Carrier 38QUS012D8S Service Manual
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Carrier 38QUS012D8S Service Manual

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Summary of Contents for Carrier 38QUS012D8S

  • Page 1 Energy Related Products SUPER DC INVERTER SERIES Service Manual Contents...
  • Page 2 Contents Part 1 General Information ....................1 Part 2 Indoor Units ......................... 5 Part 3 Outdoor Units ......................55 Part 4 Installation ......................... 68 Part 5 Electrical Control System ..................95 Caution: Risk of fire/flammable materials ※The specifications, designs, and information in this book are subject to change without notice for product improvement.
  • Page 3 General Information Part 1 General Information 1. Model List ..................... 2 2. External Appearance ................3 2.1 Indoor Units ....................... 3 2.2 Outdoor Units ......................3 3. Nomenclature..................4 General Information...
  • Page 4 ● Ceiling-floor Cooling and heating ● ● ● ● ● 1.2 Outdoor Units Universal Outdoor unit Model Compressor type Compressor Brand Matched indoor units 42QTD012D8S* 38QUS012D8S* Rotary GMCC 42QSS012D8S* 42QTD018D8S* 38QUS018D8S* Rotary GMCC 42QSS018D8S* 42QZL018D8S* 42QTD018R8S* 38QUS018R8S* Rotary GMCC 42QSS018R8S*...
  • Page 5 External Appearance 2. External Appearance 2.1 Indoor Units Compact cassette Super Slim Cassette Ducted Ceiling-Floor 2.2 Outdoor Units Single fan outdoor unit Double fan outdoor unit General Information...
  • Page 6 Nomenclature 3. Nomenclature 3 8 Q H C 0 0 9 R 8 S U ni t type C ustom er code 38 : condensi ng uni t G : G erm any 42 : i ndoor uni t N : N ordi c M ode S ystem type K : cool i ng onl y...
  • Page 7 Indoor Units Part 2 Indoor Units Super Slim Cassette Type ........... 6 A6 Duct Type ..............22 Ceiling & Floor Type ............41 Indoor Units...

  • Page 8: Table Of Contents

    Super Slim Cassette Type Super Slim Cassette Type 1. Features ................7 2. Dimensions ..............10 3. Service Space ..............11 4. Wiring Diagrams ............12 5. Air Velocity Distributions (Reference Data) ....13 6. Electric Characteristics ..........16 7. Sound Levels ..............17 8.

  • Page 9: Features

    Features 1. Features 1.1 Overview  Compact design, super slim body size, less space requiring in installation  Each louver can be separately controlled, more comfort air blowing is possible. Fresh air intake function  Fresh air fulfills air quality more healthy and comfortable. Ventilation motor is optional to increase the effect of fresh air.
  • Page 10 Features Built-in draining pump  Due to the improvement of structure, more convenient to repair or replace the draining pump. Draining Pump  Built-in draining pump to make sure condensed water drain out reliably. 1.6 Terminals for alarm lamp and long-distance on-off controller connection are standard ...
  • Page 11 Features Alarm lamp Long-distance on-off controller 1.7 Twins Combination(18k-30k)  The units can be installed as Twin systems: one outdoor unit can connect with two indoor units. The indoor units can be combined in any of the different available ratings. Indoor Units...

  • Page 12: Dimensions

    Dimensions 2. Dimensions 92 92 Fresh air intake 4-install hanger Body Gas side Liquid side Wiring connection port E-parts box Service hole for Test mouth & Test cover draining pump Drain hole 92 92 92 92 Panel Unit: mm Model 42QTD018R8S* 42QTD024R8S* 42QTD036R8S*...

  • Page 13: Service Space

    Service Space 3. Service Space Indoor Units...

  • Page 14: Wiring Diagrams

    Wiring Diagrams 4. Wiring Diagrams 42QTD018R8S*, 42QTD024R8S*, 42QTD036R8S*, 42QTD048R8S*, 42QTD060R8S* Indoor Units...

  • Page 15: Air Velocity Distributions (Reference Data)

    Air Velocity Distributions (Reference Data) Air Velocity Distributions (Reference Data) 18-24K: Cooling: Heating: Indoor Units...
  • Page 16 Air Velocity Distributions (Reference Data) 30-42K: Cooling: Heating: Indoor Units...
  • Page 17 Air Velocity Distributions (Reference Data) 48-55K： Cooling: Heating: Indoor Units...

  • Page 18: Electric Characteristics

    Electric Characteristics Electric Characteristics Power Indoor Unit Supply Model Voltage 42QTD018R8S* 220-240V 198V 254V 42QTD024R8S* 220-240V 198V 254V 42QTD036R8S* 220-240V 198V 254V 42QTD048R8S* 220-240V 198V 254V 42QTD060R8S* 220-240V 198V 254V Notes: MFA: Max. Fuse Amps. (A) Indoor Units...

  • Page 19: Sound Levels

    Sound Levels Sound Levels Noise level dB(A) Noise Power dB(A) Model 42QTD018R8S* 42QTD024R8S* 42QTD036R8S* 42QTD048R8S* 42QTD060R8S* Indoor Units...

  • Page 20: Accessories

    Accessories Accessories Name Shape Quantity Installation Fittings Installation paper board Tubing & Fittings Soundproof / insulation sheath Out-let pipe sheath Out-let pipe clasp Drainpipe Fittings Drain joint Seal ring Remote controller & Its Frame Remote controller & Its Frame(The product you Remote controller holder have might not be provided the following...

  • Page 21: The Specification Of Power

    The Specification of Power 9. The Specification of Power Model(Btu/h) 18000~24000 36000 36000 48000~60000 Phase 1-phase 1-phase 1-phase Frequency 220-240V, 50Hz 220-240V, 50Hz 220-240V, 50Hz Indoor Power Voltage POWER WIRING 3×1.0 3×1.0 3×1.0 (mm2) CIRCUIT BREAKER/Fuse (A) 15/10 15/10 15/10 Phase 1-phase 1-phase...

  • Page 22: Field Wiring

    Field Wiring 10. Field Wiring 42QTD018R8S*, 42QTD024R8S*, 42QTD036R8S* Indoor Units...
  • Page 23 Field Wiring 42QTD048R8S*, 42QTD060R8S* Indoor Units...
  • Page 24 A6 Duct Type A6 Duct Type 1. Features ................. 23 2. Dimensions ..............28 3. Service Space ..............29 4. Wiring Diagrams ............30 5. Static Pressure ............... 31 6. Electric Characteristics ..........36 7. Sound Levels ..............37 8. Accessories ..............38 9.

  • Page 25: Features

    Features Features 1.1 Higher Static Pressure As a ducted air conditioner with medium static pressure, it has the widest static pressure range.   The maximum static pressure reaches 160 Pa 1.2 Slim Design  The industry Lowest height is designed to be fitted into tight roof spaces. *18K unit - 210mm,24K/36K unit - 249mm，48K unit -300mm Constant air volume control ...
  • Page 26 Features Filter 1.5 Flexible Air Intake Way (Bottom side or Rear side)  The frame size of air inlet in rear and bottom is the same. It’s very easy to switch to match different application. Air intake from rear (Standard) Air intake from bottom (Optional) 1.6 Communication wire connection ...
  • Page 27 Features  With a larger window design, once the motor and the blower wheels have been detached, heat exchanger and water receiver tray in behind can be seen very clearly. Dust can be easily removed from the inside by vacuum 1.8 Easy maintenance ...
  • Page 28 Features 1.9 Twins Function  The twin system connects two indoor units of the same type and capacity to one outdoor unit in order to ensure more air distribution in a large zone. The controller can only control the master unit. The slave unit will work in the same state as the master unit.
  • Page 29 Features Indoor Units...

  • Page 30: Dimensions

    Dimensions Dimensions Model unit (KBtu/h) inch 34.65 8.27 26.54 23.62 5.51 27.80 1.97 5.35 30.79 7.48 1.57 36.22 20.00 3.07 5.83 3.46 4.41 1100 1001 1140 inch 43.31 9.80 30.47 27.56 5.51 36.46 1.97 6.89 39.41 8.98 0.20 44.88 23.54 3.15 5.91 5.12...

  • Page 31: Service Space

    Service Space Service Space Ensure enough space required for installation and maintenance. Indoor Units...

  • Page 32: Wiring Diagrams

    Wiring Diagrams Wiring Diagrams 42QSS018R8S*, 42QSS024R8S*, 42QSS036R8S*, 42QSS048R8S* 42QSS060R8S* Indoor Units...

  • Page 33: Static Pressure

    Static Pressure 5. Static Pressure 42QSS018R8S* Air flow rate （ L/S ） （ with filter ） External Static Pressure （ pa ） Air flow rate （ L/S ） （ no filter ） External Static Pressure （ pa ） Indoor Units...
  • Page 34 Static Pressure 42QSS024R8S* Air flow rate （ L/S ） （ with filter ） External Static Pressure （ pa ） Air flow rate （ L/S ） （ no filter ） External Static Pressure （ pa ） Indoor Units...
  • Page 35 Static Pressure 42QSS036R8S* Air flow rate （ L/S ） （ with filter ） External Static Pressure （ pa ） Air flow rate （ L/S ） （ no filter ） External Static Pressure （ pa ） Indoor Units...
  • Page 36 Static Pressure 42QSS048R8S* Air flow rate （ L/S ） （ with filter ） 1344 1232 1120 1008 External Static Pressure （ pa ） Air flow rate （ L/S ） （ no filter ） 1344 1232 1120 1008 External Static Pressure （...
  • Page 37 Static Pressure 42QSS060R8S* Air flow rate （ L/S ） （ with filter ） 1333 1222 1111 1000 External Static Pressure （ pa ） Air flow rate （ L/S ） （ no filter ） 1333 1222 1111 1000 External Static Pressure （...

  • Page 38: Electric Characteristics

    Electric Characteristics 6. Electric Characteristics Indoor Unit Power Supply Model Voltage Min. Max. 42QSS018R8S* 220-240V 198V 254V 42QSS024R8S* 220-240V 198V 254V 42QSS036R8S* 220-240V 198V 254V 42QSS048R8S* 220-240V 198V 254V 42QSS060R8S* 220-240V 198V 254V Note: MFA: Max. Fuse Amps. (A) Indoor Units...

  • Page 39: Sound Levels

    Sound Levels Sound Levels Discharge Suction 1.4m Microphone Noise level dB(A) Sound Power Model dB(A) 42QSS018R8S* 42QSS024R8S* 42QSS036R8S* 42QSS048R8S* 42QSS060R8S* Indoor Units...

  • Page 40: Accessories

    Accessories 8. Accessories Name Shape Quantity Tubing & Fittings Soundproof / insulation sheath Drain joint Drainpipe Fittings (for cooling & heating) Seal ring Magnetic ring EMC & It’s Fitting (twist the electric wires L and N around (for some models) the magnetic ring to five circles) Wired controller Wired controller &...

  • Page 41: The Specification Of Power

    The Specification of Power The Specification of Power Model(Btu/h) 18000~24000 36000 36000 48000~60000 Phase 1-phase 1-phase 3-phase 3-phase Frequency 220-240V, 50Hz 220-240V, 50Hz 380-415V, 50Hz 380-415V, 50Hz POWER Voltage POWER WIRING 3×2.5 3×4.0 5×2.5 5×2.5 (mm2) CIRCUIT BREAKER/Fuse (A) 30/20 40/30 30/20 30/25...

  • Page 42: Field Wiring

    Field Wiring Field Wiring 42QSS018R8S*, 42QSS024R8S*, 42QSS036R8S*, 42QSS048R8S*, 42QSS060R8S* Indoor Units...
  • Page 43 Ceiling & Floor Type Ceiling & Floor Type 1. Features ....................42 2. Dimensions ..................43 3. Service Space ..................44 4. Wiring Diagrams ................45 5. Electric Characteristics ..............46 6. Sound Levels ..................46 7. Air Velocity and Temperature Distributions (Reference Data) ..47 8.

  • Page 44: Features

    Features 1. Features 1.1. New design, more modern and elegant appearance. 1.2. Convenient installation --The ceiling type can be easily installed into a corner of the ceiling even if the ceiling is very narrow --It is especially useful when installation of an air conditioner in the center of the ceiling is impossible due to a structure such as one lighting.

  • Page 45: Dimensions

    Dimensions 2. Dimensions Wiring connection port Drain discharge port Fresh air intake Refrigerant pipe hole Hanging arm Capacity (KBtu/h) 18/24 1068 36/48/55 1650 1565 Indoor Units...

  • Page 46: Service Space

    Service Space 3. Service Space Indoor Units...

  • Page 47: Wiring Diagrams

    Wiring Diagrams 4. Wiring Diagrams 42QZL018R8S*, 42QZL024R8S* 42QZL036R8S*, 42QZL048R8S*, 42QZL060R8S* Indoor Units...

  • Page 48: Electric Characteristics

    Electric Characteristics 5. Electric Characteristics Indoor Units Power Supply Model Voltage Min. Max. 42QZL018R8S* 220-240V 198V 254V 42QZL024R8S* 220-240V 198V 254V 42QZL036R8S* 220-240V 198V 254V 42QZL048R8S* 220-240V 198V 254V 42QZL060R8S* 220-240V 198V 254V Note: MFA: Max. Fuse Amps. (A) 6. Sound Levels Air outlet side Microphone Ceiling...

  • Page 49: Air Velocity And Temperature Distributions (Reference Data)

    Air Velocity and Temperature Distributions (Reference Data) 7. Air Velocity and Temperature Distributions (Reference Data) Model: 42QZL018R8S*, 42QZL024R8S* Ceiling installation: Discharge angle 17° Discharge angle 50° Indoor Units...
  • Page 50 Air Velocity and Temperature Distributions (Reference Data) Floor installation: Discharge angle 17° Discharge angle 50° Indoor Units...
  • Page 51 Air Velocity and Temperature Distributions (Reference Data) Model: 42QZL036R8S* Ceiling installation: Discharge angle 17° Discharge angle 50° Indoor Units...
  • Page 52 Air Velocity and Temperature Distributions (Reference Data) Floor installation: Discharge angle 17° Discharge angle 50° Indoor Units...
  • Page 53 Air Velocity and Temperature Distributions (Reference Data) Model: 42QZL048R8S*, 42QZL060R8S* Ceiling installation: Discharge angle 17° Discharge angle 50° Indoor Units...
  • Page 54 Air Velocity and Temperature Distributions (Reference Data) Floor installation: Discharge angle 17° Discharge angle 50° Indoor Units...

  • Page 55: Accessories

    Accessories 8. Accessories Name Shape Quantity 1. Remote controller Remote controller & Its holder(The product you 2. Remote controller holder have might not be provided the following accessories) 3. Mounting screw (ST2.9×10-C-H) 4. Alkaline dry batteries (AM4) 5. Owner's manual Others 6.

  • Page 56: Field Wiring

    Field Wiring 10. Field Wiring 42QZL018R8S*, 42QZL024R8S*, 42QZL036R8S*, 42QZL048R8S*,42QZL060R8S* Indoor Units...
  • Page 57 Outdoor Units Part 3 Outdoor Units 1. Dimensions ..............56 2. Service Space ..............58 3. Wiring Diagrams ............59 4. Piping Diagrams ............. 64 5. Electric Characteristics ..........65 6. Operation Limits ............66 7. Sound Levels ..............67 Outdoor Units...

  • Page 58: Dimensions

    Dimensions 1. Dimensions Unit：mm Model 38QUS018R8S* 38QUS024R8S* 38QUS036R8S* 1030 38QUS036R8T* 1030 Outdoor Units...
  • Page 59 Dimensions Unit：mm Model 38QUS048R8T* 1333 1045 38QUS060R8T* 1333 1045 Outdoor Units...

  • Page 60: Service Space

    Service Space 2. Service Space (Wall or obstacle) More than 30cm Air inlet More than 60cm More than 30cm Maintain channel Air inlet More than 60cm Air outlet More than 200cm Outdoor Units...

  • Page 61: Wiring Diagrams

    Wiring Diagrams 3. Wiring Diagrams 38QUS018R8S* Outdoor Units...
  • Page 62 Wiring Diagrams 38QUS024R8S* Outdoor Units...
  • Page 63 Wiring Diagrams 38QUS036R8S* Outdoor Units...
  • Page 64 Wiring Diagrams 38QUS036R8T* Outdoor Units...
  • Page 65 Wiring Diagrams 38QUS048R8T*, 38QUS060R8T* Outdoor Units...

  • Page 66: Piping Diagrams

    Piping Diagrams 4. Piping Diagrams 38QUS018R8S*, 38QUS024R8S* INDOOR OUTDOOR Electronic CAPILIARY TUBE expansion valve LIQUID SIDE 2-WAY VALVE T3 Condenser temp. sensor HEAT EXCHANGE (EVAPORATOR) HEAT T4 Ambient T1 Room temp. EXCHANGE T2 Evaporator temp. sensor sensor temp. sensor (CONDENSER) middle T2B Evaporator temp.

  • Page 67: Electric Characteristics

    Electric Characteristics 5. Electric Characteristics Power Supply Outdoor Unit Model Voltage Min. Max. 38QUS018R8S* 220-240V 198V 254V 38QUS024R8S* 220-240V 198V 254V 38QUS036R8S* 220-240V 198V 254V 38QUS036R8T* 380-415V 342V 440V 38QUS048R8T* 380-415V 342V 440V 38QUS060R8T* 380-415V 342V 440V Notes: MFA: Max. Fuse Amps. (A) Outdoor Units...

  • Page 68: Operation Limits

    Operation Limits 6. Operation Limits Temperature Cooling operation Heating operation Drying operation Mode Room temperature 17℃～32℃ 0℃～30℃ 17℃～32℃ 0℃～50℃ （-15℃～50℃：For Outdoor temperature 0℃～50℃ -15℃～24℃ the models with low temperature cooling system） CAUTION: 1. If the air conditioner is used beyond the above conditions, certain safety protection features may come into operation and cause the unit to operate abnormally.

  • Page 69: Sound Levels

    Sound Levels 7. Sound Levels Note: H= 0.5 × height of outdoor unit Model Noise Power dB(A) Noise level dB(A) 38QUS018R8S* 38QUS024R8S* 38QUS036R8S* 38QUS036R8T* 38QUS048R8T* 38QUS060R8T* Outdoor Units...
  • Page 70 Installation Part 4 Installation 1. Installation Procedure ............ 69 2. Location selection ............70 3. Indoor unit installation ........... 71 4. Outdoor unit installation (Side Discharge Unit) ... 81 5. Refrigerant pipe installation .......... 82 6. Drainage pipe installation ..........86 7.

  • Page 71: Installation Procedure

    Installation Procedure 1. Installation Procedure Indoor unit installation Outdoor unit installation location selection location selection Indoor unit installation Outdoor unit installation Refrigerant pipe Refrigerant pipe installation and insulation installation and insulation Drainage pipe installation Drainage pipe installation and insulation and insulation Vacuum drying and leakage checking Additional refrigerant charge Insulation the joint part of refrigerant pipe...

  • Page 72: Location Selection

    Location selection 2. Location selection 2.1 Indoor unit location selection  The place shall easily support the indoor unit’s weight.  The place can ensure the indoor unit installation and inspection.  The place can ensure the indoor unit horizontally installed. ...

  • Page 73: Indoor Unit Installation

    Indoor unit installation 3. Indoor unit installation 3.1 Super slim cassette indoor unit installation 3.1.1 Service space for indoor unit Model >235 >275 24~36 >317 48/55 3.1.2 Bolt pitch 3.1.3 Install the pendant bolt Select the position of installation hooks according to the hook holes positions showed in upper picture. Drill four holes of Ø12mm, 45~50mm deep at the selected positions on the ceiling.
  • Page 74 Indoor unit installation 3.1.4 Install the main body Make the 4 suspender through the 4 hanger of the main body to suspend it. Adjust the hexangular nuts on the four installation hooks evenly, to ensure the balance of the body. Use a leveling instrument to make sure the levelness of the main body is within ±1°.
  • Page 75 Indoor unit installation Remove the 4 corner covers. Hang the panel to the hooks on the mainbody. If the panel is with auto-lift grille, please watch the ropes lifing the grille, DO NOT make the ropes enwinded or blocked. Tighten the screws under the panel hooks till the panel closely stick on the ceiling to avoid condensate water.
  • Page 76 Indoor unit installation Hang the air-in grill to the panel, then connect the lead terminator of the swing motor and that of the control box with corresponding terminators on the body respectively. Install the 4 corner covers back. Note: The panel shall be installed after the wiring connected. Installation...
  • Page 77 Indoor unit installation 3.2 Ceiling & floor indoor unit installation 3.2.1 Service space for indoor unit 3.2.2 Bolt pitch ① Ceiling installation Capacity (KBtu/h) 18/24 36~60 1565 ② Wall-mounted installation 3.2.3 Install the pendant bolt ① Ceiling installation Select the position of installation hooks according to the hook holes positions showed in upper picture. Installation...
  • Page 78 Indoor unit installation Drill four holes of Ø12mm, 45~50mm deep at the selected positions on the ceiling. Then embed the expansible hooks (fittings). ② Wall-mounted installation Install the tapping screws onto the wall.(Refer to picture below) 3.2.4 Install the main body ①...
  • Page 79 Indoor unit installation Put the side panels and grilles back. ② Wall-mounted installation Hang the indoor unit by insert the tapping screws into the hanging arms on the main unit. (The bottom of body can touch with floor or suspended, but the body must install vertically.) Installation...
  • Page 80 Indoor unit installation 3.3 A6 duct indoor unit installation 3.3.1 Service space for indoor unit 3.3.2 Bolt pitch Size of outline dimension mounted lug Capacity(KBtu) 1140 1400 48/55 1240 3.3.3 Hang indoor unit 1. Please refer to the upper data to locate the four positioning screw bolt hole on the ceiling. Be sure to mark the areas where ceiling hook holes will be drilled.
  • Page 81 Indoor unit installation 4. After you select an installation location, align the refrigerant pipes, drain pipes, as well as indoor and outdoor wires with their connection points before mounting the unit. 5. Drill 4 holes 10cm (4”) deep at the ceiling hook positions in the internal ceiling. Be sure to hold the drill at a 90°...
  • Page 82 Indoor unit installation Change the fan motor static pressure corresponding to external duct static pressure. NOTE: 1.Do not put the connecting duct weight on the indoor unit. 2.When connecting duct, use inflammable canvas tie-in to prevent vibrating. 3. Insulation foam must be wrapped outside the duct to avoid condensate. An internal duct underlayer can be added to reduce noise, if the end-user requires.

  • Page 83: Outdoor Unit Installation (Side Discharge Unit)

    Outdoor unit installation (Side Discharge Unit) 4. Outdoor unit installation (Side Discharge Unit) 4.1 Service space for outdoor unit (Wall or obstacle) More than 30cm Air inlet More than 60cm More than 30cm Maintain channel Air inlet More than 60cm Air outlet More than 200cm 4.2 Bolt pitch...

  • Page 84: Refrigerant Pipe Installation

    Refrigerant pipe installation 5. Refrigerant pipe installation 5.1 Maximum pipe length and height drop Considering the allowable pipe length and height drop to decide the installation position. Make sure the distance and height drop between indoor and outdoor unit not exceeded the date in the following table. Model Max.
  • Page 85 Refrigerant pipe installation Flare dimension A (mm) Pipe diameter Flare shape 1/4" (6.35) 12.0 12.4 3/8" (9.52) 15.4 15.8 1/2" (12.7) 18.6 19.1 5/8" (15.9) 22.9 23.3 3/4" (19)  After flared the pipe, the opening part must be seal by end cover or adhesive tape to avoid duct or exogenous impurity come into the pipe.
  • Page 86 Refrigerant pipe installation Note: All used branch pipe must be produced by Midea, otherwise it causes malfunction. The indoor units should be installed equivalently at the both side of the U type branch pipe. Permitted Value Piping 18K+18K Total pipe length (Actual) 24K+24K L+L1+L2 30K+30K...
  • Page 87 Refrigerant pipe installation Installation...

  • Page 88: Drainage Pipe Installation

    Drainage pipe installation 6. Drainage pipe installation Install the drainage pipe as shown below and take measures against condensation. Improperly installation could lead to leakage and eventually wet furniture and belongings. 6.1 Installation principle  Ensure at least 1/100 slope of the drainage pipe ...
  • Page 89 Drainage pipe installation 6.2.3 Individual design of drainage pipe system  The drainage pipe of air conditioner shall be installed separately with other sewage pipe, rainwater pipe and drainage pipe in building.  The drainage pipe of the indoor unit with water pump should be apart from the one without water pump. 6.2.4 Supporter gap of drainage pipe ...
  • Page 90 Drainage pipe installation 6.2.7 Lifting pipe setting of indoor unit with water pump  The length of lifting pipe should not exceed the pump head of indoor unit water pump. Pump head of big four way cassette: 750mm Pump head of compact four way cassette: 500mm ...
  • Page 91 Drainage pipe installation 6.3 Drainage test 6.3.1 Water leakage test After finishing the construction of drainage pipe system, fill the pipe with water and keep it for 24 hours to check whether there is leakage at joint section. 6.3.2 Water discharge test Natural drainage mode(the indoor unit with outdoor drainage pump) Infuse above 600ml water through water test hole slowly into the water collector, observe whether the water can discharge through the transparent hard pipe at drainage outlet.

  • Page 92: Vacuum Drying And Leakage Checking

    Vacuum Drying and Leakage Checking 7. Vacuum Drying and Leakage Checking 4.1 Purpose of vacuum drying  Eliminating moisture in system to prevent the phenomena of ice-blockage and copper oxidation. Ice-blockage shall cause abnormal operation of system, while copper oxide shall damage compressor. ...

  • Page 93: Additional Refrigerant Charge

    Additional refrigerant charge 8. Additional refrigerant charge  After the vacuum drying process is carried out, the additional refrigerant charge process need to be performed.  The outdoor unit is factory charged with refrigerant. The additional refrigerant charge volume is decided by the diameter and length of the liquid pipe between indoor and outdoor unit.

  • Page 94: Engineering Of Insulation

    Engineering of insulation 9. Engineering of insulation 9.1 Insulation of refrigerant pipe 9.1.1 Operational procedure of refrigerant pipe insulation Cut the suitable pipe → insulation (except joint section) → flare the pipe → piping layout and connection→ vacuum drying → insulate the joint parts 9.1.2 Purpose of refrigerant pipe insulation ...

  • Page 95: Engineering Of Electrical Wiring

    Engineering of electrical wiring 9.2.3 Insulation material selection for drainage pipe  The insulation material should be flame retardant material, the flame retardancy of the material should be selected according to the local law.  Thickness of insulation layer is usually above 10mm. ...

  • Page 96: Test Operation

    Test operation 11. Test operation 11.1 The test operation must be carried out after the entire installation has been completed. 11.2 Please confirm the following points before the test operation.  The indoor unit and outdoor unit are installed properly. ...
  • Page 97 Electrical Control System Part 5 Electrical Control System 1. Electrical Control Function ........96 2. Troubleshooting ............108 3. Controller ..............142 Electrical Control System...
  • Page 98 Electrical Control Function 1. Electrical Control Function 1.1 Abbreviation T1: Indoor room temperature T2: Middle indoor heat exchanger coil temperature T2B: Indoor heat exchanger exhaust coil temperature T3: Outdoor heat exchanger pipe temperature T4: Outdoor ambient temperature T5: Compressor discharge temperature 1.2 Main Protection 1.2.1 Compressor Restart Delay 1.2.2 Temperature Protection of Compressor Discharge...
  • Page 99 Electrical Control Function 6：Lack of phase 7：DC voltage too low 8：Communication fault 9：Parameter fault 10：L3 Current limited 11：L5 Voltage limited 12: Target speed cannot be met during the static pressure calculation process. For other models: If the indoor fan speed is lower than 300 RPM for 50 seconds or more, it shuts off and restarts in 30 seconds. If this happens 3 times, the unit stops and the LED displays the failure code.
  • Page 100 Electrical Control Function 1.3 Operation Modes and Functions 1.3.1 Fan Mode (1) Outdoor fan and compressor cease operation. (2) Temperature setting function is disabled, and no preset temperature is displayed. (3) Louver operates the same as in cooling mode. (4) Auto fan: When it fan-only mode, operates the same as auto fan in cooling mode with the temperature set at 24℃.
  • Page 101 Electrical Control Function 24~60K 1.3.2.3 Indoor Fan Running Guidelines In cooling mode, the indoor fan runs continuously and You can select the following speeds: high, medium, low, auto or silent. When the compressor is running, The indoor fan is regulated as illustrated as in the following figure: Setting fan T1-Td ℃(°...
  • Page 102 Electrical Control Function 1.3.2.3 Evaporator Low Temperature T2 Protection. ---T2<0℃, the compressor stops and restarts only when T2≥5℃. ---0℃≤T2<4℃, the compressor frequency is limited and decreases to a lower level ---4℃≤T2<7℃, the compressor maintains its current frequency. ---T2>7℃, the compressor frequency is not limited. 1.3.2.4 High Condenser Coil Temperature Protection 24~60K Decrease...
  • Page 103 Electrical Control Function 24~60K: 1.3.3.2 Indoor Fan Running Guidelines In heating mode, indoor fan speed can be set at high, medium, low, or auto fan, and the anti-cold-wind function is preferential. When the compressor is running, The indoor fan is regulated as illustrated as in the following figure: Setting fan T1-Td℃...
  • Page 104 Electrical Control Function 1.3.3.3 Defrosting Control： Conditions for defrosting: ----the unit enters the defrosting mode according to the value of T3 and T4 as well as the compressor running time. Defrost Stop Conditions: If any one of the following conditions is satisfied, defrosting ends and the unit returns to heating mode. ----T3 rises above than TCDE1℃.
  • Page 105 Electrical Control Function The indoor fan runs at auto fan in each mode. The louver operates the same in each mode. If the machine switches mode between heating and cooling, the compressor stops for 15 minutes and then selects a mode again according to T1-Ts. If the temperature is modified, the machine selects a running function.
  • Page 106 Electrical Control Function The system checks the water level every 5 seconds. ----When the A/C operates in cooling (including auto cooling) or forced cooling mode, the pump begins running immediately and continuously until cooling stops. ----If the water level increases up to the control point, the LED displays an alarm code and the drain pump opens and continually monitors the water level.
  • Page 107 Electrical Control Function If the value is higher than 99, the digital display shows single and double digits. For example, if the digital display shows “2.0", the EXV open angle is 120×4=480p. Frequency limit Bit7 caused by IGBT radiator Frequency limit Bit6 caused by PFC The display value is a...
  • Page 108 Electrical Control Function If the indoor unit is not connected, the digital display shows: “――” If the temperature is lower than 0 ℃, the digital display shows “0”. Average of indoor room temperature If the temperature is higher than 70 ℃, the digital display shows “70”.
  • Page 109 Electrical Control Function Compressor overcurrent protection Compressor EE malfunction Compressor start-up malfunction 311 fan speed has been malfunction Low pressure protection High pressure protection PFC module malfunction Shutdown stop Electrical disconnect DR stop Electrical Control System...
  • Page 110 Troubleshooting 2. Troubleshooting 2.1 Display board 2.1.1 Icon explanation on indoor display board (Super slim cassette). 2.1.2 Icon explanation on indoor display board (A6 Duct) OPERATION TIMER DEF./FAN ALARM MANUAL 2.1.3 Auto-lifting panel of 4 way cassette 2.1.4 Display board of Ceiling-floor indoor unit Electrical Control System...
  • Page 111 Troubleshooting 2.2 Indoor Unit Malfunctions Operation Lamp Malfunction Error Code Timer Lamp (flashes) Indoor EEPROM malfunction Communication malfunction between indoor and outdoor units Indoor fan speed malfunction T1 temperature sensor open or short circuit T2 temperature sensor open or short circuit Refrigerant leakage detection Water level alarm malfunction Communication error between master and slave unit (for twins system)
  • Page 112 Troubleshooting 2.3 Outdoor Unit Malfunctions For 24K~60K: Display Malfunction or Protection Communication malfunction between indoor and outdoor units Overcurrent protection Ambient temperature sensor (T4) malfunction Outdoor heat-exchanger temperature sensor (T3) malfunction Discharge temperature sensor (T5) malfunction Outdoor EEPROM malfunction Outdoor fan speed malfunction IPM module protection DC voltage too high/too low protection Ultra-low ambient temperature protection...
  • Page 113 Troubleshooting 2.4 Resolving Typical Malfunctions 2.4.1 For Indoor Units 2.4.1.1 Temperature Sensor Open or Short Circuit Malfunction conditions If the sampling voltage is lower than 0.06V or higher than 4.94V, the LED will display the failure. Possible causes ● Wiring mistakes ●...
  • Page 114 Troubleshooting 2.4.1.3. Indoor EEPROM Malfunction Malfunction conditions Main PCB chip does not receive feedback from EEPROM chip Possible causes ● Installation mistakes ● Faulty PCB EEPROM: An electrically erasable programmable read-only memory whose contents can be erased and reprogrammed using a pulsed voltage. 2.4.1.4.
  • Page 115 Troubleshooting 2.4.1.5. Indoor Fan Speed Malfunction Malfunction conditions When indoor fan speed continues to run at too low a speed (300RPM) for a certain period of time, the unit will stop and the LED will display a failure code. Possible causes ●...
  • Page 116 Troubleshooting Color Signal Voltage Vs/Vm 200V~380V Black White 13.5-16.5V Yellow 0~6.5V Blue 13.5-16.5V Electrical Control System...
  • Page 117 Troubleshooting 2.4.1.6. Refrigerant Leakage Detection Malfunction conditions Define the evaporator coil temperature T2 of the compressor starts running as Tcool. If the following occurs 3 times, the display shows "EC" and the unit switches off: In the first 8 minutes after the compressor starts up, if T2 ＜Tcool－2℃ is not maintained for 4 seconds and compressor running frequency is not higher than 50Hz for 3 minutes Potential causes...
  • Page 118 Troubleshooting 2.4.1.7 Outdoor IGBT sensor is faulty Check the connection between temperature Ensure proper connection sensor and PCB. Is it properly wired? Measure the resistance value of the sensor. Is it Replace the sensor within acceptable parameters? Replace outdoor main PCB 2.4.1.8 Communication malfunction between indoor and outdoor units The same as E1 in outdoor.
  • Page 119 Troubleshooting 2.4.2 Super-Slim Cassettes with an Up-Down Panel 2.4.2.1 Communication Errors between Indoor Unit and Up-Down Panel F0 Displayed F0 Displayed Communication failure between Communication failure between indoor unit and up-down panel indoor unit and up-down panel Check the wire connection Check the wire connection between up-down panel and between up-down panel and...
  • Page 120 Troubleshooting 2.4.3 Units with TWINS Function (for the Super-Slim Cassette & A5 Duct) 2.4.3.1 Communication between Master Unit and Indoor Unit Malfunction F3 Displayed F3 Displayed Communication failure between Communication failure between master unit and slave unit master unit and slave unit Check the dial switch settings of Check the dial switch settings of Correct the...
  • Page 121 Troubleshooting 2.4.4 Outdoor Units 2.4.4.1. Compressor Driven Chip EEPROM Malfunction Malfunction conditions Main PCB chip does not receive feedback from EEPROM chip Possible causes ● Installation mistakes ● Faulty PCB Compressor driven chip Compressor driven chip EEPROM malfunction EEPROM malfunction Power off, then restart the Power off, then restart the unit 2 minutes later.
  • Page 122 Troubleshooting 2.4.4.2 Compressor Speed Malfunction/ Zero Speed Protection / Synchronous Fault Protection LED1(Green) off/LED2(Red) flash LED1(Green) off/LED2(Red) flash or LED1(Green) flash/LED2(Red) on or LED1(Green) flash/LED2(Red) on Is there at least one LED in Is there at least one LED in the compressor driven chip the compressor driven chip light?
  • Page 123 Troubleshooting 2.4.4.3 MCE Malfunction MCE malfunction MCE malfunction Power off, then restart the Power off, then restart the unit 2 minutes later. Does a unit 2 minutes later. Does a problem still exist? problem still exist? Replace the outdoor main PCB Replace the outdoor main PCB Electrical Control System...
  • Page 124 Troubleshooting 2.4.4.4. E1 malfunction Current loop communication: Malfunction Indoor unit does not receive feedback from outdoor unit for 110 conditions seconds. This occurs 4 times in a row. Possible causes ● Wiring mistakes ● Faulty indoor or outdoor PCB Power off, then restart the unit 2 minutes later. Power off, then restart the unit 2 minutes later.
  • Page 125 Troubleshooting For 485 Communication Malfunction Indoor unit does not receive feedback from outdoor unit for 60 conditions seconds OR outdoor unit does not receive feedback from indoor unit for 120 seconds. Possible causes ● Wiring mistakes ● Faulty indoor or outdoor PCB E1 displayed E1 displayed Communication malfunction between indoor...
  • Page 126 Troubleshooting 2.4.4.5. F0 Malfunction Malfunction conditions If the outdoor current exceeds the current limit value, the LED displays a failure code. Possible causes ● Wiring mistakes Faulty bridge rectifier ● ● System blockages ● Faulty outdoor PCB Electrical Control System...
  • Page 127 Troubleshooting F0 displayed F0 displayed Current protection of compressor Current protection of compressor Was the protection activated Was the protection activated in standby? in standby? Is the power voltage is Restart the unit when the power Is the power voltage is Restart the unit when the power normal? supply returns to normal...
  • Page 128 Troubleshooting 2.4.4.6. F1, F2, F3 Malfunction Error E4 displayed E4 displayed Judge 1: Outdoor condenser temp. sensor (T3) is malfunctioning Judge 1: Outdoor condenser temp. sensor (T3) is malfunctioning Is the wiring of the condenser temp. Reconnect the condenser Is the wiring of the condenser temp. Reconnect the condenser sensor (T3) not connected properly? temp.
  • Page 129 Troubleshooting 2.4.4.7. F4 Malfunction Malfunction conditions Main PCB chip does not receive feedback from EEPROM chip Possible causes ● Installation mistakes ● Faulty PCB F4- Display F4- Display Outdoor EEPROM malfunction Outdoor EEPROM malfunction Power off, then restart the Power off, then restart the unit 2 minutes later.
  • Page 130 Troubleshooting 2.4.4.9. P0 Malfunction Malfunction conditions When the voltage signal te IPM sends to compressor drive chip is not normal, the LED displays “P0” and the unit turns off. Possible causes Wiring mistakes ● Faulty IPM board ● Faulty outdoor fan assemby ●...
  • Page 131 Troubleshooting P0 displayed P0 displayed IPM module protection IPM module protection Restart the unit when the power supply Restart the unit when the power supply Is the power voltage normal? Is the power voltage normal? returns to normal returns to normal Is the outdoor terminal voltage Are the power wires Reconnect the power...
  • Page 132 Troubleshooting 2.4.4.10. P1 malfunction Malfunction decision An abnormal voltage rise or drop is detected by checking the conditions specified voltage detection circuit. Supposed causes Abnormal power supply   Wiring mistake  Faulty bridge rectifier  Faulty IPM board P1 display P1 display Voltage protection Voltage protection...
  • Page 133 Troubleshooting 2.4.4.11. P4 Malfunction The troubleshooting is same as the “ ” IPM module protection 2.4.4.12. J0 Malfunction Malfunction conditions When evaporator coil temperature is more than 60°C, the unit stops. It starts again only when the evaporator coil temperature is less than 54°C Possible causes ...
  • Page 134 Troubleshooting 2.4.4.13. J1 Malfunction When the outdoor pipe temperature is more than 65°C, the unit stops. It Malfunction conditions starts again only when the outdoor pipe temperature is less than 52°C. Possible causes Faulty condenser temperature sensor ● Dirty heat exchanger ●...
  • Page 135 Troubleshooting 2.4.4.14. J2 Malfunction Malfunction conditions When the compressor discharge temperature (T5) is more than 115℃ for 10 seconds, the compressor will stop and not restart until T5 is less than 90℃. Possible causes Refrigerant leakage ● Wiring mistake ● Faulty discharge temperature sensor ●...
  • Page 136 Troubleshooting 2.4.4.15. J3 Malfunction Malfunction decision When the voltage signal that IPM send to compressor drive conditions chip is abnormal, the display LED will show “P6” and AC will turn off. Supposed causes Wiring mistake ● Faulty IPM board ● Faulty outdoor fan ass’y ●...
  • Page 137 Troubleshooting 2.4.4.16. J4 Malfunction J4 displayed J4 displayed Communication error between outdoor main Communication error between outdoor main chip and compressor driven chip chip and compressor driven chip Is there at least one LED in the Is there at least one LED in the compressor driven chip light? compressor driven chip light? Check the signal wire between the...
  • Page 138 Troubleshooting 2.4.4.17. J5 Malfunction Malfunction conditions If the sampling voltage is not 5V, the LED displays a failure code. Possible causes ● Wiring mistakes Faulty overload protector ● ● System blockages ● Faulty outdoor PCB J5 displayed J5 displayed High pressure protection High pressure protection Are the high pressure Connect high pressure...
  • Page 139 Troubleshooting 2.4.4.18. P6/J6 Malfunction Malfunction conditions If the sampling voltage is not 5V, the LED displays a failure code. Possible causes ● Wiring mistake Faulty over load protector ● ● System blockages ● Faulty outdoor PCB J6 displayed J6 displayed Low pressure protection Low pressure protection Reconnect the low pressure...
  • Page 140 Troubleshooting 2.4.4.19. J8 malfunction Malfunction decision An abnormal voltage rise or drop is detected by checking the conditions specified voltage detection circuit. Supposed causes Abnormal power supply   Wiring mistake  Faulty bridge rectifier  Faulty IPM board J8 display J8 display AC power input voltage AC power input voltage...
  • Page 141 Troubleshooting Appendix 1 Temperature Sensor Resistance Value Table (℃--K) ℃ ℃ ℃ ℃ K Ohm K Ohm K Ohm K Ohm 12.6431 2.35774 0.62973 115.266 108.146 12.0561 2.27249 0.61148 101.517 11.5000 2.19073 0.59386 96.3423 10.9731 2.11241 0.57683 89.5865 10.4736 2.03732 0.56038 84.2190 10.000...
  • Page 142 Troubleshooting Appendix 2 Unit: ℃---K Discharge temperature sensor table 542.7 68.66 13.59 3.702 511.9 65.62 13.11 3.595 62.73 12.65 3.492 455.9 59.98 12.21 3.392 430.5 57.37 11.79 3.296 406.7 54.89 11.38 3.203 384.3 52.53 10.99 3.113 363.3 50.28 10.61 3.025 343.6 48.14 10.25...
  • Page 143 Troubleshooting Appendix 3 Normal voltage of P and N 208-240V(1-phase,3-phase) 380-415V(3-phase) In standby 310VDC around 530VDC around In operation With passive PFC With partial active With fully active module PFC module PFC module >200VDC >310VDC >370VDC >450VDC Electrical Control System...
  • Page 144 Controller 3. Controller 3.1Wireless Remote Controller (refer the RC manual ) 3.2 Wired Remote Controller 3.2.1 KJR-12B Name and functions of buttons on the wire controller Mode button: When press this button, the operation mode change as the following sequence: AUTO COOL HEAT...
  • Page 145 Controller off, and send instruction. If timer on or timer off has been set, it cancel this setting then send instruction to stop the machine. Adjust button: Set indoor temperature up. If press and hold on, it will increase at 1degree per 0.5 second.
  • Page 146 Controller Remark: The wired controller will reset to factory setting with auto mode, auto fan and 24℃ setting temperature when the air conditioner restarts after power failure. And this may cause inconsistent displays on the wired controller and on the air conditioner. You need to readjust the running status through the wired controller.
  • Page 147 Controller 3.2.2 KJR-120C1/BTF-E Name and functions of buttons on the wire controller Electrical Control System...
  • Page 148 Controller 1. Power button: When in off state, short press this button, the operation lamp lits brightly. When in on state, short press this button, the operation lamp does not lit. If timer on or timer off has been set, it will not cancel this setting.
  • Page 149 Controller Name and function of LCD on the wire controller Installation 1. Connect the female joint of wires group from the mainboard with the male joint of connective wires group. 2. Please connect the other side of connective wires group with the male joint of wires group leads from wire controller Electrical Control System...
  • Page 150 Controller 3. Insert a slot screwdriver into the slots in the lower part of the wire controller (2 places), and remove the upper part of the wire controller. 4.Fasten the back plate of the wire controller 4.4 For exposed mounting, fasten the back plate on the wall with the 3 screws (M4×20) and plugs.
  • Page 151 Controller 5. Battery installation 4.6 Put the battery into the installationsite and make sure the positive side of the battery is in accordance with the positive side of installationsite. 4.7 Please set the time corrected on the first time operation. Batteries in the wire controller can timing under power failure which ensure the time keep right.
  • Page 152 Controller 7. Reattach the upper part of the wire controller After adjusting the upper case and then buckle the upper case; avoid clamping the wiring during installation 3.2.3 Two-wired non-polarity wired controller(KJR-120G)(Optional) 1.Connection For Cassette: The wired controller connects to main control board directly. For Duct, Ceiling&...
  • Page 153 Controller 2.Address setting One non-polarity controller can control up to 16 indoor units. When the non-polarity controller is connected to several units, every air-conditioner in network has only one network address to distinguish each other. Address code of air-conditioner in LAN is set by code switch ENC1(Duct and Ceiling& Floor) or ADSS(Cassette) of the indoor unit, and the set range is 0-15.

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