2: 3-phase power supply phase B

L3: 3-phase power supply phase C

11. FR(D)180/S and FR(D)260/S signal line/terminal numbers and meanings

A. 6-core wire

(1) Red Compressor small relay coil

(2) Gray Reversing valve small relay coil

(3) Purple Small relay coil of outdoor fan 1

(4) Orange Small relay coil of outdoor fan 2

(5) Brown DC+12V

(6) White GND

B. 7-core wire

(1) Red DC+5V

- 57 -

Circuit diagrams

(2) Gray Outdoors tube temperature sensor

(3) Purple HP pressure controller

(4) Orange LP pressure controller

(5) Black Phase sequence 1

(6) White Phase sequence 2

(7) Brown Overcurrent

Circuit diagrams

- 58 -

List of main parts & wear parts

Chapter VI List of main parts and wear parts

1. List of main parts and wear parts for FRD23-B, FRD35-B and FRD50-B

Size/Model

Symbol Description

FRD23-B FRD35-B FRD50-B

PCB1

Main control board

PCB2 Wire Ctrlr

PCB3 Remote Ctrlr

RT2 ID PT sensor

RT3 OD PT sensor

C1 Capacitor

C

Composite capacitor

FRD35(23)-B FRD50-B

LCD

Normal

RF10A/FG.000.05 (model 3324)

053324

RF10A/FG.000.05 (model 3324)

RF10W/FG.000.00JL-01WX (model 3324)

CBB61A 0.6μF/AC

CBB61A 1.5μF/AC 450V CBB61A 2.5μF/AC 450V

450V

FRD23W.110.01

(25/1.5μF AC 450V)

FRD35W.110.02

(30/1.5μF AC 450V)

FRD50W.020.07

(50/2.5μF AC 450V)

RF10W/FG.000.01

OD PT probe wire

MC Compressor

FRD35-D.000.01

YZG-25RT1 YZG-39RCT1

FRD35W.100.00WX

SHX33SC4-U

FRD50W.080.01WX

Axial flow fan FRD35W.000.01WX FRD50W.000.05 fan

Impeller

FRD23N.021.00WX FRD35N.041.00WX

FRD23N.070.05WX

FRD50N.041.00WX

FR100N.070.04WX

T Transformer

EH PTC El heater

FRD35W.110.03

FRD35W.110.03

FRD35N.070.03

Z371

MZFR 850W

STF-0202 DHF-3D(STF-0202)

FRD35N.080.00 FRD50N.080.00WX

139℃ 15A

JQX-116F-2/220AL-2HS

139℃ 15A

KSD-A 125℃ 10A KSD-A 125℃ 10A

139℃ 15A

KSD-A 125℃ 10A

Liquid FRD50W.040.04WX

FRD50W.063.01WX

- 59 -


2. List of main parts and wear parts of FR(D)71-B and FR(D)100-B

Size/Model

Symbol Description

FR(D)71-B FR(D)100-B

C1 Capacitor

C1’ Capacitor

C3, C3’ Composite capacitor

------

------

------

3324

3324

3324

2.5μF/AC 450V

3μF/AC 450V

35/3μF/AC 450V

100μF/AC 450V

------

------

------

3324

3324

3324

Indoor fan capacitance C1, C1’, 3μ

F/AC 450V

------

Startup capacitance 60μF/AC 450V

Parallel capacitance 50μF/AC 450V

C2 Capacitor

M2 Compressor

M, M’ Indoor fan motor

KM AC contactor

YK-3.1/2.25 ------

YDK

5

120/30-6 YDK

1

120/45-6

------

Startup capacitance 6μF/AC 450V

Q2.2 ZR47K3-PFJ

YDK110/30-4

5A

2A

3TF34

40W

YDK

5

110/30-4

10A

------

STF-0408

3TF3100 (single phase)

------

3. List of special main parts & wear parts of FRD71-B & FRD100-B aux. electric heating

Size/Model

Symbol Description

FRD71-B FRD100-B

FT

1,2,3

KT

1,2,3

Auto-reset thermal protector

EH

1,2,3

PTC heater

XT1 Wiring terminal

------

139℃ 15A

KSD-A135℃ 10A

------

139℃ 15A

KSD-A135℃ 10A

MZFR 2.3KW

JXO-AB(600V 60A)

MZFR 2.3KW

JXO-AB(600V 60A)

------ ------

-----------

JQX-116F-L/220AL-2HS JQX-116F-L/220AL-2HS

- 60 -


4. List of main parts & wear parts of FR95-C and FR125/S-C

Size/Model

Symbol Description

FR95-C FR125-C/S

C1 Capacitor

C2 Capacitor

C3 Capacitor

C4 Capacitor

------

------

------

3324

3324

3324

CBB61A 5μF/AC 450V

------

------

------

3324

3324

3324

CBB61A 8μF/AC 450V

CBB611A 8μF/AC 450V

Communication

OD pipe temp probe line

M2 Compressor



CBB65A-1K 50μF/AC450V

RF10AW/FG.000.01

RF10AW/FG.000.02

------

------

RF10AW/FG.000.01

RF10AW/FG.000.02

YDK

3

120/45-6 YDK

2

120/45-6

ZR47K3-PFJ ZR61KC-TFD

T Transformer

FU Fuse

KM AC contactor

Valve

Valve

Axial flow fan

Impeller

YSK139/35-6

Z371

10A

B30-10-10(220V) or 3TF3100

YSK139/35-4

Z371

10A

STF-0408

EB16-30-00(230V)

(220V)3TF3100

Dg8 Dg8

Dg13 Dg16

RF10W/FG.000.04WX RF10W/FG.000.04WX

FR95-CN.062.00 FR95-CN.062.00

- 61 -


5. List of main parts/wear parts of FR(D)95 and FR(D)125/S

Size/Model

Symbol Description

FR（D）95 FR（D）125/S

------

------

------

------

RT1 Temperature sensor 3324


------

3324

3324


C1 Capacitor

CBB60F 10μF/AC 450V

C2 Capacitor


C3 Capacitor

C4 Capacitor

3324

CBB65A-1 15μF/AC 450V



------

CBB65A-1K 50μF/AC450V

------

Communication RF10AW/FG.000.01

OD RF10AW/FG.000.02

motor YDK

3

120/45-6

M2 Compressor ZR47K3-PFJ

RF10AW/FG.000.01

RF10AW/FG.000.02

YDK

2

120/45-6

ZR61KC-TFD

XT1 Wiring terminal seat



YV Reversing solenoid valve

Valve

Valve

Axial flow fan

JXW-2P

JXW-05

JXO-07

T Transformer Z371

FU Fuse 10A

STF-0408

Dg8

Dg13

RF10W/FG.000.04WX

Impeller RF10A/FG.062.00

YDK128/45-4

JXW-4P

JXW-05

JXO-09

Z371

10A

STF-0408

EB16-30-00(230V)

Dg8

Dg16

RF10W/FG.000.04WX

RF12A/FG.032.00

- 62 -


6. List of special main parts/wear parts for FRD95 & FRD125/S aux. electric heating

Size/Model

Symbol Description

FRD95 FRD125/S

FT

1,2,3(4,5,6) fuse

KT

1,2,3(4,5,6)


EH

1,2,3(4,5,6)

PTC heater

XT1 Wiring terminal

------

153℃ 10A

KSD-A135℃ 10A

MZFR 1.5KW

JXO-AB(600V 60A)

------

JXW-Z

11

-02

------

------

153℃ 10A

KSD-A135℃ 10A

MZFR 1.5KW

JXO-AB(600V 60A)

------

JXW-Z

11

-03

3TF3000

JQX-116F-Z/220AL-2HS

7. List of main parts/wear parts of FR180/S and FR260/S

Size/Model

Symbol Description

FR(D)180/S FR(D)260/S control ------

------

PCB3 Remote ------

C1, C2 Capacitor

C, C’ Capacitor


CBB60F 10μF/AC 450V

------

------

------

3324

3324

3324



M3, M4 Outdoor fan motor

M2 Compressor

M, M’

XT1

XT2

XT3

Indoor fan motor

Wiring terminal seat



YDK

5(6)

120/45-6 YDK145/60-8

ZR81KC-TFD-522 ZR125KC-TFD-522

YDK

2(3)

128/35-4 YDK

2,3

128/35-4

JXW-2P JXW-2P

JXW-05

JXO-AB 600V 60A

- 63 -

JXW-05

PBT660VAC 6mm

2

(4-place)


Symbol Description

T Transformer

FU Fuse

FU3 Fuse

Size/Model

FR(D)180/S FR(D)260/S

Z371

10A

------

10A

------

STF-0714

Valve

Valve

Axial flow fan

3TF34

Dg10

Dg19

RF180W/S.000.01WX

3TF34

------

------

------

Impeller RF10A/FG.062.00 ------

8. List of special main parts/wear parts for FRD180/S & FRD260/S aux. electric heating

Size/Model

Symbol Description

FRD180/s FRD260/S

FT

1,2,3,4,5,6 fuse

KT

1,2,3,4,5,6


EH

1,2,3,4,5,6

PTC heater

XT1 Wiring terminal

------

153℃ 10A

KSD-A135℃ 10A

MZFR 1KW

JXO-AB(600V 60A)

JXW-Z

11

-03

JXW-Z

11

-03

3TF3000

------

153℃ 10A

KSD-A135℃ 10A

MZFR 1.5KW

JXO-AB (600V 60A)

JXW-Z

11

-03

JXW-Z

11

-03

3TF3200

- 64 -

Type selection

Chapter VII Type selection

I. Application scope

Air duct type air conditioners of our company include card type low static pressure series

(FRD23-B, FRD35-B and FRD50-B), low static pressure series (FR(D)71-B and

FR(D)100-B), medium static pressure series (FR95-C and FR125-C/S), and high static pressure series (FR(D)95, FR(D)180/S, FR(D)125/S and FR(D)260/S). These models have similar but different features and applications: card type low static pressure models adopt extra low noise design and are suitable for homes, offices and other small areas; low and medium static pressure air duct air conditioners have low noise and relatively low exhaust air static pressure, hence suitable for houses, villa and other sites with shorter air delivery distance and high noise requirement; high static pressure air duct air conditioners have relatively high exhaust air static pressure and noise, hence suitable for supermarkets, department stores, concert and other sites requiring long air delivery distance and tolerating noise.

※

Dealers and users shall reasonably select low, medium or high static pressure air duct air conditioners according to characteristics of application sites.

※ In case an installer or designer is unaware of the relation between static pressure and noise level, and fails to select proper model, user may think that high static pressure air duct type air conditioner has low noise.

II. Applicable areas of various models of air duct type air conditioners (based on 3m ceiling height)

FR71-B

FR23-B FR35-B FR50-B

FRD71-B

FR100-B

FRD100-B

FR95(-C) FR125(-C)/S

FRD95 FRD125/S

FR180/S FR260/S

FRD180/S FRD260/S

16-25

㎡

25-38

㎡

35-55

㎡

50-60 ㎡ 70-80 ㎡ 70-80 ㎡ 80-100 ㎡

120-140

㎡

170-200

㎡

Notes: ① Office: 90～140W/㎡

②

Restaurant & bar: 200～350W/㎡

③ Shop: 150～250W/㎡ ④ Recreation: 200～350W/㎡

In case careful calculation of air conditioning loads is not carried out according to detailed cooling/heating load calculation method or rough calculation method specified in “Air conditioning design manual” and “Centralized air conditioning” standard etc. in combination with application site information, so that 5HP model is selected where 4HP or even 3HP shall be used, higher noise will occur due to small space and short delivery distance.

Solution:

Carefully calculate cooling/heating loads according to “Air conditioning design manual” and

“Centralized air conditioning” standard etc. and select proper model.

Certain margin shall be left in type selection; otherwise user may complain of bad cooling or heating effect.

In case heating effect must be ensured at low temperature, models with auxiliary electric heating are preferred.

- 65 -

Installation

Chapter VIII Installation

Installation of air duct type air conditioners must be carried out by qualified personnel.

I. Installation schematic

(1) Outdoor unit; (2) Indoor unit;

(3) Air exhaust grating; (4) Air return grating;

(5) Wire controller; (6) Connecting pipeline

Low static pressure air duct air conditioner installation schematic (based on FRD35-B)

(1) Outdoor unit; (2) Indoor unit; (3) Air delivery pipe; (4) Air delivery branch pipe;

(5) Air delivery port; (6) Branch air return port; (7) Air return port; (8) Controller

(9) Connecting pipeline

High static pressure air duct air conditioner installation schematic (based on FR260/S)

① Outdoor unit ② Indoor unit

③ Air delivery pipeline ④ Air delivery port

⑤ Branch air return port ⑥ Air return port

⑦ Wire controller ⑧ Connecting pipeline

Medium static pressure air duct air conditioner installation schematic

- 66 -

Installation

II. Installation of indoor unit

1. Selection of installation position

● At or near application site with stringent requirement on noise, indoor unit shall be installed as far away as possible. When the machine is near rooms with high silencing requirement, sound insulating doors and windows shall be used for air conditioner equipment room (subject to Owner agreement);

● The machine shall be installed in special equipment room, water closet, store room or ancillary room as much as possible;

● Site of installation shall be able to withstand weight of the machine; reinforcing measures shall be taken for mounting floor/beam subject to potential hazard before installation;

● Position of installation shall ensure shortest connecting hose between indoor and outdoor units and length of indoor air duct shall be suitable;

● Sufficient air delivery/return space shall be available to facilitate air delivery/return.

Distance between main unit air return face and wall shall exceed 800mm to ensure no right angle bend of return air;

● Drainage of indoor unit condensate shall be provided;

● Keep the machine away from heat source, inflammables, corrosive gas, strong magnetic field, dust and heavy oily smoke.

2. Indoor unit installation dimensions

Refer to the following figure and table for indoor unit installation dimensions.

FRD23-B, FRD35-B, FRD50-B

Parameter

Model

FRD23-B

FRD35-B

FRD50-B a(mm) b(mm) c(mm) d(mm) e(mm) f(mm) g(mm) h(mm)

252

888 722

128 234

750

190 465

1088 922 950

- 67 -

FR(D)95, FR(D)125/S

FR(D)95 655

400 618

FR(D)125/S 865 330 908

FR(D)71-B, FR(D)100-B

Model

Code a(mm) b(mm) c(mm) d(mm) e(mm)

FR(D)100-B 1820 1780 1850

- 68 -

Installation

Installation

FR95-C, FR125-C/S

FR(D)180/S, FR(D)260/S

Code

A(mm) B(mm) C(mm) D(mm) E(mm) F(mm)

Model

FR(D)180/S 1309

FR(D)260/S 1800

618 400

300 654 1352

330 888 1843

- 69 -

3. Installation mode for indoor unit

(1) Installation mode for FR95-C and FR125-C/S (based on upper return air)

Installation

● Determine positions of lifting hooks

As shown above, ①, ②, ③ and ④ are lifting hook installation positions for FR95-C and

FR125-C/S. Suitable positions can be selected to needs. Just select one out of ② and ③. ⑤ refers to the tapping screw to fix lifting hook on indoor unit.

● Use 4 M10 expansion bolts to fix lifting hook on bearing mounting face.

(2) Installation mode for other models (based on FR180/S and FR260/S)

The following is an ideal installation mode.

Spring dampers (4)

10mm polythene foam

5

×50 angle steels (2)

15mm wood plate

● According to size of machine, use 4 or 6 M10 bolts and associated nuts, flat washers and spring washers to fix installation support on indoor unit mounting strip;

● According to size of machine, use 4 or 6 M10 expansion bolts to fix the installation support on bearing mounting face;

- 70 -

Installation

● A damper block of the same size as the angle steel and thickness greater than 10mm shall be used on top of the angle steel to reduce vibration;

● The machine must have 2% slope in drainage connector direction.

4. Installation of auxiliary electric heating

This is limited to FRD95, FRD125/S, FRD180/S and FRD260/S. For FRD71-B and

FRD100-B, auxiliary electric heater is installed at exhaust air port inside the machine.

(1) Auxiliary electric heater installation dimensions

● Refer to the following figure and table for installation dimensions of FRD95, FRD125/S,

FRD180/S and FRD260/S auxiliary electric heater.

Model

Code a 300 330

(2) Installation of auxiliary electric heater

●

Put the side of auxiliary electric heater with label “Connect this end to indoor unit air exhaust for installation” on indoor unit air exhaust port and fix with 8 ST4×12 tapping screws;

●

Fix the heater on foundation and stick insulation material on its outer surface and interface.

- 71 -

Installation

FR(D)95, FR(D)125/S FR(D)180/S, FR(D)260/S

Notes:

1. 2 aux. electric heaters shall be provided for each FRD180/S or FRD260/S;

2. After installing the heaters, fit insulation material to avoid thermal dissipation and water leakage caused by condensing on outer surfaces.

III. Installation of outdoor unit

1. Selection of installation position

⑴

Installation base on which outdoor unit can be fixed and that can withstand 3 times the weight of this unit shall be selected;

⑵

A location where outdoor unit air intake/exhaust flow will not be interfered shall be selected;

⑶

A location away from direct sunshine, rain and other direct radiating heat source shall be selected. If not, effective sunshade or rain (snow) shelter shall be used and lowest point of such shade/shelter shall not be lower than required in the figure below. Avoid low place where water can accumulate;

⑷

A location where piping of indoor and outdoor units and power cables can be easily arranged to facilitate installation and maintenance shall be selected;

⑸

A location where ventilation is near indoor unit shall be selected and avoid extension of pipeline;

⑹

Avoid inflammables, explosives or leakage of these;

⑺

Avoid corrosive gas, dust, salty mist and other pollutants;

⑻

Refer to the following figure for space required for installation of outdoor unit.

- 72 -

Obstacle or wall

Maintenance space

Installation

Space normally required by installation of outdoor unit (based on FR(D)125/S)

Space required for FR(D)260/S outdoor unit installation

2. Installation of outdoor unit

⑴

To avoid center of gravity offset and protect compressor, never tilt the machine by more than 45 degrees during transportation;

⑵

Use M12 bolts to fix machine chassis. Fixing shall be firm and reliable, and damping measures shall be taken when necessary. Refer to figure below.

- 73 -

Installation

FR(D)95﹑FR(D)125/S, FR(D)100-B FR(D)180/S

FR95-C, FR125-C/S

Damping pad

Fix with bolts

FR(D)71-B FR(D)260/S

●

When two or more outdoor units are installed together, it is necessary to select suitable positions to avoid one unit sucking exhaust air from another.

●

Reasonable installation space required by air conditioner must strictly follow instruction manual. When arranging rain shelter, do not affect heat dissipation of the machine.

IV. Installation of air duct

1. The following shows a number of typical installation modes for air duct air conditioners of different models.

Side air return/lower air delivery

Lower air return/side air delivery;

Return air port

Air delivery port

Air return port surface

Air delivery port

Air intake

FRD23-B, FRD35-B, FRD50-B (with return air box)

- 74 -

Corrugated tube

Return air port

Installation

FR95-C, FR125-C/S

Refer to above figure for air exhaust mode of FR95-C and FR125-C/S. User can open corresponding air exhaust port as required and select air exhaust strip of correct length according to size of the port selected, round it to a ring and snap it on the port. Then connect air duct and lead it to required position.

Air delivery duct

Return air port

Air delivery duct

Return air port

Mode 2 Mode 1

Fresh air port

Air delivery duct

Mode 3

Typical installation modes of FR(D)95, FR(D)125/S, FR(D)71-B, FR(D)100-B, FR(D)180/S and FR(D)260/S are shown above:

(1) Select reasonable installation mode according to site characteristics, user requirements and machine performance;

(2) Cross sectional area of air duct shall meet specification. In case of noise requirement by user, follow relevant requirements described in air duct design and noise reduction sections of this manual;

(3) Recommended distance from main unit air return port edge to wall is above 800mm. For

FRD23-B, FRD35-B and FRD50-B, this is above 150mm;

(4) If there are many air delivery ports, to ensure even air delivery at such ports, in addition to reducing air ducts and static pressure box installed for even flow, adjustment damper should be provided at each branch air duct or air delivery ports with adjustment damper be selected.

(5) Air delivery and return ducts shall be fixed on prefabricated floor slab via iron support;

- 75 -

Installation

(6) Thermal insulation layer shall be stuck on air delivery ducts and no leakage shall exist at connections.

2. Recommended cross sectional area of air ducts

Return air duct CS area (m

2

)

Air delivery duct CS area (m

2

)

≥ 0.3

≥ 0.135

≥ 0.4

≥ 0.15

≥ 0.6

≥ 0.27

≥ 0.7

≥ 0.325

≥ 0.225

≥ 0.101

≥ 0.3

≥ 0.135

Note: FRD23-B, FRD35-B and FRD50-B can be directly connected to air delivery/return ports via soft connection. Refer to indoor unit installation dimensions for size of air delivery/return ports.

3. Arrangement of fresh air port

Rear air return

(vertical view)

Fresh air Fresh air port

Lower air return

Return air port

Return air

Delivery air

Air delivery port

Fresh air

One fresh air port at left side, right side and rear (bottom) side

Based on FRD23-B, FRD35-B and FRD50-B

One 100×100 bottom fresh air port is provided at side and bottom face of FRD23-B,

FRD35-B and FRD50-B respectively.

Arrangement of fresh air port in FR95-C and FR125-C/S is the same as in FRD23-B,

FRD35-B and FRD50-B, and one fresh air port is provided at each side of the unit and can be open to needs.

Refer to installation mode 3 for fresh air port arrangement for FR(D)95, FR(D)125/S,

FR(D)71-B, FR(D)100-B, FR(D)180/S and FR(D)260/S.

Precautions for arrangement of fresh air ports:

a. Requirement on fresh air damper: Closing of fresh air damper shall be tight and fresh air flow shall be adjustable; b. Requirements on fresh air port: Fresh air port shall be arranged upstream of air exhaust port as much as possible, and lower than air exhaust port. Fresh air port shall be arranged on north wall as much as possible and height of its bottom above outdoor floor should be not smaller than 2m, and not smaller than 1m when arranged in afforestation area. Strainer shall be provided at inlet of fresh air to purify outdoor air and improve indoor air quality.

- 76 -

Installation

4. Connection of air delivery duct with the unit

Soft connection (canvas etc.) shall be used between air delivery duct and the unit. Refer to indoor unit installation dimensions for air delivery port dimensions.

Based on FR(D)95

Air delivery duct fixing holes

5. Connection of return air duct with the unit

(1) Soft connection (e.g. canvas) shall be used between return air duct and the unit;

(2) For FR(D)95, FR(D)125/S, FR(D)180/S and FR(D)260/S, it is necessary to remove retaining strips on both sides of indoor unit return air port strainer;

(3) Use tapping screws or rivets to connect return air duct to indoor unit return air port.

Control depth of drilling for tapping screws to avoid penetrating evaporator copper tube or condensate tray;

(4) For FRD23-B, FRD35-B, FRD50-B, FR(D)71-B and FR(D)100-B, a segment of canvas air duct can be fabricated and reinforced by 8＃ iron wire. This shall be folded, and have one end connected to indoor unit air exhaust via rivet and the other end connected to return air louver or strip return air port, so that free adjustment can be made according to height of indoor ceiling. Return air grating with washable air strainer must be installed to prevent dust from entering the unit. Recommended distance between return air port edge and wall is above

150mm.

(5) Return air duct installation mode for FR95-C and FR125-C/S is the same as for FRD23-B,

FRD35-B, FRD50-B, FR(D)71-B and FR(D)100-B. 3 return air modes can be adopted: upper air return, lower air return and rear air return. Return air mode selection depends on unit installation mode and return air duct installation mode;

(5) Canvas soft connection is adopted for air delivery port, air return port and main unit. No tensile force shall exist between air duct and main unit; otherwise noise level will be higher.

⑥ Note: For FR(D)95, FR(D)125/S, FR(D)180/S and FR(D)260/S, strainer with mesh similar to unit strainer shall be fitted at end return air grating; otherwise a 70~100mm wide area on lower side face at connection between return air duct and indoor unit shall be removable, so that user can directly withdraw unit strainer for cleaning (as shown in the figure below). If return air port is complete with strainer, we recommend that indoor unit strainer be removed.

- 77 -

Installation

Return air duct fixing holes

Strainer retaining strip

Notes:

(1) Before closing ceiling decoration, it is necessary to turn on the machine to check air flow at each port, noise level, connecting pipeline leakage, cooling (heating) effect, air duct insulation and condensate pipe drainage etc. Close ceiling only when acceptance is OK.

(2) In case of no cooling (heating) effect, first check power supply phase sequence. Z6 protection display is provided on FR(D)125/S display panel.

(3) Installation team shall timely coordinate with decoration team to avoid change of position and installation mode of installed indoor unit, keep indoor unit & condensate pipe clean, and reserve maintenance openings for future maintenance.

V. Installation of LCD wire controller (for FRD23-B, FRD35-B and FRD50-B)

Refer to following figure for installation mode of LCD wire controller. Install junction box at a position in the wall easy to operate. Lead in signal line via wall-penetrating tube. Remove bottom of wire controller box, use tapping screws to fit it on the junction box. Then fit the wire controller on the bottom piece.

Junction box

Tapping screws

Wire controller bottom piece

Wire controller

- 78 -

Installation

VI. Connection of indoor unit with outdoor unit

1. Installation of wall-penetrating tube

(1) Wall-penetrating tube shall be hard polythene tube of about Φ90;

(2) Determine drilling position on wall by referencing indoor unit installation position and connecting pipe position. Hole size shall be Φ95~100mm and outdoor side of the hole shall be lower than indoor side by 5~10mm.

(3) Determine length of wall-penetrating tube according to wall thickness (longer than wall thickness by about 10mm). Insert the tube in the hole drilled on wall for threading of connecting tube, connecting cable and drainage tube.

Note: Use sealing putty to seal clearances between penetrating tube and hole, between penetrating tube and connecting tube, and between connecting cable and drain pipe, so as to prevent ingress of rainwater and air.

2. Installation of condensate drain pipe

(1) Condensate drain pipe shall be normal PVC pipe of Φ16~17 inner diameter (FR95-C,

FR125-C/S water discharge pipe inner diameter is Φ 17 while FRD23-B, FRD35-B,

FRD50-B water pipe inner diameter is Φ20~21).

(2) Install user supplied drain pipe on indoor unit drain pipe outlet, and seal with glue;

(3) Condensate drain pipe shall have 1/50~1/100 down slope, be supported by hard frame, not bent as return water type, and its tip shall not be dipped in water;

(4) Drain pipe shall be wrapped with thermal insulation material to avoid water leak due to dewing.

3. Connections

(1) Unscrew nuts on shutoff (or ball) valves on indoor unit pipeline and outdoor unit;

(2) Drip small amount of frozen oil at 2 bell mouths of connecting pipe, align bell mouth center with pipe connector, then tighten nut with spanner.

Pipe supplied with indoor unit Conical nut Auxiliary pipe

Spanner

Torque spanner

- 79 -

Installation

Notes:

(1) Ensure quality of user supplied connecting pipe. Before connection, clean inside of pipe and prepare bell mouths. You can order these from our factory.

(2) Site fabrication of bell mouths must use special pipe-expander to avoid F22 leak after installed.

(3) Use two spanners to tighten connection between indoor unit and connecting pipe; otherwise indoor unit tubing may twist, deform or even break.

4. Venting of system

(1) Loosen nut on upper air pipe (large pipe) of outdoor unit large shutoff (ball) valve by half a round;

(2) Unscrew valve core nut on the two valves;

(3) Open small shutoff (or ball) valve core by one round. When you feel that air coming out of air pipe nut on the large shutoff (or ball) valve is cold, this means that air is basically vent.

Immediately tighten air pipe nut with spanner. Then open both shutoff (ball) valve cores, put on valve core nuts and tighten.

Steam pipe

Loosen half round before venting

Liquid pipe

Large shutoff (ball) valve

Small shutoff (ball) valve

For venting, unscrew nut and open valve core by one round

Note: Use of the unit without opening all valve cores will cause failure or poor performance.

When ball valve core is rotated parallel to pipeline axis, the valve is open.

5. System leakage detection

(1) Fully open large and small shutoff (or ball) valve cores to detect leakage; confirm no refrigerant leakage;

(2) Halogen mutual detection meter shall be used for detection, or apply soapy water at connections and valve cores etc.;

(3) In case of slight leakage, use spanner to tighten leaking connection till the leak vanishes; otherwise it is necessary to correct threaded connector and bell mouth jointing face and

- 80 -

Installation reconnect the parts, and again vent air and detect leakage.

(4) After detection, use dry cloth to wipe out soapy water. Sort all connecting pipes.

6. Precautions

(1) After sorting of connecting pipes, wrap them and indoor unit connectors with thermal insulation material to avoid water leakage due to dewing.

(2) When connecting pipe is too long, both unit performance and reliability will deteriorate.

With increased number of pipeline bends, refrigerant flow resistance will increase and cooling/heating performance fall.

Product series/models

FRD23-B

FRD35-B

FRD50-B

FR(D)71-B

FR(D)100-B

FR(D)95

FR(D)125/S

FR95-C

FR125-C/S

FR(D)180/S FR(D)260/S

Recommended max length (m)

Recommended max HGT diff (m)

Recommended max elbows

15

5

3

20

8

5

20

8

5

20

8

5

20

10

5

When length and height exceed above values, consult us for suitable measures.

(3) If FRD23-B, FRD35-B, FRD50-B connecting pipe length exceeds 5m, add 20g/m refrigerant.

(4) If FR(D)71-B, FR(D)100-B connecting pipe length exceeds 8m, add 30g/m refrigerant and

10g/m frozen oil.

(5) If FR(D)95, FR(D)125/S, FR95-C, FR125-C/S connecting pipe length exceeds 8m, add

30g/m refrigerant and 10g/m frozen oil.

(6) If FR(D)180/S connecting pipe length exceeds 8m, add 80g/m refrigerant.

(7) Amount of refrigerant filled inside FR260/S is for 5m connecting pipe. For extended length of connecting pipe, add 170g/m refrigerant.

Notes:

1. Use T valve filling port to add refrigerant;

2. Add refrigerant during cooling operation;

3. Do not directly pour liquid refrigerant;

4. Model of frozen oil: Sontex200LT white oil or 3GS oil.

7. Electric wiring

(1) Electric wiring shall be carried out by electricians with qualification certificates. State electric wiring code shall be followed;

(2) Electric box must be fixed on indoor unit casing; earthing must be reliable;

- 81 -

Installation

(3) According to requirements by electric wiring diagram, connect wire controller to indoor electric box. Connect indoor/outdoor connecting cable and outdoor pipe temperature probe connecting cable to outdoor electric box. Plugs shall be firmly and reliably in place and held tight by wire clamp.

(4) Special power supply cables must be used for the units. For FRD23-B, 250V 10A power plug shall be used, 250V 15A plug for FRD35-B, and 250V 25A for FRD50-B. User must select sockets corresponding to these plugs. For other models of air duct air conditioners, we will not supply power plug and user must adopt special power lines.

(5) Units with auxiliary electric heating must connect an electric heating power cable on the electric box (YZ3X1.5+1X1 cable for FRD125/S, RVV3X2.5 sheathed cable for FRD95, 2

YZ3X1.5+1X1 cables for FRD180, and 2 YZ3X1.5+1X1 cables for FRD260) to wiring terminal seat on electric heating box in a corresponding manner, connect earthing line, hold tight with wire clamp, and fix cover plate on the seat. Only turn on machine with wires connected; otherwise short circuit can occur.

Notes:

1. For FR(D)125/S, FR(D)180/S and FR(D)260/S, check for correct rotation direction of compressor before system installation and operation. Compared with normal operation, reverse compressor rotation can cause high noise and small current. FR(D)180/S and

FR(D)260/S wire controller will indicate E6 (confirm no absent phase) for reverse compressor rotation. Shutoff the unit at once, disconnect power and swap 2 any phases.

2. Indoor/outdoor connecting cable must be sheathed cable meeting state standards. Signal lines shall be ≥1mm

2

sheathed cable.

FR95, FR95-C power cable shall be ≥2.5mm

2

cable (with yellow/green earthing line); indoor/outdoor power connecting cable shall be ≥2.5 mm

2

cable (with yellow/green earthing line).

FRD95 power cable shall be ≥6mm

2

cable (with yellow/green earthing line); indoor/outdoor power connecting cable shall be ≥2.5 mm

2


FR125/S, FR125-C/S power cable shall be ≥1.5mm

2

cable (with yellow/green earthing line); indoor/outdoor power connecting cable shall be ≥1.5mm

2

cable (with yellow/green earthing line.

FRD125/S power cable shall be ≥ 4mm

2

cable (with yellow/green earthing line); indoor/outdoor power connecting cable shall be ≥1.5mm

2


FRD71-B, FR100-B power cable (with yellow/green earthing line) and indoor/outdoor power connecting cable shall be ≥2.5 mm

2


FRD71-B, FRD100-B indoor power cable shall be ≥ 4mm

2

cable (with yellow/green earthing line). Indoor/ outdoor power connecting cable shall be ≥2.5mm

2

cable (with yellow/green earthing line). Indoor and outdoor signal cables shall be ≥1mm

2

cable.

- 82 -

Air duct design & noise reduction

Chapter IX Air duct design & noise reduction

I. Air duct design and its effect on noise

(1) Noise of air conditioning system mainly consists of aerodynamic noise, mechanic noise and electric current noise. Among them, aerodynamic noise makes main contribution.

(2) Noise reduction measures

Installation of air duct type air conditioner is system engineering. Noise reduction includes that in indoor unit installation and that in air duct design and installation. Refer to introduction of indoor unit installation for details of noise reduction in indoor unit installation. Air duct design and noise reduction methods are described below:

Design air duct and air port air speed according to state codes and standards, “Product installation and operation manual” and “Chunlan design code for home (commercial) centralized air conditioning system”. Data in following tables can be referenced for design.

(These data may have slight deviations that do not affect functioning as design reference).

Table 1: Air speed in low speed air duct (m/s)

Permitted indoor noise dB

( m/s)

Main duct air speed

25—35 3—4

Branch duct air speed

≤ 2

35—50 4—7 2—3

Fresh air entrance

3

3.5

50—65 6—9 2—5 4—4.5

65—85 8—12 5—8

5

Table 2: Max. air delivery speed at lateral delivery louver port (m/s)

Building Building Max air delivery speed

Studio

1.5—2.5

Residence

2.5—3.8

Hotel room

2.5—3.8

Theatre

2.5—3.8

Hall

2.5—3.8

Personal office

Personal office (no sound insulation)

Ordinary office

Cinema

Department store

Max air delivery speed

2.5—5.0

4.0—6.3

2.5—3.8

2.5—3.8

7.5

- 83 -


Table 3: Maximum air delivery speed of diffuser (m/s)

Net indoor height /m

Building

Permitted noise

/dB (A)

Theatre, residence, operation room

Hotel, personal office

Shop, bank, restaurant, department store

33—39

40—46

47—53

4.4 4.6 4.8 5.0 5.2

5.2 5.4 5.7 5.9 6.1

6.2 6.6 7.0 7.2 7.4

Public building; office, department store bottom floor

54—60

7.4 7.9 8.3 8.7 8.9

Table 4: Max. air delivery speed at orifice, strip seam and spout (m/s)

Air port

Max air delivery speed

Remark

Orifice 3—5

Seam port 2—4

Spout 4—10

Upper limit is preferred for high even delivery requirement or hot air, for high installed position of port, or higher air speed is allowed in area of personnel activities.

Room lower part

Table 5: Air suction speed at return air port (m/s)

Position of return air port

Room upper part

Near points of stay of personnel

Air suction speed

4—5

1.5—2

Table 6: Recommended criteria for indoor noise control (referencing “High building air conditioning design” published by China Architectural Industry Publishing House).

Guest room

Restaurant

Banquet hall

Type of room

Multifunction hall

Grade I

Grade II

Grade III

Grade IV

Grade I

Grade II

Grade III

Grade IV

Noise level

30

35

40

55

（ 35）

40

45

55

- 84 -


Type of room

Commercial

Service

Vestibule

Seasons hall

Grade I

Grade II

Grade III

Grade IV

Grade I

Grade II

Grade III

Hairdressing/Barber’s room

Recreation facilities

Grade I

Meeting room

Office

Grade II

Grade III

Grade IV

Ballroom, non-operating time

Operating time

Noise level

45

45

55

55

45

45

45

45

45

（

30）

40

45

55

40

—

Note: In short, air duct/port design/type selection shall follow the 3 steps below:

1. Roughly calculate air duct cross sectional area and air port air delivery/return areas according to rated unit air flow and suitable air speed;

2. According to “National common ventilating pipeline calculation table”, preliminarily determine air duct size and dimensions; preliminarily determine air port size by referencing relevant manufacturer product samples;

3. Calculate air resistance in air delivery/return system; further verify air duct by referencing unit air exhaust static pressure; select correct type of air ports. When necessary, repeat these 3 steps.

Note: For higher user requirement on noise, silencers shall be installed on air delivery/return ducts; a. Resistive silencer. By means of sound absorbing material stuck on inner wall of air duct, sound energy propagating along air duct is partly converted to thermal energy to reduce noise.

This type of silencer has good performance for medium and high frequency noise and relatively poor effect on low frequency noise. b. Reactive silencer. By means of sudden expansion, contraction and bypassing (resonance cavity) of air duct cross section, noise propagating along air duct at specific frequencies and frequency bands is reflected at points of sudden change. The type of silencers has good performance for low and medium frequency noise. c. Combined resistive and reactive silencer (wide frequency band silencer). This type of silencer integrates advantages of above types and has good performance at low, medium and high frequencies. Reduction of noise at low frequencies and some medium frequencies makes use of reactive silencing by sudden change of pipeline cross sectional area and resonance sound absorption by cavity. Reduction of noise at high frequencies and most medium frequencies makes use of sound absorbing materials.

- 85 -


II. Existing problems in air duct noise control and measures of solution

z Main equipment

Problem 1: Too large size of unit selected

Careful air conditioning load is not carried out according to cooling/heating load detailed calculation method or rough calculation method specified in relevant standard or book, or in combination with application site information. For instance, 5HP unit is selected where 4HP or 3HP should have been selected. This will cause higher noise due to limited space if air conditioning and small distance between indoor unit and conditioned space.

Solution:

By referencing relevant standard, book or experience, carefully calculate air conditioning cooling/heating load and select correct type.

Problem 2: Improper installation

Proper installation position is not selected according to installation key points described in

“Product installation and operation manual” and “Chunlan home (commercial) centralized air conditioning system design code: (e.g.: indoor unit is too near conditioned area or in such area), or proper fixing, damping and sound insulation is not carried out.

Solution:

(1) Indoor unit shall be installed away from environment and rooms that require quietness.

The unit can be can be installed in special equipment room, toilet, storeroom or other ancillary rooms. If this is not feasible, make sure to contact our quality management section to obtain proper noise reduction solution as soon as possible to avoid rework and loss.

(2) Use elastic material to fill air delivery/return dust penetrations through enclosure and gap around holes;

(3) Suitable sound insulation measures shall be taken in equipment room according to permitted noise level of nearby rooms and buildings. If the equipment room is near room(s) with high requirement, sound insulating doors and windows shall be used for equipment room

(this clause is subject to Owner agreement).

(4) Lifting and installation method shown in the figure below is preferred. In the figure, at lower end of unit are two angle steels, on top of which is a 15mm wood plate of the same size as that of unit bottom size. 10mm thick PE board is mated on the wood plate. z Air duct system

Problem 1: Flexible connection is not used for unit air delivery/return ports

Air delivery/return duct is directly connected with unit and no flexible hose connection is used, causing unit vibration being transmitted by pipeline and excessive noise in conditioned area.

Solution:

Use 200mm-300mm long canvas, 3-proof cloth or soft metal insulating tube between unit air

- 86 -

Air duct design & noise reduction delivery/return port and air delivery/return hose, for isolation of vibration.

Problem 2: Unreasonable design of air speed

Careful design of air speed at air delivery/return main duct, branch duct and ports according to conditioned area noise requirement and unit air delivery static pressure is not carried out, causing higher air speed and higher noise caused thereby.

Solution:

Design air duct and air port air speed according to national standard, “Product installation and operation manual” and “Chunlan hole (commercial) centralized air conditioning system design code”. Data in Tables 1 to 6 in this manual can be used for design reference (slight deviations will not affect design). Design and type selection of air ducts and air ports shall follow the following 3 steps:

(1) Roughly calculate air duct cross sectional area and areas of air delivery/return ports according to unit rated air flow and suitable air speed;

(2) Reference “National common ventilating air duct calculation table” for preliminary determination of air duct size and dimensions; reference manufacturer product samples for preliminary determination of air port size;

(3) Calculate air resistance in air delivery/return systems. Further verify correct type selection of air duct and ports by referencing unit air exhaust static pressure. When necessary, repeat above 3 steps.

Problem 3: Local high resistance in air duct

Improper design of local resistance members such as air duct elbow, reducing pieces and T branches etc. causing large eddy current and hence high air flow noise.

Solution:

(1) Avoid sharp turning of pipeline at indoor unit entrance/exit;

(2) Arrange diffuser or reducing tube of suitable length at reducing segment of air duct to avoid sudden expansion or reducing of air duct;

(3) At elbows and T branches etc., take even-flow measures such as transition arc or flow guide piece;

(4) Reduce or eliminate regulating valves.

Problem 4: Proper silencing measures not taken for pipeline system

In case of high noise requirement, silencing devices such as static pressure box, return air box, silencing straight tube, silencing branch tube, silencing elbow or silencing air port are not provided or incorrect or unreasonable.

Solution:

(1) When permitted by installation space, static pressure box and return air box (designed section air speed not exceeding 2-2.5m/s) to requirements as much as possible. Inside these

- 87 -

Air duct design & noise reduction boxes, stick 50mm thick sagging sponge or other sound absorption material to form silencing static pressure box or return air box, for substantial reduction of noise at unit air delivery port/exhaust;

(2) Note: Ceiling space accommodating the unit is itself a large static pressure box. If material of ceiling cover plate is mineral wool or other sound absorbing material, equipment room walls are brick masonry instead of glass, and wall tightness is good, noise radiated by unit casing will be greatly reduced;

(3) Design correct and reasonable silencing straight tube, branch tube, elbow or air port (for particular type selection, reference manufacturer product samples);

(4) Increase thickness of air duct wall and wrap ultra-fine glass wool (or other sound absorbing material) of suitable thickness on exterior of air duct;

(5) Due to limited sound absorption performance of traditional galvanized air duct and fiberglass reinforced plastics air duct, stretching metal (non-metal) flexible hose, polyurethane composite air duct, super air duct and other new type of sound absorption/thermal insulating air duct can be considered.

III. How to avoid poor cooling/heating effect

(1) Carry out correct type selection;

(2) To extend pipeline, add freon to requirement by manual.

(3) For higher user requirement on heating, unit with auxiliary electric heating is recommended.

- 88 -

Chapter X Method of operation

I. Description of wire controller

1. Ordinary wire controller

Power indicator Display window

Remote control reception window

Temperature setting key

Method of operation

Air speed setting key Timing key

Functional key

Power ON/OFF key

Power ON/OFF key

● When power is turned on, power indicator (red) lights up and the unit is in stop status.

● Press power ON/OFF key, the unit will be in ventilating status (high air flow) and temperature is set at 22℃. At this time, use functional key to select operating status. With unit in operating status, press power ON/OFF key will stop the unit and place it in standby status.

● After pressing power ON/OFF key, if power supply is interrupted and resumed, the unit will be restored to the status before power interruption.

Functional key

● Press this key and the unit will cycle through following modes and displays:

Cooling

(green)

Air speed setting key

Heating

(red)

- 89 -

Ventilating

(orange)

Method of operation

Low speed

(orange)

Medium speed

(red)

High speed

(green)

Timing key

● After pressing this key, indoor unit air delivery status will cycle as follows:

● When the air conditioner is in ON status, you can select timed shutdown. Before such shutdown, press timing key to display remaining time in the display window; temperature display will resume after 5s. When the timing expires, the air conditioner is shutdown, and all display contents on wire controller vanish except for power supply indicator.

● When the air conditioner is in OFF status, you can select timed turn-on. Before such turn-on, press timing key to display remaining time in the display window; this display will vanish after 5s. When this timing expires, the air conditioner will operate in set mode and timing status automatically changes to normal operation.

● Time setting is 01~24h. Initial value is 01, interval is 1h and this setting will increase 1h every time the timing key is pressed. Holding down this key will cycle this setting to 24h and then to 01h again.

Temperature setting keys

● A temperature increase key and a temperature decrease key are provided. Press the former to increase temperature by 1 degree and press the latter to decrease temperature by 1 degree.

● Temperature setting range is 12℃~30℃. When temperature display is 12℃, temperature decrease key is not functional; and when temperature display is 30℃, temperature increase key is not functional.

2. LCD wire controller

Remote control reception window



LCD display

Functional key

Power ON/OFF key


- 90 -

Method of operation

Power ON/OFF key

● Turn on main unit power, the LCD only displays clock and the unit is in stop status.

● Press power ON/OFF key, the unit is in ventilating status at high air speed and 22℃. At this time, use functional key to select operating mode. Press power ON/OFF key with unit in operating status, the unit will not stop and enter stop status.

● After pressing power ON/OFF key, if power is interrupted and resumed later, the unit will be restored to the status before power interruption.

Functional key (also timing key and clock setting key)

● Press this key and the unit will cycle as follow:


● Press this key and indoor unit air delivery status will cycle as follows.


●

is temperature increase key and press this key to increase temperature by 1 degree; is temperature decrease key and press this key to decrease temperature by 1 degree.

● Temperature setting range is

12℃～32℃; when temperature display is 12℃, temperature decrease key is not functional; when temperature display is 32℃, temperature increase key is not functional.

● Entering timing function:

Hold down functional key for about 5s to enter timing status and will be displayed. If the unit is

ON at this time, “OFF” will flash; if the unit is OFF at this time, “ON” will flash. Press to change hour setting (increase 1 hour every time this key is pressed) and press to change minute setting

(increase 15min every time this key is pressed). Press “Timing” key on remote controller can also enter timing status.

●

Setting of clock: After entering timing status, continue holding functional key for about 6s and then release to enter clock setting status. At this time, will flash and press can change hour setting (increase 1 hour every time this key is pressed) and press to change minute setting (increase

1min every time this key is pressed). Continue setting till the clock is 24h system Beijing time.

- 91 -

Method of operation

II. Description of remote controller

The remote controller has 8 keys of the same functions as those of corresponding keys on wire controller. When timing key is pressed, the unit enters timing status and press ∧ to change hour setting (increase 1 hour every time this key is pressed) and press ∨ to change minute setting (increase 15 min every time this key is pressed).

III. Installation of remote controller batteries

①

Remove batteries cover in direction shown by the arrow;

②

Fit 2 valid 5# batteries to +/- polarity requirement in battery chamber;

③

Close batteries cover by pushing upward.

Notes:

(1) Use 2 5#1.5V batteries; do not mix different batteries;

(2) Remove batteries if the remote controller will not be used for a long time (>2 months);

(3) Replace batteries when remote control signal is weak;

(4) Batteries supplied with equipment are valid for 6 months.

IV. Method of operation

(1) Precautions a. Before startup of air conditioner, connect power to requirements and ensure reliable earthing. b. After shutdown of air conditioner, it is necessary to wait at least 3min before restart or change of operating mode, so as to protect compressor. c. In normal operating status of air conditioner, shutdown the machine by power ON/OFF key.

- 92 -

Method of operation

Never shutdown the machine by unplugging power cord.

(2) Cooling

Prep Turn on power

Turn on

Press ON/OFF key to start

Use func’n key to select cooling

Use AS key to air speed

Use temp key to set room temp.

Off Press power ON/OFF key

Notes: a. When cooling is selected, temperature shall be set lower than current indoor temperature; otherwise the unit will be in ventilating mode; b. If ambient is too high, cooling load will be too high so that set temperature won’t be met; c. For your health and power saving, proposed set room temperature is 25℃～30℃.

(3) Heating

Prep Connect power supply

Press power ON/OFF to start

Turn on

Use func’n key to select heating

Use AS key to select air speed

Use TS key to set room temp.

Off Press power ON/OFF key

(4) Ventilating

Notes: a. When heating is selected, set temperature shall be higher than current room temperature; otherwise the unit won’t work; b. To prevent cold air at startup, indoor unit will operate later than outdoor unit; c. During heating, the computer will control the unit for auto defrosting, during which no fan will operate and the compressor will operate, and after which heating will start.

Turn on

Press power ON/OFF key

Use F key to select ventilating

Off

Use AS key to select air speed

Press power ON/OFF key

Warning: When the unit is not to be used for a long time, use “ventilating” function for 3~4 hours to completely dry up the air conditioner.

- 93 -

Maintenance

Chapter XI Maintenance

● To place the unit in outage, first stop the air conditioner and then turn off power switch.

● After long operation of outdoor unit, dust will accumulate on surface of heat exchanger, lowering heat transfer efficiency and hence unit performance. Use long hair brush or compressor air to clean such surface.

● Cleaning cycle of indoor strainer depends on installation position and environment.

Frequently clean indoor strainer to avoid failure.

Indoor units of FR(D)95, FR(D)125/S, FR(D)180/S, FR(D)260/S, FR95-C and FR125-C/S are complete with strainer. Indoor units of other models are not complete with strainer; hence return air grating with strainer must be used.

Method to remove strainer of indoor units of FR(D)95, FR(D)125/S, FR(D)180/S,

FR(D)260/S, FR95-C and FR125-C/S:

① Remove reserved seal plate on return air duct;

② Lightly push strainer upward, move limiting chute out, and lightly remove strainer from under.

Strainer

Direction of force

- 94 -

Troubleshooting

Chapter XII Troubleshooting

I. Failure codes

Microprocessor-based controller of this unit features troubleshooting and protection display functions.

Display code

Failure category

FRD23-B,

FRD50-B

FRD50-B

FR(D)71-B

FR(D)100-B

FR(D)95, FR95-C FR(D)180/S

FR(D)125/S, FR125-C/S FR(D)260/S

High pressure protection

Antifreeze protection

---

E1

E0

E1

---

E1

E0

E1 circuit

E2 E2

ID pipe temp probe short circuit E3

OD pipe temp probe short circuit E4

E3

E4

E3

E4

E2

E3

E4

Communication failure

Phase sequence protection

E5

---

E5

---

E5

---

E5

E6

Overcurrent protection

Load relief protection

Low pressure protection

---

E8

---

---

E8

---

---

E8

---

E7

E8

E9

In case of repeated protections of air conditioner, cut off power supply and have failure corrected by specialty maintenance personnel, before restarting the machine.

II. Common troubleshooting

In case of AC failure, immediately cut off power supply. Check the following before requesting maintenance:

Machine not operating

Power off Use when power is resumed

Power not meeting requirement Check power supply before use

Molten fuse or open CB

Replace fuse or close circuit breaker

Machine operating at Clogged air strainer Clean air strainer poor cooling/heating ID or OD unit air intake clogged

Remove obstacles cooling or heating

Improper temp control setting Reset temperature control

Open door/window Close doors/windows

- 95 -

Troubleshooting

Molten fuse in operation

Failed controller

Not receiving RC signal

Failed communication

Direct sunshine ID (in cooling) Use window curtain for shading

Heat sources in room Reduce heat sources

Line short circuit

Notify appointed maintenance dept.

Microprocessor interfered

RC batteries old or not properly installed

Reconnect power and start machine

Replace batteries and correct installation

Bad contact between wire Properly connect cables between controller and main board them

If the failure is still not cleared, turn off air conditioner, cut off power and contact appointed maintenance department.

Do not repair the air conditioner on yourself.

Note: This unit features innovative and unique program design capable of automatic control of number of operating outdoor fans and motor speed according to change of outdoor ambient temperature etc. to obtain optimum system load configuration.

(I) Unit system and structure troubleshooting

(1) Neither indoor unit nor outdoor unit operating

Neither unit operating

Power outage Restore power supply

Locate fault, repair/replace transformer

Clear short circuit, replace fuse fuse

Short circuit between lines

Line earth fault

(bad insulation)

Clear earth fault, replace wire

Power plug not in place or bad contact Correct bad contact, plug in socket

Indoor/outdoor wiring mistake

Molten controller fuse

Controller burnt down

Unit failure protection activated

Follow electric diagram in correct wiring

Replace controller fuse

Replace controller

Check per failure characteristics/display

- 96 -

Troubleshooting

(2) Display of remote controller or wire controller indicates air delivery position, but fans are not operating.

Display of remote Indoor fan burnt or broken wire Repair or replace fan controller indicates air delivery position, but fans are not operating

Bad contact in main ctrl board relay or coil broken wire

Replace capacitor

Replace main control board relay

Fan card contact open Repair bad contact

Note: During heating, defrosting or prevention of cold air, remote controller indicating air speed but fans not operating is normal and not failure.

(3) Troubleshooting for failure of outdoor fan or compressor operation at “Cooling” or

“Heating”:

Replace relay compressor operating at “Cooling” or “Heating” broken wire or bad contact

Compressor operating but outdoor fan not operating at “Cooling” or

“Heating”

OD fan motor failure or Replace motor or damaged fan capacitor capacitor

OD control board relay failed Replace relay

Compressor failure Replace compressor compressor not operating

OD control board relay failure Replace relay

Outdoor fan operating but

AC contact unreliable/damaged Replace AC contactor capacitor damaged

(4) Compressor shutdown shortly after startup

Compressor shutdown shortly after startup

During cooling, sunshine or blocked ventilation can cause higher condensation pressure; and when this is serious, compressor overload protection will act to stop compressor.

Remove obstruction and use rain shelter

- 97 -

Troubleshooting

During heating, small openness of or closed air delivery port in air conditioned room can cause higher Check and adjust condensation pressure, and when serious, compressor overload protection will act to shutdown compressor air port openness

Power voltage is low and less than 10% rated voltage, causing increased current and action of overload protection

Use AC voltage regulator

Insufficient power grid capacitance

Increase power grid capacitance

Compressor “jammed”, causing sharp increase of current and action of protection

Replace compressor

(5) Bad or no cooling in cooling mode

Phenomena Possible method

Bad or no Improper OD unit installation position, e.g. direct Reinstall, remove obstacle or use rain shelter cooling mode

Damaged or failed temperature sensor Replace temperature sensor

Dust accumulated on air strainer in long operation Clean strainer to remove will reduce air cycle and lower evaporator heat dust and let it dry in cool air exchange efficiency, hence cooling effect before reinstallation

Dust accumulated on air conditioner fins can Use long hair brush or cause insufficient cold air cycle or bad heat compressed air to remove dissipation, hence lowering cooling effect dust

Clogged capillary in cooling cycling system Again pump vacuum, fill causing sudden failure of this system or lowered refrigerant or replace cooling effect capillary (strainer etc.)

Refrigerant leakage due to bad welding of system Carry out repair weld or pipeline or damaged copper tube, bad sealing of replace shutoff valve and fill shutoff valve filling port sometimes refrigerant after detection evaporated in evaporator, causing lowered heat absorption capability and cooling effect

Air mixed in system affecting heat exchange, Drain refrigerant, re-pump causing higher condensation pressure and lowered cooling effect vacuum and fill new refrigerant

- 98 -

Troubleshooting

Phenomena Possible method

Damaged fan capacitor, bad contact, damaged fan motor, or failure of fan power supply line, causing

Check power line, each switch, temperature indoor fan not operating or operating at lower controller, terminal board, speed, hence no cold air out or poor cooling replace capacitor/motor

High (low) voltage or wrong power supply wiring Use AC voltage regulator, operating; or failure of compressor (e.g. motor burnt down, jammed, damaged valve disc etc.)

Excessive cooling load Check expected cooling load

Set temperature too high Lower set temperature

Leaking refrigerant or closed shutoff valve, Check and repair leakage, or clogged system open shutoff valve

Compressor failure (connecting HP and LP) etc. Replace compressor

Bad thermal insulation of indoor/outdoor unit Apply separate thermal connecting pipe insulation for bid and small pipes

Reversing valve failure Replace reversing valve

Improper air delivery pipeline design, installation Re-design or re-install air or user operation, causing reduced indoor air delivery path; proper use of delivery amount air conditioning unit by user

(6) Poor or no heating in heating mode

Poor or no Excessive heating load heating in heating

Improper outdoor unit installation position mode

Set temperature too low

Check expected heating load

Re-install & ensure good ventilation

Increase set temperature

Clogging in heating cycling system

Again pump vacuum, fill refrigerant or replace dirt/clogged parts

Clogged air strainer Clean strainer periodically

Excessive dust accumulated on heat Clean by long hair brush or exchanger compressed air

- 99 -

Troubleshooting

Compressor failure

Reversing valve failure

Replace compressor

Replace reversing valve

Leaking refrigerant or shutoff valve not open, clogging system

Detect and repair leakage or open shutoff valve

Insufficient or excessive refrigerant Add (discharge) refrigerant

Poor thermal insulation of indoor unit connecting pipe

Separate thermal insulation for big and small pipes

Defrosting controller failed Replace defrosting controller

Poor air delivery duct design, installation or user operation causing reduced indoor air delivery

Re-design or re-install air delivery duct, proper use of unit by user

(7) Water leakage on indoor unit

Dewing of drain pipe Replace with insulated pipe or wrap drain pipe with insulation

Indoor unit water leakage

Clogged or broken drain pipe Clean or replace drain pipe

Wrapping of pipe connector not tight, Wrap tight dewing

Water leakage in indoor condensate tray Replace condensate tray

Serious inclination of indoor unit Re-install indoor unit

(II) Electrics and control troubleshooting

1. Maintenance prompts

In case of abnormity of air conditioner, do not remove circuit board; check the following: a. Failure in power supply line: power input must be safe and reliable; b. Correct operation of air conditioner and operating conditions of each operating mode (refer to operation manual for method of operation); c. Good contact of cards and reliable installation of indoor/outdoor connecting cable; d. Normal status of compressor, fans and sensors (refer to instruction manual for electric wiring); e. Functional protection caused by external environment is normal protection and no servicing

- 100 -

Troubleshooting is required.

2. Electrics and control protections and functions for FR23-B, FRD35-B, FRD50-B, FR(D)95,

FR(D)125/S, FR(D)71-B and FR(D)100-B

A. Unit control objectives a. Indoor fan (one for all models except FR(D)100-B, which has two 3-speed fans) b. Outdoor fan (one for all models; 1-speed for FR23-B, FRD35-B, FRD50-B, 2-speed for others) c. Compressor d. Reversing valve e. Indoor PTC auxiliary electric heater

B. Electrics and control troubleshooting

Failure Phenomena anti-freeze protection

When 3 consecutive such protection signals are detected in

Check for normal cooling system; check for bad

1h, AC unit stops, wire controller

contact at ID pipe temperature sensor connection;

displays E1, you can only put it

check for broken wire or short circuit at sensor; if

into operation after re-powerup

normal, check if R6 on indoor board is 10K

ID ambient temp probe broken wire

Wire controller displays E2, put it into operation after re-powerup

First check ID ambient temperature sensor connection for bad contact, check for broken wire or short circuit in sensor; if normal, check if R7 on ID

(short circuit) board is 10K

ID pipe temp probe broken wire


First check ID pipe temperature sensor connection for bad contact, check for broken wire or short circuit

(short circuit) in sensor; if normal, check if R6 on ID board is 10K

OD pipe temp probe broken wire


First check OD pipe temperature sensor connection for bad contact, check for broken wire or short circuit

(short circuit) in sensor; if normal, check if R5 on ID board is 10K


Check for reliable welding on main control board CN6 and wire controller CN1 needle seat, reliable insertion of cards and broken or short circuit of communication line;

In case of communication failure Check for DC12V input on wire controller, DC5V between main control board and output on main control board 7805-3 pin, and DC5V wire controller, the latter displays on RG1-3 of wire controller;

E5, and you can only put it into Check normal voltage on main control board 2003 operation after re-powerup driving block;

Check for normal voltage on crystal oscillator pin of main control board and wire controller;

Check for normal voltage at communication input/output of main control board and wire controller

- 101 -

Troubleshooting

Schedule of other common failures of FRD23-B, FRD35-B, FRD50-B, FR(D)95, FR(D)125/S,

FR(D)71-B and FR(D)100-B air conditioner PCB board:

Failure phenomena Method of correction

Remote control failure

Remote controller failure

Check for normal remote control receiver;

Check for normal remote control transmitter;

Check for normal remote controller

Check for normal 3V batteries;

Check crystal oscillator circuit;

Check for normal transmitter;

Check for displaced or bad contact in conducting rubber

Check for normal temperature sensor RT1;

No cooling function

Check for normal DC12V, DC5V power supply;

Check for reliable connection of output ports of compressor, ID/OD fans;

Check for main control board damage



No heating function

Check for reliable output port connection of compressor, reversing valve,

ID fans and OD fans;



Indoor fan failure

Check for intact connection of outdoor unit wiring terminal;

Check for damaged main control board;

Check for intact reversing valve

Check for intact connection of indoor unit wiring terminal and damage of main control board;

Check for intact indoor fans;

Check for intact fan capacitors

Outdoor fan failure



Check for intact outdoor fans;

Check for intact fan capacitor

3. FR180/S and FR260/S electric control, protections and functions (refer to contents of

FRD95 and FRD125/S for electric heating type).

- 102 -

Troubleshooting

A. Unit control objectives a. Indoor fans (2 sets, 3-speed) b. Outdoor fans (2 sets, 1-speed) c. Compressor d. Reversing valve

B. Troubleshooting

Failure Phenomena protection

Wire controller displays E0, only

HV switch

-powerup

HV switch shall be ON and card connection shall have good contact; put it to operation after re

Check for bad contact at indoor/outdoor connecting cable card

When 3 consecutive antifreeze protection signals are received in

3 occurrences of

Check for normal cooling system;

1 hour, AC unit stops and wire Check for drifting of indoor pipe temperature antifreeze protection controller displays E1, only put it sensor resistance

(short circuit) to operation after re -powerup

Wire controller displays E2, only First check for bad contact in indoor ambient

-powerup temperature sensor connection;

Check for broken wire or short circuit of sensor

ID pipe temp probe Wire controller displays E3, only First check for bad contact in indoor pipe temperature circuit) -powerup Check for broken wire or short circuit of sensor

OD pipe temp probe Wire controller displays E4, only First check for bad contact in outdoor pipe circuit) -powerup Check for broken wire or short circuit of sensor

Check for reliable welding at main control board

CN6 and wire controller CN1 needle seat, reliable connection of corresponding cards, and broken wire or short circuit of communication line;

In case of communication failure Check for DC12V input at wire controller, DC5V between main control board and output at main control board 7805-3 pin, and

Communication failure operation after re -powerup 2003 driving block;

Check for normal voltage at crystal oscillator pin of main control board and wire controller;

Check for normal input/output voltages of main control board and wire controller

- 103 -

Troubleshooting

Failure Phenomena

Check for correct compressor power phase sequence;

Check for protection action in compressor;

Check for phase absence in compressor power


Phase sequence line;

(absence) protection

-powerup Check for damaged triode on main control board;

Check for damaged LM339N on outdoor board;

Check for bad connection of ID/OD connecting cable;

Check for damaged OD board current transformer

Overcurrent protection

Check if 8HP compressor current exceeds 18A;


Check if 10HP compressor current exceeds 28A;

Check for damaged OD board LM339N; put it to operation after re

Check for damaged triode on main control board;

-powerup

Check for bad contact at ID/OD connecting cable;

Check for damaged OD board current transformer

Check for normal cooling system;


Load relief

During cooling, check if OD pipe temperature protection

-powerup During heating, check if ID pipe temperature sensor exceeds 68℃

LV switch protection


LV switch shall be ON; check for bad contact at card connection; put it to operation after re

Check for bad contact at ID?OD connecting cable

-powerup card connection

Schedule of other common failures of FR180/S and FR260/S air conditioner PCB board:

Phenomena Method of correction

Check for normal remote control receiver;

Remote control failure

Check for normal remote control transmitter;


Remote controller failure

Check for normal 3V batteries;

Check crystal oscillator circuit;



- 104 -

Troubleshooting

Phenomena

No heating function

Method of correction



Check for reliable output port connection of compressor, reversing valve, ID fans and OD fans;


Check for correct reversing of reversing valve




Check for bad contact at ID/OD connecting cable cards

Indoor fan failure

Outdoor fan failure








In FRD23-B, FRD35-B, FRD50-B, FR(D)95, FR(D)125/S, FR(D)71-B and FR(D)100-B air conditioners, program controlled PCB board consists of main control board PCB1, wire controller PCB2 and remote controller PCB3. Refer to following table for their universality:

FR71-B

FRD23-B

FRD35-B

FRD50-B

FR95-C FR100-B

FR125-C/S FR95

FR180/S

FR260/S

FR125

FRD71-B

FRD100-B FRD180/S

FRD95

FRD125/S

FRD260/S

MCB PCB1

FRD35-B FRD50-B FRD95 FR95 FR180/S FRD95 FRD260/S

WC PCB2

RC PCB3 Universal PCB3

Outdoor electric part is shared by FR180/S and FRD180/S, by FR260/S and FRD260/S, and by FRD95 and FRD100-B. Others have different outdoor electric part.

- 105 -

Troubleshooting

Under following conditions, program controlled electric system will automatically detect failure. Wire controller will display failure codes:

Failure protection

Failure phenomena Failure analysis

When 3 consecutive such protection signals are detected

Check for normal cooling system; check for bad contact at ID pipe temperature sensor connection; displays E1, you can check for broken wire or short circuit at sensor; if operation after re-powerup

(short circuit) displays E2, put it into operation after re-powerup for bad contact, check for broken wire or short circuit in sensor; if normal, check if R7 on ID board is 10K

ID pipe temp Wire controller displays E3, put it

First check ID pipe temperature sensor connection for bad contact, check for broken wire or short circuit in circuit) re-powerup sensor; if normal, check if R6 on ID board is 10K

OD pipe temp Wire controller displays E4, put it

First check OD pipe temperature sensor connection for bad contact, check for broken wire or short circuit circuit) re-powerup in sensor; if normal, check if R5 on ID board is 10K


Check for reliable welding on main control board CN6 and wire controller CN1 needle seat, reliable insertion of cards and broken or short circuit of communication line; communication failure between main

Check for DC12V input on wire controller, DC5V control board and wire controller, the on RG1-3 of wire controller; latter displays E5, Check normal voltage on main control board 2003 and you can only put driving block; it into operation after

Check for normal voltage on crystal oscillator pin of re-powerup main control board and wire controller;

Check for normal voltage at communication input/output of main control board and wire controller

- 106 -

Troubleshooting

C. Other failures

Failure Method of correction

Check for molten FU fuse;

Check for normal DC12V, DC12V output on main control board

7812-3 pin, and DC12V input on wire controller;

Main control board Check for normal DC5V, DC5V output at main control board 7805-3

PCB1 not operating pin, and DC5V on wire controller RG1-3;

Check crystal circuit on main control board and for normal voltage at crystal oscillator pins of chips 1 and 2;

Check for normal resetting circuit 7042 on main control board

Check for normal remote control receiver; failure


Check for normal 3V batteries; failure

No cooling function





Check for reliable connection of output ports of compressor, ID/OD fans;




No heating function

Check for reliable output port connection of compressor, reversing valve, ID fans and OD fans;


Check for intact connection of outdoor unit wiring terminals; failure

Indoor fan failure relay RL1 shall close by suction;

Check for intact reversing valve


- 107 -

Troubleshooting

Failure

Outdoor fan failure

Method of correction







- 108 -

Typical case analysis

Chapter XIII Typical case analysis

Case I: A user installed a number of FR125/S air duct type air conditioners and complained about poor heating effect. Pressure measurement showed that indoor unit and outdoor unit systems were normal without clogging or leakage, and indoor area and thermal insulation met requirements.

Analysis: (1) The indoor unit was installed in ceiling layer of toilet with ventilating windows.

Fresh air leaked into return air so that indoor unit return air temperature in winter was lower than 0℃; (2) Insulation on air delivery hose and static pressure box was merely 5mm thick sticky sponge.

Solution: (1) Fabricate fresh air duct plus air damper control and seal for insulation; or block fresh air window and cancel fresh air duct; (2) Increase air duct thermal insulation to above

15mm.

Case II: A user installed more than 10 sets of FR125/S air duct air conditioners and complained of poor heating effect. For this reason, user installed auxiliary electric heating of sufficient power, so that indoor air delivery temperature was as high as 52℃. However, even at high air speed setting, air delivery was very small and room temperature was low.

Analysis: (1) Space surrounding indoor unit was small and natural return air was used.

Distance between unit return air face to obstacle was only 5cm and return air was seriously blocked; (2) Air delivery main hose was only 0.8m long, i.e. a branch hose leading 2 lines of right angle bends. This branch hose was 20cm diameter round corrugated plastic hose and total air delivery cross sectional area was less than 0.1 m

2

, hence air delivery side was seriously blocked.

Solution: (1) Reinstall indoor unit and change its orientation; also ensure certain space to allow free air return; (2) Increase air delivery branch hose cross sectional area or increase number of such branch hoses, so that total air delivery cross sectional area at any section is larger than 0.15 m

2

; avoid local flattening and short distance right angel sharp turning.

Case III: A user recently installed two FR95 air duct type air conditioners and found poor heating effect and small air delivery. Measured indoor unit air intake temperature was 21.7℃, indoor unit air delivery temperature was 34℃, room air delivery port temperature was 28℃, outdoor ambient was 8.2℃, operating current was 11.5A and heating pressure was 1.4Mpa.

Analysis: (1) Under nominal operating condition, rated operating current was 16A and heating pressure was 1.8Mpa; amount of freon in the unit was apparently small; (2) There was no return air port in any room and air return depended on side doors; (3) The static pressure box had an air delivery hole and was too near indoor unit air return, causing air short circuit and affecting air delivery in other rooms.

Solution: (1) Add freon to specified value and carry out overall leakage detection of pipeline;

(2) Provide effective air return twice the size of air delivery port area to ensure favorable energy cycling and no loss; (3) Block static pressure box air delivery hole and provide thermal

- 109 -

Typical case analysis insulation.

Case IV: A user installed 11 sets of Chunlan FR260/S, FR180/S and FR125/S air duct type air conditioners. During test run, it was found that heating effect was poor and highest air delivery temperature in rooms was only 28℃. Measurement showed that current, voltage and system pressure were all normal.

Analysis: (1) Design of air return was not reasonable. Air return ports provided were as small as half a book and in some rooms, even no such port is provided; (2) Fresh air port was normally open and not controlled by air damper; (3) Room area/space was too large.

Solution: (1) Provide effective air return with sufficient area; (2) Fabricate effective air damper to control fresh air port or block fresh air port; (3) Increase number of air conditioning units or add auxiliary heating.

Case V: A user installed 26 sets of Chunlan air duct type air conditioners, in which 23 were

FR260/S. Now the user complains high noise in many units beyond what he can accept.

Analysis: (1) All units adopt air duct return air to ensure efficiency. Air delivery hose of each unit adopts 3 φ120mm round plastic air ducts and return air duct adopts 5 φ180mm round plastic air ducts. Calculation shows that total air delivery area is 0.0989m

2

, less than 0.135 m

2 recommended by instruction manual; and total return air cross sectional area is 0.127 m

2

, also less than 0.3 m

2

recommended by instruction manual. Calculated air speed in air delivery branch hose and air return branch hose are 5.3/s and 4.15m/s respectively. By consulting tables, noise level is apparently high; (2) Unit installed on support angle steel by hard contact causes resonance and hard contact between metal air duct and ceiling running water pipe aggravates the resonance; (3) Some indoor units are directly installed in operating environment, e.g. ceiling of offices, and rooms in which the units operate are too near sound sources, hence higher noise.

Solution: (1) Increase air delivery/return branch hose cross sectional areas or number of such branch hoses so that sum of cross sectional area of air delivery/return hoses meets instruction manual specification; (2) Avoid hard contact at unit support faces, add wood or rubber pads to isolate vibration; (3) Rooms where air conditioners are used shall be at a longer distance from indoor unit, outdoor unit and other sound sources; if this is not feasible, wrap a 5cm thick sound absorbing sponge plus plastic cloth on indoor unit (except air return port).

Case 6: A user installed two sets of FR180/S air duct type air conditioners early 2003. These share an air system. In summer of the year, it was found that cooling effect was not good and room temperature cannot be brought under 26℃.

Analysis: Measurement showed that one unit was not operating and further inspection showed that there was no display on wire controller of this unit. After replacement of wire controller, there was still no display on wire controller. By swapping wire controller cards on indoor main control boards of two units, the originally failed unit now operated normally while there was no display on the originally normal unit. Measurement of wire controller connecting cable showed that there were m any extension connections on it and the cable had been wetted and had large resistance.

- 110 -


Solution: Replace with complete wire controller connecting cable of sufficient length.

Case VII: A user installed two sets of FR180/S Chunlan air duct type air conditioners. After a period of use, it was found that cooling effect was not good, no cold air was blown out, and air suction hose was frosting.

Analysis: One fan motor was found not operating. Measurement showed that this motor was damaged. After replacing the motor, air delivery was still small and hose side was frosting.

Return air strainer was checked for clogging. After cleaning, air delivery was still small.

Finally, it was found that return air duct was leaking and indoor unit strainer was seriously blocked.

Solution: Repair leakage in return air duct and remove indoor unit strainer for cleaning.

Case VIII: A user installed two sets of FR260/S Chunlan air duct type air conditioners in 2001.

Shortly afterward, it was found that E6 protection occurred on one of them. Our Jinan service agent went on site for inspection. Measurement showed that each parameter of power supply was normal. After re-poweron and operation for 2 hours, E6 protection occurred again. Later,

E2 and E7 protections occurred sometimes, but after re-poweron, normal operation lasted for a period and no abnormity was found in voltage, current or pressure. Bizarre enough, after swapping indoor/outdoor main control boards and wire controllers of two units, the same protections occurred on the same unit.

Analysis: According to past maintenance experience, main control board manufactured before

2002 and used in humid environment can cause such wrong protections sometimes.

Solution: Replace with new indoor/outdoor main control boards.

Case IX: An installation company installed more than 10 air duct type air conditioners in

Dafeng, Jiangsu. For commissioning, when wire controller was plugged on, it was found that wire controllers of several units displayed E5 protection and some even had no display. After replacing with good wire controllers, the same failure occurred. This fault was not cleared after replacing main control board.

Analysis: Bad connection on wire controller socket due to being covered by coating and paint used for room decoration.

Solution: Use needle to remove covering material at wire controller socket and reconnect.

Case X: 9 sets of FR260/S air duct type air conditioners were installed in a ballroom. User complained about high temperature in rooms (29℃) that cannot be brought down and poor cooling and heating effect. Site inspection showed that current system and pressure were normal. Area of application was about 150m

2

/unit. Unit type selection was correct and room thermal insulation was good.

Analysis: (1) Poor sealing between return air duct and air delivery port diffuser. Clearance was between 2mm and 15mm. That return air duct only returned ceiling hot air was the main cause of te phenomena.

(2) Air delivery in each room was not even, hence poor effect.

- 111 -


Solution: (1) Use canvas flexible connection for sealing between return air duct and air delivery port so that good circulation of indoor air is permitted.

(2) Adjust guide damper in air delivery hose of each room so that air delivery in each room is basically equal. After correction, room temperature dropped from 29℃ to 25℃.

Case XI: 9 sets of FR260/S and 3 sets of FR180/S air conditioners were installed in an office building. Installation personnel found during commissioning that indoor noise was too high and beyond the level acceptable by user.

Analysis: (1) In installation, instruction manual requirement was not followed in fixing of indoor unit by angle steel at bottom;

(2) Flexible connection was not used between return air box and static pressure box.

Solution: (1) Follow instruction manual to transform the installation, i.e. use angle steel to fix indoor unit at bottom and add damping measures.

(2) Use canvas flexible connection between return air box and static pressure box;

(3) Increase length of return air duct; noise was apparently reduced.

Case XII: One set of FR100/S air duct type air conditioner was in a hairdressing center. User complained about poor cooling and heating effect.

Analysis: (1) There were a total of 3 air delivery ports: one was too near and the other two had small delivery speed;

(2) Incorrect air delivery angle.

Solution: (1) Change air delivery port area of the first port from 30×30mm

2

to 10×10mm

2 to reduce air delivery amount and increase air speed.

(2) Change area of the other 2 ports from 20×80mm

2

to 20×60mm

2

to apparently increase air speed;

(3) Change air delivery grating angle.

Case XIII: An installation company installed 12 sets of FR125/S air duct type air conditioners.

Main units were installed in office area and user complained of high noise preventing work.

Analysis: Flexible connection was not used for air delivery/return box, cross sectional areas of return air box and static pressure box were small, and silencing measure was taken inside.

Solution:

(1) Remove return air box and adopt ceiling natural air return;

(2) Increase cross sectional area of static pressure box, adopt flexible connection between static pressure box and main unit, and use sagging sponge in static pressure box to reduce noise;

(3) Re-fix main unit as follows: Use 2 pieces of 4×40 angle steels for fixing at bottom. Add wood plate (15mm thick) on these angle steels and stick PE plates (10mm thick) on such wood plate. Size of wood plate and PE plate shall be the same as that of indoor unit bottom

- 112 -

Typical case analysis face.

Case XIV: In installation company installed one FR71-B air duct type air conditioner. Main unit was installed in office. As limited by decoration structure, no air duct was used for indoor unit and direct lateral air exhaust was used. Noise of air flow was too high.

Analysis:

(1) Sectional size of return air box was too small and air speed too high;

(2) Right angle bent connection used between main unit and air delivery hose.

Solution:

(1) Remove return air box, increase air return cross sectional area and lower air speed;

(2) Use arc transition connection between air delivery hose and main unit to reduce resistance.

Case XV: A user installed one FR260/S air duct type air conditioner. Main unit air delivery port had high noise.

Analysis:

(1) Fixing of indoor unit did not follow instruction manual requirements;

(2) Distance between return air box and ceiling was only 12cm and return air space was too small.

(3) Static pressure box was not installed.

Solution:

(1) Re-fix indoor unit to instruction manual requirements;

(2) Remove return air box to increase return air space;

(3) Install static pressure box and use sagging sponge inside for noise reduction;

(4) Use cotton felt for noise reduction of indoor unit.

Note:

1. For relevant models and parameters provided in this manual, actual products and nameplate information shall govern;

2. This manual has been carefully checked. In case of printing error, our company shall not bear responsibility for the consequences.

3. Our company is in constant technology advancement and product series and sizes will be adjusted from time to time. Please note information of our new products.

- 113 -

CHUNLAN FRD35-B Service manual

Assistant Bot

Air duct Type Air Conditioner

Service Manual

JIANGSU CHUNLAN REFRIGERATING EQUIPMENT Co., Ltd.

AUGUST 2004

Contents

Chapter I Structure & features

Chapter II Exploded views & dismantling sequence of parts

Chapter III Main technical parameters

Chapter IV Performance curve

Chapter V Circuit diagrams

Chapter VI List of main parts and wear parts

Chapter VII Type selection

Chapter VIII Installation

Chapter IX Air duct design & noise reduction

Chapter X Method of operation

Chapter XI Maintenance

Chapter XII Troubleshooting

Chapter XIII Typical case analysis

Related manuals

CHUNLAN FRD35-B Service manual

Assistant Bot

Air duct Type Air Conditioner

Service Manual

JIANGSU CHUNLAN REFRIGERATING EQUIPMENT Co., Ltd.

AUGUST 2004

Contents

Chapter I Structure & features

Chapter II Exploded views & dismantling sequence of parts

Chapter III Main technical parameters

Chapter IV Performance curve

Chapter V Circuit diagrams

Chapter VI List of main parts and wear parts

Chapter VII Type selection

Chapter VIII Installation

Chapter IX Air duct design & noise reduction

Chapter X Method of operation

Chapter XI Maintenance

Chapter XII Troubleshooting

Chapter XIII Typical case analysis

Related manuals

Fujitsu

AOYG07KGCB

Vents

KSD

DENAIR

DA Series

Vents

KSD

Just Fire

EC10 Double Duct Airco

Chigo

CS-35H3A MA114A

GREE

FM-1.25-9-K

Frecon

FR100 Series

Breeze

CPD Series

Fintek

iCOOL

Exclusive Heritage

KSD-3221-D7-UBS

Exclusive Heritage

KSD-2421-S-UBS