“P” SERIES 18K – 24K – 220V INVERTER-DRIVEN AIR CONDITIONING UNITS
Installation and Maintenance Manual
"P" SERIES
18K - 24K - 220V
INVERTER-DRIVEN AIR
CONDITIONING UNITS
READ AND UNDERSTAND
THIS MANUAL BEFORE
USING THIS INVERTER-
DRIVEN AIR CONDITIONING
UNIT. KEEP THIS MANUAL
FOR FUTURE REFERENCE.
INDOOR UNIT
DHP18NWB21S
DCP18NWB21S
DHP24NWB21S
DCP24NWB21S
OUTDOOR UNIT
DHP18CSB21S
DCP18CSB21S
DHP24CSB21S
DCP24CSB21S
Type Model
Model Type
IMPORTANT:
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Important Notice
● Johnson Controls, Inc. pursues a policy of continuing improvement in design and performance in its products. As such, Johnson Controls, Inc. reserves the right to make changes at any time without prior notice.
● Johnson Controls, Inc. cannot anticipate every possible circumstance that might involve a potential hazard.
● This inverter air conditioning unit is designed for standard air conditioning applications only. Do not use this unit for anything other than the purposes for which it was intended for.
● The installer and system specialist shall safeguard against leakage in accordance with local pipefitter and electrical codes. The following standards may be applicable, if local regulations are not available.
International Organization for Standardization: (ISO 5149 or European Standard, EN 378). No part of this manual may be reproduced in any way without the expressed written consent of Johnson Controls, Inc.
● This inverter-driven (cooling or heat pump) air conditioning unit will be operated and serviced in the United States of America and comes with all required Safety, Danger, and Caution, warnings.
● If you have questions, please contact your distributor or dealer.
● This manual provides common descriptions, basic and advanced information to maintain and service this inverter-driven (cooling or heat pump) air conditioning unit which you operate, as well for other models.
● This inverter-driven (cooling or heat pump) air conditioning unit has been designed for a specific temperature range. For optimum performance and long life, operate this unit within range limits.
● This manual should be considered as a permanent part of the air conditioning equipment and should remain with the air conditioning equipment.
Product Inspection upon Arrival
1.
Upon receiving this product, inspect it for any damages incurred in transit. Claims for damage, either apparent or concealed, should be filed immediately with the shipping company.
2.
Check the model number, electrical characteristics (power supply, voltage, and frequency rating), and any accessories to determine if they agree with the purchase order.
3.
The standard utilization for this unit is explained in these instructions. Use of this equipment for purposes other than what it designed for is not recommended.
4.
Please contact your local agent or contractor as any issues involving installation, performance, or maintenance arise. Liability does not cover defects originating from unauthorized modifications performed by a customer without the written consent of Johnson Controls, Inc. Performing any mechanical alterations on this product without the consent of the manufacturer will render your warranty null and void.
Table of contents
Table of Contents
2. Installation ................................................................................................................�.�
2.� ����������������������������������������������............................................................��...�
2.4 Installation - Checking Parts ...........................................................................................4
2.5 Selection of Installation Location ......................................................................................4
2.6 Electric Connection Requirement ....................................................................................4
2.7 Installation of Indoor Unit ..................................................................................................4
2.8 Installation of Outdoor Unit ...............................................................................................7
2.9 Vacuum Pump/Leak Detection .........................................................................................8
2.10 Post Installation Testing .................................................................................................8
3. Maintenance ............................................................................................................... 9
3.1 Precautions before Maintenance ...................................................................................... 9
3.2 Error Code List ...............................................................................................................10
3.3 Troubleshooting for Main Malfunction ............................................................................13
3.4 Troubleshooting for Normal Malfunction .........................................................................27
Appendix: ........................................................................................................................29
Appendix 1: Reference Sheet of Celsius and Fahrenheit ....................................................29 Appendix 2: Configuration of Connection Pipe .....................................................................29 Appendix 3: Pipe Expanding Method ...................................................................................30 Appendix 4: List of Resistance for Temperature Sensor ......................................................31
2.1 Installation Dimension Diagram ...................................................................................��...1
1. ������������ and ������������������� ...................................................i
2.� Installation Procedures.....................................................................................................3
Customer Service, Technical Support ....................................................34
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1.
Introduction
This manual should be considered as a permanent part of the air conditioning equipment and should remain with the air conditioning equipment.
This manual concentrates on inverter-driven cooling or heat pump air conditioning units. Read this manual carefully before installation.
2. Important Safety Instructions
Safety Messages
Indicates a hazardous situation that, if not avoided, could result in death or serious injury.
Indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.
Indicates information considered important, but not hazard-related (for example, messages relating to property damage).
General Precautions
To reduce the risk of serious injury or death, read these instructions thoroughly and follow all warnings or cautions included in all manuals that accompanied the product and are attached to the unit. Refer back to these safety instructions as needed.
● This system should be installed by personnel certified by Johnson Controls, Inc. Personnel must be qualified according to local, state and national building and safety codes and regulations. Incorrect installation could cause leaks, electric shock, fire or explosion. In areas where Seismic ‘’Performance requirements are specified, the appropriate measures should be taken during installation to guard against possible damage or injury that might occur in an earthquake if the unit is not installed correctly, injuries may occur due to a falling unit.
● Use appropriate Personal Protective Equipment (PPE), such as gloves and protective goggles and, where appropriate, have a gas mask nearby. Also use electrical protection equipment and tools suited for electrical operation purposes. Keep a quenching cloth and a fire extinguisher nearby during brazing.
Use care in handling, rigging, and setting of bulky equipment.
● When transporting, be careful when picking up, moving and mounting these units. Although the unit may be packed using plastic straps, do not use them for transporting the unit from one location to another. Do not stand on or put any material on the unit. Get a partner to help, and bend with your knees when lifting to reduce strain on your back. Sharp edges or thin aluminum fins on the air conditioner can cut fingers, so wear protective gloves.
● Do not touch or adjust any safety devices inside the indoor or outdoor units. All safety features, disengagement, and interlocks must be in place and functioning correctly before the equipment is put into operation. If these devices are improperly adjusted or tampered with in any way, a serious accident can occur. Never bypass or jump-out any safety device or switch.
● Johnson Controls, Inc. will not assume any liability for injuries or damage caused by not following steps outlined or described in this manual. Unauthorized modifications to Johnson Controls products are prohibited as they… ◦ May create hazards which could result in death, serious injury or equipment damage.
◦ Will void product warranties.
◦ May invalidate product regulatory certifications.
◦ May violate OSHA standards.
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Take the following precautions to reduce the risk of property damage.
● Be careful that moisture, dust, or variant refrigerant compounds not enter the refrigerant cycle during installation work. Foreign matter could damage internal components or cause blockages.
● If air filters are required on this unit, do not operate the unit without the air filter set in place. If the air filter is not installed, dust may accumulate and breakdown may result.
● Do not install this unit in any place where silicon gases can coalesce. If the silicon gas molecules attach themselves to the surface of the heat exchanger, the finned surfaces will repel water. As a result, any amount of condensate can overflow from the condensate pan and could run inside of the electrical box, possibly causing electrical failures.
● When installing the unit in a hospital or other facility where electromagnetic waves are generated from nearby medical and/or electronic devices, be prepared for noise and electronic interference Electromagnetic Interference (EMI). Do not install where the waves can directly radiate into the electrical box, controller cable, or controller. Inverters, appliances, high-frequency medical equipment, and radio communications equipment may cause the unit to malfunction. The operation of the unit may also adversely affect these same devices. Install the unit at least 10 ft. (approximately 3m) away from such devices.
● When a wireless zone controller is used, locate at a distance of at least 3.3 ft. (approximately 1 meter) between the indoor unit and electric lighting. If not, the receiver part of the unit may have difficulty receiving operation commands.
● Do not install the unit in any location where animals and plants can come into direct contact with the outlet air stream. Exposure could adversely affect the animals and plants.
● Do not install the unit with any downward slope to the side of the drain boss. If you do, you may have water flowing back which may cause leaks.
● Be sure the condensate hose discharges water properly. If connected incorrectly, it may cause leaks.
● Do not install the unit in any place where oil can seep onto the units, such as table or seating areas in restaurants, and so forth. For these locations or social venues, use specialized units with oil-resistant features built into them. In addition, use a specialized ceiling fan designed for restaurant use. These specialized oil-resistant units can be ordered for such applications. However, in places where large quantities of oil can splash onto the unit, such as a factory, even the specialized units cannot be used.
These products should not be installed in such locations.
Installation Precautions
To reduce the risk of serious injury or death, the following installation precautions must be followed.
● When installing the unit into… ▫ A wall: Make sure the wall is strong enough to hold the unit’s weight. It may be necessary to construct a strong wood or metal frame to provide added support.
▫ A room: Properly insulate any refrigerant tubing run inside a room to prevent “sweating” that can cause dripping and water damage to wall and floors.
▫ Damp or uneven areas: Use a raised concrete pad or concrete blocks to provide a solid, level foundation for the unit to prevent water damage and abnormal vibration.
▫ An area with high winds: Securely anchor the outdoor unit down with bolts and a metal frame.
Provide a suitable air baffle.
▫ A snowy area (only for heat pump model): Install the outdoor unit on a raised platform that is higher than drifting snow. Provide snow vents.
● Do not install the unit in the following places. Doing so can result in an explosion, fire, deformation, corrosion, or product failure. ▫ Explosive or flammable atmosphere
▫ Where fire, oil, steam, or powder can directly enter the unit, such as in close proximity or directly above a kitchen stove.
▫ Where oil (including machinery oil) may be present.
▫ Where corrosive gases such as chlorine, bromine, or sulfide can accumulate, such as near a hot tub or hot spring.
▫ Where dense, salt-laden airflow is heavy, such as in coastal regions.
▫ Where the air quality is of high acidity.
▫ Where harmful gases can be generated from decomposition.
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● Do not position the condensate pipe for the indoor unit near any sanitary sewers where corrosive gases may be present. If you do, toxic gases can seep into breathable air spaces and can cause respiratory injuries. If the condensate pipe is installed incorrectly, water leakage and damage to the ceiling, floor, furniture, or other possessions may result. If condensate piping becomes clogged, moisture can back up and can drip from the indoor unit. Do not install the indoor unit where such dripping can cause moisture damage or uneven locations: Use a raised concrete pad or concrete blocks to provide a solid, level foundation for the unit to prevent water damage and abnormal vibration.
● Before performing any brazing work, be sure that there are no flammable materials or open flames nearby.
● Perform a run test to ensure normal operation. Safety guards, shields, barriers, covers, and protective devices must be in place while the compressor/unit is operating. During the test run, keep fingers and clothing away from any moving parts.
● Clean up the site when finished, remembering to check that no metal scraps or bits of wiring have been left inside the unit being installed.
● During transportation, do not allow the backrest of the forklift to make contact with the unit, otherwise, it may cause damage to the heat exchanger and also may cause injury when stopped or started suddenly.
● Remove gas inside the closing pipe when the brazing work is performed. If the brazing filler metal is melted with remaining gas inside, the pipes will be blown off and it may cause injury.
● Be sure to use nitrogen gas for an airtight test. If other gases such as oxygen gas, acetylene gas or fluorocarbon gas are accidentally used, it may cause explosion or gas intoxication.
After installation work for the system has been completed, explain the “Safety Precautions,” the proper use and maintenance of the unit to the customer according to the information in all manuals that came with the system. All manuals and warranty information must be given to the user or left near the Indoor Unit.
Refrigerant Precautions
To reduce the risk of serious injury or death, the following refrigerant precautions must be followed.
● As originally manufactured, this unit contains refrigerant installed by Johnson Controls. Johnson Controls uses only refrigerants that have been approved for use in the unit’s intended home country or market. Johnson Controls distributors similarly are only authorized to provide refrigerants that have been approved for use in the countries or markets they serve. The refrigerant used in this unit is identified on the unit’s faceplate and/or in the associated manuals. Any additions of refrigerant into this unit must comply with the country’s requirements with regard to refrigerant use and should be obtained from Johnson Controls distributors. Use of any non-approved refrigerant substitutes will void the warranty and will increase the potential risk of injury or death.
● If installed in a small room, take measures to prevent the refrigerant from exceeding the maximum allowable concentration in the event that refrigerant gases should escape. Refrigerant gases can cause asphyxiation (0.42 kg/m3 based on ISO 5149 for R410A). Consult with your distributor for countermeasures (ventilation system and so on). If refrigerant gas has leaked during the installation work, ventilate the room immediately.
● The design pressure for this product is 601 psi (4.15MPa). The pressure of R410A refrigerant is 1.4 times higher than that of the refrigerant R22. Therefore, the refrigerant piping for R410A shall be thicker than that for R22. Make sure to use the specified refrigerant piping. If not, the refrigerant piping may rupture due to an excessive refrigerant pressure. Besides, pay attention to the piping thickness when using copper refrigerant piping. The thickness of copper refrigerant piping differs depending on its material.
● The refrigerant R410A is adopted. The refrigerant oil tends to be affected by foreign matters such as moisture, oxide film, (or fat). Perform the installation work with care to prevent moisture, dust, or different refrigerant from entering the refrigerant cycle. Foreign matter can be introduced into the cycle from such parts as expansion valve and the operation may be unavailable.
● To avoid the possibility of different refrigerant or refrigerant oil being introduced into the cycle, the sizes of the charging connections have been changed from R407C type and R22 type. It is necessary to prepare the appropriate tools before performing the installation work.
● Use refrigerant pipes and joints which are approved for use with R410A.
● A compressor/unit comprises a pressurized system. Never loosen threaded joints while the system is
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under pressure and never open pressurized system parts.
● Before installation is complete, make sure that the refrigerant leak test has been performed. If refrigerant gases escape into the air, turn OFF the main switch, extinguish any open flames and contact your service contractor. Refrigerant (Fluorocarbon) for this unit is odorless. If the refrigerant should leak and come into contact with open flames, toxic gas could be generated. Also, because the fluorocarbons are heavier than air, they settle to the floor, which could cause asphyxiation.
● When installing the unit, and connecting refrigerant piping, keep all piping runs as short as possible, and make sure to securely connect the refrigerant piping before the compressor starts operating. If the refrigerant piping is not connected and the compressor activates with the stop valve opened, the refrigerant cycle will become subjected to extremely high pressure, which can cause an explosion or fire.
● Tighten the flare nut with a torque wrench in the specified manner. Do not apply excessive force to the flare nut when tightening. If you do, the flare nut can crack and refrigerant leakage may occur.
● When maintaining, relocating, and disposing of the unit, dismantle the refrigerant piping after the compressor stops.
● When pipes are removed out from under the piping cover, after the insulation work is completed, cover the gap between the piping cover and pipes by a packing (field-supplied). If the gap is not covered, the unit may be damaged if snow, rain water or small animals enter the unit.
● Do not apply an excessive force to the spindle valve at the end of opening. Otherwise, the spindle valve flies out due to refrigerant pressure. At the run test, fully open the gas and liquid valves, otherwise, these devices will be damaged. (It is closed before shipment.)
● If the arrangement for outdoor units is incorrect, it may cause flowback of the refrigerant and result in failure of the outdoor unit.
● The refrigerant system may be damaged if the slope of the piping connection kit exceeds +15o.
Electrical Precautions
Take the following precautions to reduce the risk of electric shock, fire or explosion resulting in serious injury or death.
● Highly dangerous electrical voltages are used in this system. Carefully refer to the wiring diagram and these instructions when wiring. Improper connections and inadequate grounding can cause serious injury or death.
● Perform all electrical work in strict accordance with this installation and maintenance manual and all the relevant regulatory standards.
● Before servicing, open and tag all disconnect switches. Never assume electrical power is disconnected. Check with meter and equipment.
● Only use electrical protection equipment and tools suited for this installation.
● Use specified cables between units.
● The new air conditioner may not function normally in the following instances:
▫ If electrical power for the new air conditioner is supplied from the same transformer as the device* referred to below.
▫ If the power source cables for this device* and the new air conditioner unit are located in close proximity to each other.
Device*: (Example): A lift, container crane, rectifier for electric railway, inverter power device, arc furnace, electric furnace, large-sized induction motor and large-sized switch.
Regarding the cases mentioned above, surge voltage may be inducted into the power supply cables for the packaged air conditioner due to a rapid change in power consumption of the device and an activation of a switch.
Check field regulations and standards before performing electrical work in order to protect the power supply for the new air conditioner unit.
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● Use an exclusive power supply for the air conditioner at the unit’s rated voltage.
● Be sure to install circuit breakers (ground fault interrupter, isolating switch, molded case circuit breaker and so on), with the specified capacity. Ensure that the wiring terminals are tightened securely to recommended torque specifications.
● Clamp electrical wires securely with a cable clamp after all wiring is connected to the terminal block.
In addition, run wires securely through the wiring access channel.
● When installing the power lines, do not apply tension to the cables. Secure the suspended cables at regular intervals, but not too tightly.
● Make sure that the terminals do not come into contact with the surface of the electrical box. If the terminals are too close to the surface, it may lead to failures at the terminal connection.
● Turn OFF and disconnect the unit from the power source when handling the service connector. Do not open the service cover or access panel to the indoor or outdoor units without turning OFF the main power supply.
● After ceasing operation, be sure to wait at least five minutes before turning off the main power switch. Otherwise, water leakage or electrical breakdown may result. Disconnect the power source completely before attempting any maintenance for electrical parts. Check to ensure that no residual voltage is present after disconnecting the power source.
● Do not clean with, or pour water into, the controller as it could cause electric shock and/or damage the unit. Do not use strong detergent such as a solvent. Clean with a soft cloth.
● Check that the ground wire is securely connected. Do not connect ground wiring to gas piping, water piping, lighting conductor, or telephone ground wiring.
● If a circuit breaker or fuse is frequently activated, shut down the system and contact your service contractor.
● Perform all electrical work in accordance with this manual and in compliance with all regulations and safety standards.
● Do not open a service access cover or panel of an indoor or outdoor unit without first turning OFF the power at the main power supply.
● Residual voltage can cause electric shock. At all times, check for residual voltage after disconnecting from the power source before starting work on the unit.
● This equipment can be installed with a Ground Fault Circuit Breaker (GFCI), which is a recognized measure for added protection to a properly grounded unit. Install appropriate sized breakers/fuses/ overcurrent protection switches, and wiring in accordance with local, state and NEC codes and requirements. The equipment installer is responsible for understanding and abiding by applicable codes and requirements.
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Installation and Maintenance
2. Installation
2.1 Installation Dimension Diagram
unit:inch
Space to the ceiling
Space to the wall
At least 8
At least 72
At least 6
At least 6
Space to the wall
Space to the obstruction
or pace t o t he olf S
Space to the obstruction
Condensate pipe
Space to the wall
Space to the obstruction
Space to the obstructio
Space to the obstruction
At least 24
At least 12
At least 24
At least 12
At least 78
At least 118
1
2 Installation and Maintenance
2.2 Main Tools for Installation and Maintenance
1. Level meter, measuring tape
4. Electroprobe
7. Electronic leakage detector
10. Pipe pliers, pipe cutter
2. Screw driver
5. Universal meter
8. Vacuum pump
11. Pipe expander, pipe bender
3. Impact drill, drill head, electric drill
6. Torque wrench, open-end wrench, inner hex wrench
9. Manifold gauge
12. Soldering appliance, refrigerant container
3 Installation and Maintenance
Preparation before installation
Prepare tools Read the requirements for electric connection
Select installation location
Select indoor unit installation location
Install wall-mounting frame, drill wall holes
Connect pipes of indoor unit and drainage pipe
Connect wires of indoor unit
Connect wires of outdoor unit
Bind up pipes and hang the indoor unit
Make the bound pipes pass through the wall hole and then connect outdoor unit
Arrange the pipes
Vacuum pumping and leakage detection
Check after installation and test operation
Finish installation
Note: This flow is only for reference. Please find more detailed installation steps in this manual.
Select outdoor unit installation location
Mount support of outdoor unit (select it according to the actual situation)
Install drainage joint of outdoor unit (only for cooling and heating unit)
Connect pipes of outdoor unit
Start installation
Mount outdoor unit
2.3 Installation Procedures
4 Installation and Maintenance
No.
Name No.
Name
1 Indoor unit 8 Sealant
2 Outdoor unit 9 Wrapping tape
3 Connection pipe 10 Support of outdoor unit
4 Condensate pipe 11 Securing screw
5 Wall-mounting frame 12 Drainage plug(cooling and heating unit)
6 Connecting cable(power cord) 13 Owner’s manual, remote controller
7 Wall pipe
1. Safety Precaution (1) All electric safety regulations must be followed when installing the unit. (2) Use proper power supply circuit and air switch in accordance with local safety regulations. (3) The power supply must be sized to meet the requirements of air conditioning unit. Incorrect sizing/ wiring may result in electric shock,fire hazard or malfunction.
(4) Properly connect the live wire, neutral wire and grounding wire of power socket. (5) Be sure to cut off the main power supply before performing any electrical work. (6) Do not turn power back on until installation is complete. (7) For appliances with type Y attachment,the instructions shall contain the substance of thefollowing.If the supply cord is damaged, it must be replaced by the manufacturer, its service agent or a qualified technician to avoid any shock hazards. (8) The temperature of refrigerant circuit will be high, please keep the interconnection cable away from the copper tube.
2.4 Installation - Checking Parts
2.5 Selection of Installation Location
2.6 Electric Connection Requirement
2.7 Installation of Indoor Unit
Air-conditioner Air switch capacity
18/24K 25A
1.Please contact the distributor for installation.
2.Use specified cables according to standards and regulations.
1. Basic Requirement: Installing the unit in the following places may cause malfunction. If it is unavoidable, please consult the local dealer:(1) Areas with strong heat sources, vapors, flammable or explosive gas, or volatile objects spread in the air. (2) Areas with high-frequency devices (such as welding machine, medical equipment). (3) Areas near coast. (4) Areas with oil or fumes in the air. (5) Areas with sulfureted gas. (6) Other places with special circumstances.
2. Grounding Requirements: (1) The air conditioner must be properly grounded with a specialized grounding device by an authorized professional. Please make sure it is always grounded effectively, otherwise it may cause electric shock. (2) The yellow-green wire in air conditioner is grounding wire, which can't be used for other purposes. (3) The grounding resistance should comply with national electric safety regulations. (4) The unit must be positioned so that the plug is accessible. (5) An all-pole disconnection switch having a contact separation of at least 1/8 inch in all poles should be connected in fixed wiring. (6) Including an air switch with suitable capacity, please note the following: Use a breaker of appropriate capacity to protect the circuit.
1. Choosing Installation Iocation Recommend the installation location to the customer and then confirm it with the customer.
2. Install Wall-mounting Frame (1) Hang the wall-mounting frame on the wall. Adjust it in horizontal position with a level meter and then measure out the screw fixing holes on the wall. (2) Drill the screw fixing holes on the wall with impact drill (the specification of drill head should be the same as the plastic expansion particle) and then fill the plastic expansion particles
2. Indoor Unit: (1) There should be no obstruction near air inlet and air outlet.(2) Select a location where condensation can be dispersed easily and won't affect people. (3) Select a location which is convenient to connect the outdoor unit and near a power socket. (4) Select a location which is out of reach for children. (5) The location should be able to withstand the weight of indoor unit and won't increase electromagnetic interference and vibration. (6) The unit must be installed 72 inches above a floor. (7) Don't install the indoor unit right above an electric appliance.
3. Outdoor Unit: (1) Select a location where noise and outflow air emitted by the outdoor unit will not affect the environment. (2) The location should be well ventilated and away from strong winds. (3) The location should be able to withstand the weight of outdoor unit. (4) Make sure that the installation follows the requirements of installation dimension diagram. (5) Select a location which is out of reach for children and far away from animals or plants.If it is unavoidable, please add fence or barricade for safety purposes. (6) Install above local snow line.
Note:
5 Installation and Maintenance
Outlet pipe
Condensate hose
Condensate hose
Tape
Outlet pipe
Insulating pipe
Torque wrench
Open-end wrench
Indoor pipe
Pipe
Union nut
Union nut Pipe joint Pipe
Refer to the following table for tightening torque:
Left
Rear left
Right Rear right
Cut
the hole
Left Right Condensate hose
Insulating pipe
5-10°
2 3/16 or (2 3/4)inch
Indoor Outdoor
(1) Pay attention to dust prevention and take relevant safety measures when opening the hole. (2) The plastic screw expander can be bought at a local hardware store.
(1) Add insulating pipe in the indoor condensate hose in order to prevent condensation. (2) The screw expander can be found at a local hardware store. (As shown in Fig.10)
Fig.1
Fig.2
Fig.5 Fig.6
Fig.7
Fig.8 Fig.9
Fig.10
Fig.3
Fig.4
in the holes. (3) Secure the wall-mounting frame on the wall with tapping screws (ST4.2X25TA) and then check if the frame is firmly installed by pulling the frame. If the plastic expansion particle is loose, please drill another fixing hole nearby.
3. Install Wall-mounting Frame (1) Choose the position of piping hole according to the directions of outlet pipe. The position of piping hole should be a little lower than the wall-mounted frame. (As shown in Fig.1)
5. Connect the Pipe of Indoor Unit (1) Aim the pipe joint at the corresponding bellmouth. (As shown in Fig.5) (2) Pretighten the union nut by hand. (3) Adjust the torque force by referring to the following.
Place the open-end wrench on the pipe joint and place the torque wrench on the union nut. Tighten the union nut with torque wrench. (As show in Fig.6) (4) Wrap the indoor pipe and joint of connection pipe with insulating pipe, and then wrap it with tape. (As shown in Fig.7)
6. Install Condensate Hose (1) Connect the condensate hose to the outlet pipe of indoor unit. (As shown in Fig.8) (2) Bind the joint with tape. (As shown in Fig.9)
4. Outlet Pipe (1) The pipe can be led out in the direction of right, rear right, left or rear left. (As shown in Fig.3) (2) When selecting leading out of the pipe from left or right, please cut the corresponding hole on the bottom case. (As shown, in Fig.4)
(2) Open a piping hole with a diameter of 2-3/16 (2-3/4) inches on the selected outlet pipe position. In order to drain smoothly, slant the piping hole on the wall slightly downward to the outdoor side with a gradient of 5-10°. (As shown in Fig.2)
Note:
Note:
Hex nut diameter(inch) Tightening torque(ft·Ibf)
Φ1/4
11.10~14.75
Φ3/8
22.12~29.50
Φ1/2
33.19~40.56
Φ5/8
44.24~47.94
Φ3/4
51.32~55.31
Left
Wall
Φ2 3/16(2 3/4)
Φ2 3/16(2 3/4) Right
Mark in the middle of it Level meter
Rear piping hole
Wall
Space to the wall above 6inch
Space to the wall above 6inch
Rear piping hole
6 Installation and Maintenance
connection wire sleeve
(4) Put wiring cover back and then tighten the screw. (5) Close the panel.
Indoor unit Gas pipe
Indoor and outdoor power cord
Liquid pipe
Drain hose
Band
Drain hose Band Connection pipe
Indoor power cord
Note: (1) All wires of indoor unit and outdoor unit should be connected by a professional. (2) If the length of power connection wire is insufficient, please contact the supplier for a new one. Avoid extending the wire by yourself. (3) For the air conditioning unit a with plug, the plug should be reachable after finishing installation. (4) For the air conditioning unit without a plug, an air switch must be installed in the line. The air switch should be all-pole parting and the contact parting distance should be more than 3/32 inch.
Note: (1) The power cord and control wire can't be crossed or wound together. (2) The condensate hose should be bound at the bottom.
Note: Do not bend the condensate hose too excessively in order to prevent blocking.
7. Connect Wire of Indoor Unit
(1) Open the panel, remove the screw on the wiring cover and then take down the cover. (As shown in Fig.11)
8. Bind up Pipe
(1) Bind up the connection pipe, power cord and condensate hose with the band. (As shown in Fig.14) (2) Reserve a certain length of condensate hose and power cord for installation when binding them. When binding to a certain degree, separate the indoor power and then separate the condensate hose.(As shown in Fig.15) (3) Bind them evenly. (4) The liquid pipe and gas pipe should be bound separately at the end.
9. Hang the Indoor Unit
(1) Put the bound pipes in the wall pipe and then make them pass through the wall hole. (2) Hang the indoor unit on the wall-mounting frame. (3) Stuff the gap between pipes and wall hole with sealant. (4) Fix the wall pipe.(As shown in Fig.16) (5) Check if the indoor unit is installed firmly and close to the wall.(As shown in Fig.17)
(2) Fix the wire crossing board on connection wire sleeve at the bottom case. Let the connection wire sleeve go through the wire crossing hole at the back of indoor unit, and then pull it out from the front.(As shown in Fig.12)
(3) Remove the wire clip; connect the power connection wire to the wiring terminal; tighten the screw and then fix the power connection wire with wire clip.(As shown in Fig.13)
Indoor Outdoor Wall pipe
Sealant
Upper hook
Lower hook of wall-mounting frame
Fig.11
Fig.12
Fig.13
Fig.14
Fig.15
Fig.16
Fig.17
Wiring cover
Screw Panel
Outdoor unit connection
L2’ S
L1’ G
green
green)
red black (brown) (yellow-white (blue)
7 Installation and Maintenance
(1) Take sufficient protective measures when installing the outdoor unit. (2) Make sure the support can withstand at least four times the unit weight. (3) The outdoor unit should be installed at least 1 3/16 inch above the floor in order to install drain joint.(As shown in Fig.18) (4) For the unit with cooling capacity of 2300W~5000W, six expansion screws are needed; for the unit with cooling capacity of 6000W~8000W, eight expansion screws are needed; for the unit with cooling capacity of 10000W~16000W, 10 expansion screws are needed.
(1) After tightening the screw, pull the power cord slightly to check if it is firm. (2) Never cut the power connection wire to prolong or shorten the distance.
(1) The through-wall height of condensate hose shouldn't be higher than the outlet pipe hole of indoor unit.(As show n in Fig.25) (2) Slant the condensate hose slightly downwards. The condensate hose can't be curved, raised and fluctuant, etc.(As shown in Fig.26)
Note:
Note:
Note:
The drain hos can't raise upwards
gas pipe
Liquid pipe
Liquid valve
gas valve
Union nut
Pipe joint
Foot holes
Foot holes
2.9 Installation of Outdoor Unit
1. Fix the Support of Outdoor Unit(Install above local snow line.) (1) Select installation location according to the house structure. (2) Fix the support of outdoor unit on the selected location with expansion screws.
5. Connect Outdoor Electric Wire (1) Let the connection wire sleeve go through the two holes of baffle; tighten the connection joint of sleeve and baffle; remove the wire clip; connect the power connection wire and power cord to the wiring terminal according to the color; fix them with screws.(As shown in Fig.23)
6. Neaten the Pipes (1) The pipes should be placed along the wall, bent reasonably and hidden if possible. Min. semidiameter of bending the pipe is 3 15/16inch. (2) If the outdoor unit is higher than the wall hole, you must set a U-shaped curve in the pipe before pipe goes into the room, in order to prevent rain from getting into the room.(As shown in Fig.24)
(2) Fix the power connection wire and power cord with wire clip. (3) Fix the stopper on handle with screw.
2. Install Drain Joint(only for cooling and heating unit) (1) Connect the outdoor drain joint into the hole on the chassis.(2) Connect the condensate hose into the drain vent. (As shown in Fig.19)
3. Fix Outdoor Unit (1) Place the outdoor unit on the support. (2) Fix the foot holes of outdoor unit with bolts. (As show in Fig.20)
4. Connect Indoor and Outdoor Pipes (1) Remove the screw on the right handle and valve cover of outdoor unit and then remove the handle and valve cover. (As shown in Fig.21) (2) Remove the screw cap of valve and aim the pipe joint at the bellmouth of pipe.(As show in Fig.22)
(3) Pretighten the union nut by hand. (4) Tighten the union nut with torque wrench .
Hex nut diameter(inch) Tightening torque(ft·Ibf)
Φ1/4
11.10~14.75
Φ3/8
22.12~29.50
Φ1/2
33.19~40.56
Φ5/8
44.24~47.94
Φ3/4
51.32~55.31
Refer to the following table for wrench tightening:
Fig.18 Fig.19
Fig.20 Fig.21
Fig.22
Fig.23
Fig.24
Fig.25
U-shaped curve
Wall
Drain hose
At least 1 3/16 inch above the floor
Chassis
Outdoor drain joint Drain hose
Drain vent
Handle
18、24K：
Indoor unit connection
POWER
L1’ S
L2’ L2
L2
L1 G
L1
(blue) white (blue) white red black (brown) (brown) black
(yellow-green
green) (yellow-green
green)
Handle
Valve cover
8 Installation and Maintenance
(3) The water outlet can't be placed in water in order to drain smoothly.(As show in Fig.27)
Liquid valve
Gas valve
Refrigerant charging vent
Nut of refrigerant
Charging vent
Vacuum pump
Manifold gauge
Valve cap
Lo Hi
Inner hex wrench
Open Close
The drain hose can't be fluctuant
The drain hose can't be fluctuant The water outlet can't be fluctuant
NO.
Items to be checked Possible malfunction
1 Has the unit been installed firmly?
The unit may drop, shake or emit noise.
2 Have you done the refrigerant leakage test?
It may cause insufficient cooling (heating) capacity.
3 Is heat insulation of pipeline sufficient?
It may cause condensation and water dripping.
4 Is water drained well?
It may cause condensation and water dripping.
5
Is the voltage of power supply according to the voltage marked on the nameplate?
It may cause malfunction or damage the parts.
6
Is electric wiring and pipeline installed correctly?
It may cause malfunction or damage the parts.
7 Is the unit grounded securely?
It may cause electric shock.
8 Does the power cord follow the specification?
It may cause malfunction or damage the parts.
9 Is there any obstruction in air inlet and air outlet?
It may cause insufficient cooling (heating).
10
The dust and sundries caused during installation are removed?
It may cause malfunction or damaging the parts.
11
The gas valve and liquid valve of connection pipe are open completely?
It may cause insufficient cooling (heating).
The water outlet can't be placed in water
1. Use Vacuum Pump (1) Remove the valve caps on the liquid valve and gas valve and the nut of refrigerant charging vent. (2) Connect the charging hose of manifold gauge to the refrigerant charging vent of gas valve and then connect the other charging hose to the vacuum pump. (3) Open the piezometer completely and operate for 10-15min to check if the pressure of manifold gauge remains in -14.5ISP. (4) Close the vacuum pump and maintain this status for 1-2min to check if the pressure of manifold gauge remains in -14.5ISP. If the pressure decreases, there may be leakage. (5) Remove the manifold gauge, open the valve core of liquid valve and gas valve completely with inner hex wrench. (6) Tighten the screw caps of valves and refrigerant charging vent. (As shown in Fig.28)
1. Check after Installation Check according to the following requirements after finishing installation.
2. Test Operation (1) Preparation of test operation ● The customer approves the air conditioner installation. ● Specify the important notes for air conditioner to the customer. (2) Method of test operation ● Apply power, press ON/OFF button on the remote controller to start operation. ● Press MODE button to select AUTO, COOL, DRY, FAN and HEAT to check whether the operation is normal or not. ● If the ambient temperature is lower than 61°F (16℃) , the air conditioning unit can’t start cooling.
2. Leakage Detection (1) Check for leaks using the leak detector: (2) With soap water: if a leak detection tool is unavailable, use soap water to detect any leak. Apply soap water to the suspected leak position and observe for 3 minutes, if bubbles appear then there is a leak.
2.8 Vacuum Pump/Leak Detection
2.10 Post Installation Testing
Fig.26
Fig.27
Fig.28
9 Installation and Maintenance
There are high-capacity electrolytic capacitors on the outdoor mainboard. Thus, even if the power is cut off, there is high voltage inside the capacitors and it needs more than 20 min. to reduce the voltage to safety value. Touching the electrolytic capacitor within 20 min. after cutting the power will cause electric shock. If maintenance is needed, follow the steps below to discharge electricity of electrolytic capacitor after power off.
(1) Open the top cover of outdoor unit and then remove the cover of the electric box.
(2) After finishing discharging electricity, measure the voltage between points A and B with universal meter to make sure if electricity discharging is completed, in order to prevent electric shock. If the voltage between the two points is below 20V, you can perform maintenance safely.
3. Maintenance
3.1 Precautions before Maintenance
outdoor mainboard
cover of electric box
10 Installation and Maintenance
3.2 Error Code List
Malfunction of zero-cross direction U8
Off 3s and blink
17 times The complete unit stops
1.Power supply is abnormal
2.Detection circuit of indoor control mainboard is abnormal
13
cooling, dehumidifying, except the indoor fan motor is running, others will stop to run; heating; all stop running
11 Installation and Maintenance
It’s the normal state
Off 3s and blink once (during blinking, ON 10s and Off 05s)
Defrosting will occur in heating mode.Compressor will operate while indoor fan will stop.
Complete unit current detection malfunction
Off 3s and blink
13 times U5
12 Installation and Maintenance
13 Installation and Maintenance
3.3 Troubleshooting for Main Malfunction
●Indoor unit:
1. Malfunction of Temperature Sensor F1, F2 Main detection points: ● Is the wiring terminal between the temperature sensor and the controller loose or poorly contacted? ● Is there short circuit due to trip-over of the parts? ● Is the temperature sensor broken? ● Is mainboard broken?
Malfunction diagnosis process:
Is the wiring terminal between the temperature sensor and the controller loose or poorly contacted?
Start
Insert the temperature
sensor tightly
Yes
Yes
Yes
Yes
Yes
Yes
No
No
No
No
No
No
Is malfunction
eliminated
Is malfunction
eliminated
Is malfunction
eliminated
Replace it with a
temperature sensor with
the same model
Make the parts upright
Is there short circuit due to trip-
over of the parts
Is the temperature sensor normal according to the resistance table?
Replace the mainboard with
the same model.
End
14 Installation and Maintenance
End
No
Yes No
Yes
No
Yes
Yes
Yes
No
No
No
Yes
Yes No
Turn the fan blades by hand under power-off condition
Whether the fan blades can run smoothly?
Adjust the motor and blade assembly so that rotor can run smoothly.
Under power-off condition, check whether the wiring terminal between indoor fan and main board is loose.
Turn unit on to check whether the malfunction is eliminated.
Turn unit on to check whether the malfunction is eliminated.
Reinsert the wiring terminal of indoor fan.
It's the malfunction of main board.
Replace a new main board that is of the same model.
It's the malfunction of main board.
Replace a new main board that is of the same model.
Replace a new main board that is of the same model.
It's the malfunction of main board.
Then check whether the voltage between terminal 2 and terminal 3 of the motor interface is 15VDC.
Connect power and restart the unit.
Test whether the voltage between terminal 1 and terminal 2 of motor interface is within 280~310VDC.
Then check whether there is voltage between terminal 2 and terminal 4 of the motor interface.
It's the malfunction of motor.
Replace a new motor that is of the same model.
Start
2. Malfunction of Blocked Protection of IDU Fan Motor H6 Main detection points: ● Is the control terminal of PG motor connected tightly? ● Is the feedback interface of PG motor connected tightly? ● The fan motor can't operate? ● The motor is broken? ● Detection circuit of the mainboard is defined abnormal?
Malfunction diagnosis process:
15 Installation and Maintenance
3. Malfunction of Protection of Jumper Cap C5 Main detection points: ● Is there jumper cap on the mainboard? ● Is the jumper cap inserted correctly and tightly? ● The jumper is broken? ● The motor is broken? ● Detection circuit of the mainboard is defined abnormal?
Malfunction diagnosis process:
Start
Is there jumper cap on the mainboard?
Is the jumper cap inserted correctly
and tightly?
Replace the jumper cap with
the same model
Appearance of the
jumper cap
Assemble the jumper
cap with the same model
Insert the jumper
cap tightly
Is malfunction
eliminated?
Is malfunction
eliminated?
Is malfunction
eliminated?
Replace the mainboard
with the same model
End
Yes
Yes
Yes
Yes
Yes
No
No
No
No
No
16 Installation and Maintenance
4. Communication malfunction E6
Start
Cut off power supply. Check if connection line of IDU and ODU and the wire inside electric box are correctly connected.
Correct connection?
Main board matches with display board? Main board of IDU matches with that of ODU?
Communication cord is damaged?
Replace IDU's main board
Malfunction eliminated?
End
Connect the line according to wiring diagram.
Match correctly according to product specification
Replace communication cord
Replace ODU's main board.
Malfunction eliminated?
Malfunction eliminated?
Malfunction eliminated?
yes
yes
yes
yes
yes
yes
yes
no
no
no
no
no no
no
IDU = Indoor Unit ODU = Outdoor Unit
17 Installation and Maintenance
●Outdoor unit:
Key detection point
"Test point NO." Test point Related elements Test value under normal conditions
Test 1 Between A and C Neutral wire ,live wire
160V-265V
Test 2 Between B and C Neutral wire ,live wire
160V-265V
Test 3 Between D and E Electrolytic capacitor of DC bas bar
DC 180V-380V
Test 4 Between F and G Electrolytic capacitor of switch power
DC 180V-380V
Test 5 Both ends of diode D59 D59(IPM module +15V)
DC 14.5V-15.5
Test 6 Both ends of electrolytic capacitor C47 C47(+12V power)
DC 12V-13V
Test 7 Both ends of electrolytic capacitor C60 C60(+5V power)
DC 5V
Test 8 Both ends of electrolytic capacitor C73 C73(+3.3V power)
DC 3.3V
Test 9 Between S and T Communication circular current
DC 56V
Test 10 Between point N and GND C50 to N terminal (ground) (signal receiving terminal of outdoor unit) Jumping between 0V and 3.3V
Test 11 U7 Between 1 and 2 at leading foot of U7 Jumping between 0V and 3.3V
Test 12 Between point M and GND R77 to N terminal (ground) (signal receiving terminal of
outdoor unit) Jumping between 0V and 3.3V
Test 13 U8 Between 3 and 4 at leading foot of U8 Jumping between 0V and 3.3V
18 Installation and Maintenance
1.Capacity charging malfunction (outdoor unit malfunction) (AP1 below is control board of outdoor unit)
Main detection point:
● Detect if the voltage of L and N terminals of wiring board is between 210AC-240AC by alternating voltage meter. ● Is reactor (L) well connected? Is connection wire loose or pulled out? Is reactor (L) damaged?
Malfunction diagnosis process:
N
Y
N
Y
N
Y
N
Y
N
Y
Turn on the unit
and wait 1 minute
Use DC voltmeter to measure the voltage on the two ends of electrolytic
capacitor
Voltage higher than 200V?
Fault with the voltage testing circuit on control panel AP1 Replace the control panel AP1
Measure the AC voltage between terminal L and N on wiring board XT(power supply)
Voltage within
210VAC~250VAC?
Shut down the power and repair the power supply to restore the range
210VAC~250VAC
power on and restart the unit
Is the fault eliminated?
Shut down the power and wait 20 minutes or use DC voltmeter to measure the voltage on the two ends of capacitor (test3), until the voltage is lower than 20V
Check the connection of reactor (L in the Electrical Wiring Diagram)
If the wiring of
reactor L is normal?
Connect the reactor
trical Wiring Diag-ram correctly
Laccording to Elec-Re-energize and turn on the unit
Is the fault eliminated?
End
Replace the control panel AP1
19 Installation and Maintenance
2.IPM protection, desynchronizing malfunction, phase current of compressor is overcurrent (AP1 below is control board of outdoor unit)
Main detection point:
● If control board AP1 and compressor COMP is well connected? If they are loosened? If the connection sequence is correct? ● Is voltage input in the normal range? (Test the voltage between L, N of wiring board XT by DC voltage meter.) ● If coil resistance of compressor is normal? Is compressor coil insulating to copper pipe well? ● If the work load of unit is heavy? If radiating of unit is well? ● If the refrigerant charging is appropriate?
Malfunction diagnosis process:
20 Installation and Maintenance
Energize and switch on
IPM protection occurs after the machine has run for aperiod of time?
Use AC voltmeter to measure the voltage between terminal L and N on the wiring board XT
If the voltage between terminal L and N on wiring board XT is within
210VAC~250VAC?
Check the supply voltage and restore it to
210VAC~250VAC
Voltage between the two ends of celectrolytic capacitor (test3) is
Restart the unit. Before protection occurs, use DC voltmeter to measure the voltage between the two ends of electrolytic capacitor on control panel AP1 (test3)
If the unit can work normally?
Please confirm:
1. If the indoor and
outdoor heat exchangers are dirty. If they are obstructed by other objects which affect the heat exchange of indoor and outdoor unit.
2. If the indoor and outdoor fans are working normally?
3. If the environment temperature is too high, resulting in that the system pressure is too high and exceeds the permissible range?
4. If the charge volume of refrigerant is too much, resulting in that the system pressure is too high?
5. Other conditions resulting in that the system pressure becomes too high.
The connection of capacitor C2 is loose.
Reconnect the capacitor C2 according to Electrical Wiring Diagram. Then, Restart the unit.
Stop the unit and disconnect the power supply. Wait 20 minutes, or use DC voltmeter to measure the voltage between the two ends of capacitor C2, until the voltage is lower than 20V
Replace the capacitor C2. Then, energize and start the unit.
Replace the control panel AP1
Take corrective actions according to Technical Service Manual, and then energize and start the unit.
If there is any abnormality described above?
Replace the control panel AP1
If the connection between AP1 and COMP is unsecure or the connection order is wrong?
Connect the control panel AP1 and compressor COMP correctly according to the Electrical Wiring Diagram. Then, energize and start the unit.
Use ohmmeter to measure the resistance between the three terminals on compressor COMP, and compare the measurements with the compressor resistance on Service Manual.
If the resistance is normal?
Use ohmmeter to measure the resistance between the two terminals of compressor COMP and copper tube.
Replace the compressor
COMP
Resistance higher than 500MΩ?
Replace the control panel AP1
END
Y N
Y N
Y
N
Y
If the unit can work normallv?
Y
If the unit can work normally?
Y
N
N
Y
N
If the unit can work normally?
Y Y
N N
If the unit can work normally?
Y
Y
N
Y
N
N
Y
higher than
250V
Remove the wires on the two ends of capacitor C2. Then, use capacitance meter to measure the capacitor C2.
Verify as per the Parameters Sheet.
Stop the unit and disconnect the power supply. Then, check the connection of capacitor C2 according to Electrical Wiring Diagram.
If capacitor C2 is failed?
Refer to the Electrical Wiring Diagram and check if the connection between AP1 and COMP is loose and if the connection order is correct.
21 Installation and Maintenance
3.Diagnosis for anti-high temperature, overload protection (AP1 below is control board of outdoor unit)
Main detection point:
● If the outdoor ambient temperature is in normal range. ● If the indoor and outdoor fan is running normal. ● If the radiating environment of indoor and outdoor unit is well.
Malfunction diagnosis process:
1. Check if fan terminal OFAN is connected well
2. Test if resistance value of any two terminals is less than 1k with ohmic meter
If the indoor and outdoor fan work well?
After the unit de-energized for 20 min.
Replace control board AP1
If the radiating of outdoor and indoor unit is well?
Improve the radiating environment of unit
Replace outdoor fan
Y
Replace fan capacitor C1
Anti-high temperature, overload protection
Normal protection, please use it after improved outdoor ambient temperature
If the outdoor ambient temperature is higher than 127.4 °F?
N
Y
N
Y
N
End
22 Installation and Maintenance
4.Diagnosis for failure start up malfunction (AP1 below is control board of outdoor unit)
Main detection point:
● If the compressor wiring is correct? ● If the stop time of compressor is enough? ● If the compressor is damaged? ● If the refrigerant charging is too much?
Malfunction diagnosis process:
Energize the unit and start it
If the compressor wire COMP(UVW) is well connected and connection sequence is correct.
Replace control board AP1
Replace the compressor
If malfunction is removed?
If the stop time of compressor is more than 3 min?
N
If the stop time is not enough and the high and low pressure of system is not balanced, please start it after 3 min.
Improve the connection situation of control board AP1 and compressor COMP, connect it with wiring diagram.
N
Y
N
If the refrigerant charging is too much?
Y
Does the unit start up normally?
N
Charge the refrigerant according to service manual.
Y
Does the unit start up normally?
N
Y
End
23 Installation and Maintenance
5. Diagnosis for compressor synchronism (AP1 below is control board of outdoor unit)
Main detection point:
● If the system pressure is over-high? ● If the work voltage is over-low?
Malfunction diagnosis process:
If the compressor wire COMP(UVW) is well connected, the connection sequence forwards to clockwise direction?
Check if the fan terminal OFAN is
connected well
Replace compressor
If the outdoor fan works normally?
If the stop time of compressor is more than 3min
Synchronism after energize the unit and start it
Connect wire well
Synchronism
occurred during operation
Replace control board AP1
If the radiating of unit is well?
Remove malfunction?
Improve the radiating of unit (clean heat exchanger and increase ventilation)
Replace fan capacitor C1
Replace outdoor fan
Y
N
N
N
Y
Y
N
Replace control board AP1
Remove malfunction?
Replace compressor
Y
N
N
Y
If the input voltage of unit is normal?
Start to run until the power resume normal voltage
N
If the refrigerant is too much?
Charge the
refrigerant according to service manual
Y
Y
N
Y
End
End
24 Installation and Maintenance
6.Diagnosis for overload and discharge malfunction (AP1 below is control board of outdoor unit)
Main detection point:
● If the electronic expansion valve is connected well? Is the expansion valve damaged? ● If the refrigerant is leaking? ● If the overload protector is damaged?
Malfunction diagnosis process:
Connect wire well with wiring diagram
Replace EKV coil of electron expansion valve
If the wiring terminal FA of electron expansion is well connected?
Remove malfunction?
The resistance value of firs t
4 l e ad an d th e fifth lead is similar, less than 100
After the unit de-energized
for 20 min
Remove malfunction?
Y
N
N
N
If the overload protector SAT is well connected?
N
Under ambient temperature, test the resistance of overload protector with ohmic
Y
Y
Replace overload protector SAT
N
Y
Check refrigerant, if there is leakage, please refer to specification
Replace control board AP1
End
25 Installation and Maintenance
7.Communication malfunction (AP1 below is control board of outdoor unit)
Main detection point:
● Check if the connection wire and the built-in wiring of indoor and outdoor unit is connected well and not damaged. ● If the communication circuit of indoor mainboard is damaged? If the communication circuit of outdoor mainboard (AP1) is dam-aged.
Malfunction diagnosis process:
Start
Check communication circuit of outdoor unit
Problem of communication circuit
Check built-in wiring of indoor and outdoor unit
Connection correct?
Malfunction of circuit is detected with control board AP1 voltage
Check connection wire of indoor and outdoor unit with circuit diagram
Check connection wire of indoor and outdoor unit with circuit diagram
If the unit is operation normal before malfunction
Y
N
Y
N
If the wiring is damaged?
If the malfunction is removed?
N
Y
N
If the malfunction is removed?
N
Replace indoor board
Replace outdoor mainboard AP11
If the malfunction is removed?
Y
N
Y
N
Y
Y End
26 Installation and Maintenance
8.Diagnosis process for outdoor communication circuit
Start
Test voltage value with Test
10 position in diagram with voltage meter
Number jumping
Outdoor unit malfunction
Test voltage value with Test
13 position in diagram with voltage meter
Number jumping
Test voltage value with Test
11 position in diagram with voltage meter
Number jumping
Test voltage value with Test
12 position in diagram with voltage meter
Y
Y
Y
Y
Number jumping
The circuit of outdoor unit communication is normal
Y
N
N
N
N
End
27 Installation and Maintenance
Possible Causes Discriminating Method (Air Conditioner Status) Troubleshooting
Set temperature is improper Observe the set temperature on remote controller Adjust the set temperature
Rotation speed of the IDU fan motor is set too low Blows ineffectively Set the fan speed at high or medium
Filter of indoor unit is blocked Check the filter to see it's blocked Clean the filter
Installation location for indoor unit and outdoor unit is improper
Check whether the installation location is proper according to installation requirements for air conditioning unit
Adjust the installation position, and install the rainproof and sunproof for outdoor unit
Refrigerant is leaking
Discharged air temperature during cooling is higher than normal discharged air temperature.
Discharged air temperature during heating is lower than normal discharged air temperature.
Unit's pressure is much lower than regulated range.
Find out the leakage causes and deal with it.
Add refrigerant.
Malfunction of 4-way valve Blows cold during heating Replace the 4-way valve
Malfunction of capillary
Discharged air temperature during cooling is higher than normal discharged wind temperature; Discharged air temperature during heating is lower than normal discharged wind temperature; Unit't pressure is much lower than regulated range. If refrigerant isn’t leaking, part of capillary is blocked
Replace the capillary
Flow volume of valve is insufficient
The pressure of valves is much lower than that stated in the specification Open the valve completely
Malfunction of horizontal louver Horizontal louver can’t swing Refer to point 3 of maintenance methods for details
Malfunction of the IDU fan motor The IDU fan motor doesn't operate Refer to troubleshooting for H6 for maintenance methods in detail
Malfunction of the ODU fan motor The ODU fan motor doesn't operate Refer to point 4 of maintenance method for details
Malfunction of compressor Compressor doesn't operate Refer to point 5 of maintenance methods for details
3.4 Troubleshooting for Normal Malfunction
1. Air conditioning unit doesn't start
2. Poor cooling (heating) of air conditioning unit
3. Horizontal louver doesn't swing
Possible Causes Discriminating Method (Air Conditioner Status) Troubleshooting
No power supply, or poor connection for power plug
After energization, operation indicator isn’t bright and the buzzer can't give out sound.
Confirm whether it's due to power failure. If yes, wait for power recovery. If not, check power supply circuit and make sure the power plug is connected well.
Wrong wire connection between indoor unit and outdoor unit, or poor connection for wiring terminals
Under normal power supply circumstances, operation indicator isn't bright after energization
Check the circuit according to circuit diagram and connect wires correctly. Make sure all wiring terminals are connected firmly.
Electric leakage for air conditionerAfter energization, room circuit breaker trips off at
once.
Make sure the air conditioner is grounded reliably Make sure wires of air conditioner connected
correctly Check the wiring inside air conditioner. Check whether the insulation layer of power cord is damaged. If yes, place the power cord.
Model selection for air switch is improper
After energization, air switch trips off.
Select proper air switch
Malfunction of remote controller
After energization, operation indicator is bright, while no display on remote controller or buttons have no action.
Replace batteries for remote controller Repair or replace remote controller
Possible Causes Discriminating Method (Air Conditioner Status) Troubleshooting
Wrong wire connection, or poor connection
Check the wiring status according to circuit diagram
Connect wires according to wiring diagram to make sure all wiring terminals are connected firmly
Actuator is damaged
Actuator doesn't operate Repair or replace actuator
Main board is damaged Others are all normal, while horizontal louver can't operate Replace the main board with the same model
28 Installation and Maintenance
7. Abnormal sound and vibration
Possible causes Discriminating method (Air Conditioner Status) Troubleshooting
When turning on or turning off unit, the panel and other parts will expand and there's abnormal sound
There's the sound of "PAPA" Normal phenomenon. Abnormal sound will disappear after a few minutes.
When turning on or turning off the unit, there's abnormal sound due to flow of refrigerant inside air conditioner
Water-running sound can be heard Normal phenomenon. Abnormal sound will disappear after a few minutes.
Foreign objects inside the indoor unit or there're parts touching together inside the indoor unit
There's abnormal sound from indoor unit
Remove foreign objects. Adjust all parts' position of indoor unit, tighten screws and stick damping plaster between connected parts
Foreign objects inside the outdoor unit or there're parts touching together inside the outdoor unit
There's abnormal sound fro outdoor unit
Remove foreign objects. Adjust all parts' position of outdoor unit, tighten screws and stick damping plaster between connected parts
Short circuit inside the magnetic coil
During heating, the way valve has abnormal electromagnetic sound Replace magnetic coil
Abnormal shake of compressor Outdoor unit gives out abnormal sound Adjust the support foot mat of compressor, tighten the bolts
Abnormal sound inside the compressor Abnormal sound inside the compressor
If too much refrigerant was added during maintenance, reduce refrigerant properly.
Replace compressor for other circumstances.
6. Air conditioning unit is leaking
Possible causes Discriminating method (air conditioner status) Troubleshooting
Condensate pipe is blocked Water leaking from indoor unit Eliminate any foreign objects inside the condensate pipe
Condernsate pipe is broken Water leaking from condensate pipe Replace condensate pipe
Wrapping is not tight Water leaking from the pipe connection place of indoor unit Wrap it again and bundle it tightly
5. Compressor doesn't operate
Possible causes Discriminating method (air conditioner status) Troubleshooting
Wrong wire connection, or poor connection
Check the wiring status according to circuit diagram
Connect wires according to wiring diagram to make sure all wiring terminals are connected firmly
Capacity of compressor is damaged
Measure the capacity of fan capacitor with a universal meter and find that the capacity is out of the deviation range indicated on the nameplate of fan capacitor.
Replace the compressor capacitor
Power voltage is a little low or high
Use universal meter to measure the power supply voltage. The voltage is a little high or low Suggest to equip with voltage regulator
Coil of compressor is burned out Use universal meter to measure the resistance
between compressor terminals and it's 0 Repair or replace compressor
Cylinder of compressor is blocked Compressor can't operate Repair or replace compressor
4. ODU fan motor doesn't operate
Possible causes Discriminating method (Air Conditioner Status) Troubleshooting
Wrong wire connection, or poor connection
Check the wiring status according to circuit diagram
Connect wires according to wiring diagram to make sure all wiring terminals are connected firmly
Capacity of the ODU fan motor is damaged
Measure the capacity of fan capacitor with a universal meter and find that the capacity is out of the deviation range indicated on the nameplate of fan capacitor.
Replace the capacity of fan
Power voltage is a little low or high
Use universal meter to measure the power supply voltage. The voltage is a little high or low Suggest to equip with voltage regulator
Motor of outdoor unit is damaged
When unit is on, cooling/heating performance is poor and ODU compressor generates a lot of noise and heat.
Change compressor oil and refrigerant. If no better, replace the compressor with a new one
29 Installation and Maintenance
Appendix:
Appendix 1: Reference Sheet of Celsius and Fahrenheit
Appendix 2: Configuration of Connection Pipe
Set temperature Conversion formula for Fahrenheit degree and Celsius degree: Tf=Tcx1.8+32
Ambient temperature
Fahrenheit
display
temperature
（℉）
Fahrenheit
（℉） Celsius（℃）
Fahrenheit
display
temperature
（℉）
Fahrenheit
（℉） Celsius（℃）
Fahrenheit
display
temperature
（℉）
Fahrenheit
（℉） Celsius（℃）
32/33 32
55/56
55.4 13
79/80
78.8 26
34/35
33.8 1
57/58
57.2 14 81
80.6 27
36
35.6 2
59/60 59 15
82/83
82.4 28
37/38
37.4 3
61/62
60.8 16
84/85
84.2 29
39/40
39.2 4 63
62.6 17
86/87 86 30
41/42 41 5
64/65
64.4 18
88/89
87.8 31
43/44
42.8 6
66/67
66.2 19 90
89.6 32
45
44.6 7
68/69 68 20
91/92
91.4 33
46/47
46.4 8
70/71
69.8 21
93/94
93.2 34
48/49
48.2 9 72
71.6 22
95/96 95 35
50/51 50 10
73/74
73.4 23
97/98
96.8 36
52/53
51.8 11
75/76
75.2 24 99
98.6 37
54
53.6 12
77/78 77 25
Fahrenheit
display
temperature
（℉）
Fahrenheit
（℉） Celsius（℃）
Fahrenheit
display
temperature
（℉）
Fahrenheit
（℉） Celsius（℃）
Fahrenheit
display
temperature
（℉）
Fahrenheit
（℉） Celsius（℃）
61
60.8 16
69/70
69.8 21
78/79
78.8 26
62/63
62.6 17
71/72
71.6 22
80/81
80.6 27
64/65
64.4 18
73/74
73.4 23
82/83
82.4 28
66/67
66.2 19
75/76
75.2 24
84/85
84.2 29
68 68 20 77 77 25 86 86 30
Additional refrigerant charging amount for R22, R407C, R410A and R134a
Diameter of connection pipe Outdoor unit throttle
Liquid pipe(inch) Gas pipe(inch) Cooling only(oz/ft.) Cooling and heating(oz/ft.)
Ф1/4 Ф3/8or Ф1/2
0.2
0.2
Ф1/4 or Ф3/8 Ф5/8 or Ф3/4
0.2
0.2
Ф1/2 Ф3/4 or Ф7/8
0.3
1.3
Ф5/8 Ф1 or Ф1 1/4
0.7
1.3
Ф3/4 /
2.7
2.7
Ф7/8 /
3.8
3.8
Cooling capacity Max length of
connection pipe
Max height difference
5000 Btu/h(1465 W)
49.21ft
16.40ft
7000 Btu/h(2051 W)
49.21ft
16.40ft
9000 Btu/h(2637 W)
49.21ft
32.81ft
12000 Btu/h(3516 W)
65.62ft
32.81ft
18000 Btu/h(5274 W)
80.02ft
32.81ft
24000 Btu/h(7032 W)
80.02ft
32.81ft
28000 Btu/h(8204 W)
98.43ft
32.81ft
36000 Btu/h(10548 W)
98.43ft
65.62ft
42000 Btu/h(12306 W)
98.43ft
65.62ft
48000 Btu/h(14064 W)
98.43ft
65.62ft
1.Standard length of connection pipe ● 16.40ft, 24.61ft, 26.25ft.
2.Min. length of connection pipe is 9.84ft.
3.Max. length of connection pipe and max. high difference.
4.The additional refrigerant oil and refrigerant charging required after prolonging connection pipe ● After the length of connection pipe is prolonged for 32.81ft at the basis of standard length, you should add 5ml of refrigerant oil for each additional 16.40ft of connection pipe. ● The calculation method of additional refrigerant charging amount (on the basis of liquid pipe):
● When the length of connection pipe is above 16.40ft, add refrigerant according to the prolonged length of liquid pipe. The additional refrigerant charging amount per meter is different according to the diameter of liquid pipe. See the following sheet. ● Additional refrigerant charging amount = prolonged length of liquid pipe X additional refrigerant charging amount per meter
30 Installation and Maintenance
F:Inspection ● Check the quality of expanding port. If there is any blemish, expand the port again according to the steps above.
The length is equal
Improper expanding
leaning damaged surface crack uneven thickness
Smooth surface
Downwards
Pipe
Shaper
Union pipe
Pipe
Expander
Hard mold
Pipe
Pipe
Pipe cutter
Leaning Uneven Burr
Improper pipe expanding is the main cause of refrigerant leakage.Please expand the pipe according to the following steps:
A:Cut the pip ● Confirm the pipe length according to the distance of indoor unit and outdoor unit. ● Cut the required pipe with pipe cutter.
B:Remove the burrs ● Remove the burrs with shaper and prevent the burrs from getting into the pipe.
C:Put on suitable insulating pipe
D:Put on the union nut
● Remove the union nut on the indoor connection pipe and outdoor valve; install
the union nut on the pipe.
E:Expand the port ● Expand the port with expander.
● "A" is different according to the diameter, please refer to the sheet below:
Outer diameter(inch) A(inch)
Max Min
Ф1/4
2/39
1/36
Ф3/8
1/16
1/51
Ф1/2
1/14
1/51
Ф5/8
5/53
2/23
Appendix 3: Pipe Expanding Method
Note:
Note:
31 Installation and Maintenance
Appendix 4: List of Resistance for Temperature Sensor
Resistance Table of Ambient Temperature Sensor for Indoor and Outdoor Units(15K)
Temp.(
oF) Resistance(kΩ) Temp.(
oF) Resistance(kΩ) Temp.(
oF) Resistance(kΩ) Temp.(
oF) Resistance(kΩ)
-2.2
138.1 68
18.75
138.2
3.848
208.4
1.071
-0.4
128.6
69.8
17.93 140
3.711
210.2
1.039
1.4
121.6
71.6
17.14
141.8
3.579 212
1.009
3.2 115
73.4
16.39
143.6
3.454
213.8
0.98
5
108.7
75.2
15.68
145.4
3.333
215.6
0.952
6.8
102.9 77 15
147.2
3.217
217.4
0.925
8.6
97.4
78.8
14.36 149
3.105
219.2
0.898
10.4
92.22
80.6
13.74
150.8
2.998 221
0.873
12.2
87.35
82.4
13.16
152.6
2.896
222.8
0.848
14
82.75
84.2
12.6
154.4
2.797
224.6
0.825
15.8
78.43 86
12.07
156.2
2.702
226.4
0.802
17.6
74.35
87.8
11.57 158
2.611
228.2
0.779
19.4
70.5
89.6
11.09
159.8
2.523 230
0.758
21.2
66.88
91.4
10.63
161.6
2.439
231.8
0.737
23
63.46
93.2
10.2
163.4
2.358
233.6
0.717
24.8
60.23 95
9.779
165.2
2.28
235.4
0.697
26.6
57.18
96.8
9.382 167
2.206
237.2
0.678
28.4
54.31
98.6
9.003
168.8
2.133 239
0.66
30.2
51.59
100.4
8.642
170.6
2.064
240.8
0.642
32
49.02
102.2
8.297
172.4
1.997
242.6
0.625
33.8
46.6 104
7.967
174.2
1.933
244.4
0.608
35.6
44.31
105.8
7.653 176
1.871
246.2
0.592
37.4
42.14
107.6
7.352
177.8
1.811 248
0.577
39.2
40.09
109.4
7.065
179.6
1.754
249.8
0.561
41
38.15
111.2
6.791
181.4
1.699
251.6
0.547
42.8
36.32 113
6.529
183.2
1.645
253.4
0.532
44.6
34.58
114.8
6.278 185
1.594
255.2
0.519
46.4
32.94
116.6
6.038
186.8
1.544 257
0.505
48.2
31.38
118.4
5.809
188.6
1.497
258.8
0.492
50
29.9
120.2
5.589
190.4
1.451
260.6
0.48
51.8
28.51 122
5.379
192.2
1.408
262.4
0.467
53.6
27.18
123.8
5.197 194
1.363
264.2
0.456
55.4
25.92
125.6
4.986
195.8
1.322 266
0.444
57.2
24.73
127.4
4.802
197.6
1.282
267.8
0.433
59
23.6
129.2
4.625
199.4
1.244
269.6
0.422
60.8
22.53 131
4.456
201.2
1.207
271.4
0.412
62.6
21.51
132.8
4.294 203
1.171
273.2
0.401
64.4
20.54
134.6
4.139
204.8
1.136 275
0.391
66.2
19.63
136.4
3.99
206.6
1.103
276.8
0.382
32 Installation and Maintenance
Resistance Table of Tube Temperature Sensors for Indoor and Outdoor (20K)
Temp.(
oF) Resistance(kΩ) Temp.(
oF) Resistance(kΩ) Temp.(
oF) Resistance(kΩ) Temp.(
oF) Resistance(kΩ)
-2.2
181.4 68
25.01
138.2
5.13
208.4
1.427
-0.4
171.4
69.8
23.9 140
4.948
210.2
1.386
1.4
162.1
71.6
22.85
141.8
4.773 212
1.346
3.2
153.3
73.4
21.85
143.6
4.605
213.8
1.307
5 145
75.2
20.9
145.4
4.443
215.6
1.269
6.8
137.2 77 20
147.2
4.289
217.4
1.233
8.6
129.9
78.8
19.14 149
4.14
219.2
1.198
10.4 123
80.6
18.13
150.8
3.998 221
1.164
12.2
116.5
82.4
17.55
152.6
3.861
222.8
1.131
14
110.3
84.2
16.8
154.4
3.729
224.6
1.099
15.8
104.6 86
16.1
156.2
3.603
226.4
1.069
17.6
99.13
87.8
15.43 158
3.481
228.2
1.039
19.4 94
89.6
14.79
159.8
3.364 230
1.01
21.2
89.17
91.4
14.18
161.6
3.252
231.8
0.983
23
84.61
93.2
13.59
163.4
3.144
233.6
0.956
24.8
80.31 95
13.04
165.2
3.04
235.4
0.93
26.6
76.24
96.8
12.51 167
2.94
237.2
0.904
28.4
72.41
98.6 12
168.8
2.844 239
0.88
30.2
68.79
100.4
11.52
170.6
2.752
240.8
0.856
32
65.37
102.2
11.06
172.4
2.663
242.6
0.833
33.8
62.13 104
10.62
174.2
2.577
244.4
0.811
35.6
59.08
105.8
10.2 176
2.495
246.2
0.77
37.4
56.19
107.6
9.803
177.8
2.415 248
0.769
39.2
53.46
109.4
9.42
179.6
2.339
249.8
0.746
41
50.87
111.2
9.054
181.4
2.265
251.6
0.729
42.8
48.42 113
8.705
183.2
2.194
253.4
0.71
44.6
46.11
114.8
8.37 185
2.125
255.2
0.692
46.4
43.92
116.6
8.051
186.8
2.059 257
0.674
48.2
41.84
118.4
7.745
188.6
1.996
258.8
0.658
50
39.87
120.2
7.453
190.4
1.934
260.6
0.64
51.8
38.01 122
7.173
192.2
1.875
262.4
0.623
53.6
36.24
123.8
6.905 194
1.818
264.2
0.607
55.4
34.57
125.6
6.648
195.8
1.736 266
0.592
57.2
32.98
127.4
6.403
197.6
1.71
267.8
0.577
59
31.47
129.2
6.167
199.4
1.658
269.6
0.563
60.8
30.04 131
5.942
201.2
1.609
271.4
0.549
62.6
28.68
132.8
5.726 203
1.561
273.2
0.535
64.4
27.39
134.6
5.519
204.8
1.515 275
0.521
66.2
26.17
136.4
5.32
206.6
1.47
276.8
0.509
33 Installation and Maintenance
Resistance Table of Discharge Temperature Sensor for Outdoor(50K)
Temp.(
oF) Resistance(kΩ) Temp.(
oF) Resistance(kΩ) Temp.(
oF) Resistance(kΩ) Temp.(
oF) Resistance(kΩ)
-20.2
853.5 50 98
120.2
18.34
190.4
4.754
-18.4
799.8
51.8
93.42 122
17.65
192.2
4.609
-16.6 750
53.6
89.07
123.8
16.99 194
4.469
-14.8
703.8
55.4
84.95
125.6
16.36
195.8
4.334
-13
660.8
57.2
81.05
127.4
15.75
197.6
4.204
-11.2
620.8 59
77.35
129.2
15.17
199.4
4.079
-9.4
580.6
60.8
73.83 131
14.62
201.2
3.958
-7.6
548.9
62.6
70.5
132.8
14.09 203
3.841
-5.8
516.6
64.4
67.34
134.6
13.58
204.8
3.728
-4
486.5
66.2
64.33
136.4
13.09
206.6
3.619
-2.2
458.3 68
61.48
138.2
12.62
208.4
3.514
-0.4 432
69.8
58.77 140
12.17
210.2
3.413
1.4
407.4
71.6
56.19
141.8
11.74 212
3.315
3.2
384.5
73.4
53.74
143.6
11.32
213.8
3.22
5
362.9
75.2
51.41
145.4
10.93
215.6
3.129
6.8
342.8 77
49.19
147.2
10.54
217.4
3.04
8.6
323.9
78.8
47.08 149
10.18
219.2
2.955
10.4
306.2
80.6
45.07
150.8
9.827 221
2.872
12.2
289.6
82.4
43.16
152.6
9.489
222.8
2.792
14 274
84.2
41.34
154.4
9.165
224.6
2.715
15.8
259.3 86
39.61
156.2
8.854
226.4
2.64
17.6
245.6
87.8
37.96 158
8.555
228.2
2.568
19.4
232.6
89.6
36.38
159.8
8.268 230
2.498
21.2
220.5
91.4
34.88
161.6
7.991
231.8
2.431
23 209
93.2
33.45
163.4
7.726
233.6
2.365
24.8
198.3 95
32.09
165.2
7.47
235.4
2.302
26.6
199.1
96.8
30.79 167
7.224
237.2
2.241
28.4
178.5
98.6
29.54
168.8
6.998 239
2.182
30.2
169.5
100.4
28.36
170.6
6.761
240.8
2.124
32 161
102.2
27.23
172.4
6.542
242.6
2.069
33.8 153 104
26.15
174.2
6.331
244.4
2.015
35.6
145.4
105.8
25.11 176
6.129
246.2
1.963
37.4
138.3
107.6
24.13
177.8
5.933 248
1.912
39.2
131.5
109.4
23.19
179.6
5.746
249.8
1.863
41
125.1
111.2
22.29
181.4
5.565
251.6
1.816
42.8
119.1 113
21.43
183.2
5.39
253.4
1.77
44.6
113.4
114.8
20.6 185
5.222
255.2
1.725
46.4 108
116.6
19.81
186.8
5.06 257
1.682
48.2
102.8
118.4
19.06
188.6
4.904
258.8
1.64
34
Support Contact Information
Technical Support Support during installation, commissioning, service, and troubleshooting
Customer Service Assistance ordering equipment, parts, and accessories
Warranty Assistance with warranty registration, warranty claims, etc.
Application and Design
Pre-sale assistance with equipment applications and design support, as well as use of Selection Tool
For all functions mentioned above, please call: 1(844) 873-4445
Product improvement, specifications and appearance in this manual are subject to change without prior notice.
© Johnson Controls, Inc. USA
LIT 12012174
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