innovair Inverter FLEX24 SEV2040H2R18 Service Manual
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innovair Inverter FLEX24 SEV2040H2R18 Service Manual

Heat pump split system
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FLEX24
HEAT PUMP
SPLIT SYSTEM
SERVICE MANUAL
• The information contained in the manual is intended for use by a qualified service technician
familiar with safety procedures and equipped with the proper tools and test instruments
• Installation or repairs made by unqualified persons can result in hazards to you and others.
• Failure to carefully read and follow all instructions in this manual can result in equipment
malfunction, property damage, personal injury and/or death.
• This service is only for service engineer to use.
SEV2040H2R18
SEV3060H2R18
DEV24H2R18
DEV36H2R18
DEV48H2R18
DEV60H2R18

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Summary of Contents for innovair Inverter FLEX24 SEV2040H2R18

  • Page 1 FLEX24 HEAT PUMP SPLIT SYSTEM SERVICE MANUAL SEV2040H2R18 SEV3060H2R18 DEV24H2R18 DEV36H2R18 DEV48H2R18 DEV60H2R18 • The information contained in the manual is intended for use by a qualified service technician familiar with safety procedures and equipped with the proper tools and test instruments •...
  • Page 2 Innovair Elite Mini Split Foreword Thank you for choosing Innovair FLEX24 air conditioners. In order to correctly install and use our units, and for the satisfactory operation effect, please read this manual carefully. This manual specifies safe operation requirements from perspectives of product introduction, control, troubleshooting and maintenance, as well as basic principles and implementation methods.

  • Page 3: Table Of Contents

    SERVICE MANUAL CONTENTS 1 Product Introduction ...................... 3 1.1 Lists of Units .......................... 3 1.2 Electrical Parameters ......................5 2 Control ..........................6 2.1 Operation Mode ........................6 2.2 Control Mode ......................... 8 2.3 Functions ..........................10 3 Troubleshooting ......................14 3.1 Wiring Diagrams ........................
  • Page 4 SERVICE MANUAL Safety Notice on Maintenance PROHIBITED： (1) Do not pierce or burn. (2) Please note that refrigerant may be odorless. (3) The appliance shall be stored in a room without continuously operating ignition sources (For example: open flames, an operating gas appliance or an operating electric heater). (4) Indoor unit adopts special joints that can’t be detached.
  • Page 5 SERVICE MANUAL high speed; Otherwise personal injury may occur. (5) Measure the insulation resistance after maintenance. The resistance must be 1M or higher. Bad insulation may lead to electric shock. (6) Welding and cutting work must be done in a well-ventilated place. (7) Gas appliances, heaters and other fire sources should be kept away from the installation and maintenance site.

  • Page 6: Product Introduction

    SERVICE MANUAL 1 Product Introduction 1.1 Lists of Units 1.1.1 List of Outdoor Units Power Supply Model Appearance V/Ph/Hz SEV2040H2R18 208/230V-1Ph-60Hz SEV3060H2R18 208/230V-1Ph-60Hz...
  • Page 7 SERVICE MANUAL 1.1.2 List of Indoor Units Power Supply Cooling/Heating Model Appearance Capacity (Btu/h) V/Ph/Hz Airhandler DEV24H2R18 24000/24000 208/230V-1Ph-60Hz Airhandler DEV36H2R18 36000/36000 208/230V-1Ph-60Hz Airhandler DEV48H2R18 48000/48000 208/230V-1Ph-60Hz Airhandler DEV60H2R18 54000/54000 208/230V-1Ph-60Hz NOTE: 1 Ton =12000Btu/h = 3.517kW...

  • Page 8: Electrical Parameters

    SERVICE MANUAL 1.2 Electrical Parameters Power supply Circuit breaker capacity Model V/Ph/Hz SEV2040H2R18 208/230V-1Ph-60Hz SEV3060H2R18 208/230V-1Ph-60Hz Power Supply Fuse Capacity Circuit Breaker Capacity Model V/Ph/Hz DEV24H2R18 208/230V-1Ph-60Hz DEV36H2R18 208/230V-1Ph-60Hz 3.15 DEV48H2R18 208/230V-1Ph-60Hz 3.15 DEV60H2R18 208/230V-1Ph-60Hz 3.15...

  • Page 9: Control

    SERVICE MANUAL 2 Control 2.1 Operation Mode 2.1.1 Cooling Mode...
  • Page 10 SERVICE MANUAL 2.1.2 Heating Mode...

  • Page 11: Control Mode

    SERVICE MANUAL 2.2 Control Mode 2.2.1 Based Control 2.2.1.1 Compressor Control When cooling or heating mode is turned on, indoor fan will run for a while before the compressor starts. Under different modes, the compressor can only be stopped after running for some time (special cases excluded). This is to protect the compressor from frequent start or stop.
  • Page 12 SERVICE MANUAL and outdoor and indoor fan will both stop. When the temperature sensed by outdoor tube temperature sensor reaches the preset value of defrosting stop, system will quit defrosting. The 4-way valve will switch back to the heating condition, compressor and outdoor unit fan restart. 2.2.2.2 Oil Return Control If the unit is running at low frequency for a long time, system will enable oil return control.

  • Page 13: Functions

    SERVICE MANUAL detected open for continuously a little time. Under discharge high temperature protection, system will be shut down and display error code E4. When discharge high temperature protection occurs, system will restore operation if the discharge high temperature sensor is detected to be reclosed within a few minutes after shutdown. If discharge high temperature protection occurs for several times in a period of time, system will not restore operation automatically.
  • Page 14 SERVICE MANUAL 2.3.3 Set Operating Mode The third dip switch and the fourth dip switch are selecting the operating mode. Standard mode is the conventional mode. By setting the strong mode dip switches of the condensing unit, the air conditioner can quickly increase the capacity output and ensure reliable operation in a short time, so as to meet the user's demand for the indoor temperature to quickly reach the set temperature.
  • Page 15 SERVICE MANUAL Level 3 Capacity 48K indoor unit dip switches 60K indoor unit dip switches Level 1 (Default) Level 2 Level 3 2.3.5 Forced Defrost Control Press and hold "SW1" for about 5s to enter the first level menu of the debugging mode, the outdoor unit mainboard LED displayer flashes.
  • Page 16 SERVICE MANUAL switching to "09", short press "SW2" or "SW3" to enter the forced operation control mode, "01" denotes that turn on the forced operation cooling mode; "02" denotes that turn on the forced operation cooling mode; "OF" indicates that shut down the forced cooling / heating mode. And then short press "SW1" to save. During debugging, if no operation is performed within 10s, the debugging mode interface will be exited.

  • Page 17: Troubleshooting

    SERVICE MANUAL 3 Troubleshooting 3.1 Wiring Diagrams The following electric diagram is for reference only. Please refer to diagram sticked on the unit as the latest version. 3.1.1 Wiring Diagrams of ODUS Model: SEV2040H2R18...
  • Page 18 SERVICE MANUAL Model: SEV3060H2R18 3.1.2 Wiring Diagrams of IDUs Model: DEV24H2R18, DEV36H2R18...
  • Page 19 SERVICE MANUAL Model: DEV48H2R18, DEV60H2R18...

  • Page 20: Pcb Layout

    SERVICE MANUAL 3.2 PCB Layout 3.2.1 Interface Indoor unit: Model: DEV24H2R18, DEV36H2R18, DEV48H2R18, DEV60H2R18 Mainboard Printing Interface Printing Interface AC-N（X2） Neutral wire input X9(G_SCAN) Indoor motor check AC motor high speed AC-L （X1） Live wire input X14(OFAN-H-OUT) output Wired control communication X11(OFAN-H-IN) AC motor high speed input...
  • Page 21 SERVICE MANUAL Pinboard Printing Interface Printing Interface DC-MOTOR1 DC motor output COM2 DC motor control signal input...
  • Page 22 SERVICE MANUAL Outdoor unit: Model: SEV2040H2R18, SEV3060H2R18 Mainboard Printing Interface Printing Interface AC-L Live wire input H-PRESS High pressure sensor interface System low pressure protection AC-N Neutral wire input interface System high pressure protection HEAT_TIE_B Chassis electric heating belt interface 2.
  • Page 23 SERVICE MANUAL Printing Interface Printing Interface Electromagnetic valve COM7 Unit communication interface interface Electronic expansion valve GPRS communication interface interface Electronic expansion valve 1 interface COM-MANUAL Thermostat interface Refrigerant heat dissipation Drive communication DC_MOTOR1 COMM1 DC motor output interface DC_MOTOR2 Low pressure sensor L-PRESS PWR1...
  • Page 24 SERVICE MANUAL Printing Interface Printing Interface Communication terminal, same with COMM Compressor V phase terminal COMM1 Drive power supply terminal Compressor W phase terminal DC-MOTOR1 DC fan terminal JTAG1 Programming interface (for testing) DC-BUS1 Power discharge terminal (for testing) Model: SEV3060H2R18 Printing Interface...
  • Page 25 SERVICE MANUAL Filtering Board: Model: SEV2040H2R18 ⑩ ⑩ ⑩ ⑩ ⑩ ⑩ ⑩ Printing Interface Printing Interface AC-L Power input live wire terminal N-OUT Power output neutral wire terminal (reserved) AC-N Power input neutral wire terminal N-OUT Power output neutral wire terminal Filtering board ground wire terminal L-OUT Power output live wire terminal...
  • Page 26 SERVICE MANUAL 3.2.2 IPM, PFC Testing Method 3.2.2.1Method of Testing IPM Module (1) Preparation before test: prepare a universal meter and turn to its diode option, and then remove the wires U, V, W of the compressor after it is powered off for one minute. (2) Testing Steps Step 1: put the black probe on the place P and the red one on the wiring terminal U, V, W respectively as shown in the following figure to measure the voltage between UP, VP and WP.
  • Page 27 SERVICE MANUAL SEV2040H2R18 SEV4060H2R18...

  • Page 28: Error Code

    SERVICE MANUAL 3.3 Error Code Error code Error Compressor high pressure protection Compressor low pressure protection Compressor air discharge high-temperature protection Condenser temperature sensor error Outdoor ambient temperature sensor error Discharge temperature sensor error ODU tube temperature sensor error ODU memory chip error Overload IPM protection DC fan error...

  • Page 29: Troubleshooting

    SERVICE MANUAL 3.4 Troubleshooting 3.4.1 “E1” Compressor High Pressure Protection Error display: ODU mainboard LED displayer Error judgment condition and method: It is judged through the action of high pressure switch. If the high pressure switch is cut off, it is judged that high pressure is too high and the system stops operation for protection.
  • Page 30 SERVICE MANUAL Troubleshooting：...
  • Page 31 SERVICE MANUAL 3.4.2 “E3” Compressor Low-pressure Protection, Refrigerant Shortage Protection, Refrigerant Recovery Mode Error display: ODU mainboard LED displayer Error judgment condition and method: It is judged through the action of low pressure switch. If the low pressure switch is cut off, it is judged that low pressure is too low and the system stops operation for protection.
  • Page 32 SERVICE MANUAL Troubleshooting： E3 protection Enter Charge debugging mode refrigerant through wired Check if the according to the controller and select system low requirement and without refrigerant pressure is lower then turn on the unit lacking protection; then than 0.05MPa to see if E3 turn on the unit to see protection still...
  • Page 33 SERVICE MANUAL Possible reason： Cut -off valve of ODU is not fully opened; E lectronic expansion valve is abnormal; Outdoor or indoor fan is not working properly; IDU filter or air duct is blocked (cooling mode); Ambient temperature exceeds allowable operation range; Refrigerant charging amount is insufficient;...
  • Page 34 SERVICE MANUAL Troubleshooting： 3.4.4 “F2” Condenser Temperature Sensor Error Error display: ODU mainboard LED displayer Error judgment condition and method: Sample the AD value of temperature sensor through temperature sensor detecting circuit and judge the range of AD value, If the sampling AD value exceeds upper limit and lower limit in 5 seconds continuously, report...
  • Page 35 SERVICE MANUAL the error. Possible reason: Poor contact between temperature sensor and terminal in mainboard interface Temperature sensor is abnormal Detecting circuit is abnormal Troubleshooting： Malfunction of condenser temperature sensor Check if the condenser Correctly insert the temperature sensor on temperature sensor mainboard is inserted on the on the needle stand...
  • Page 36 SERVICE MANUAL Possible reason: Poor contact between ambient temperature sensor and terminal in mainboard interface Ambient temperature sensor is abnormal Detecting circuit is abnormal Troubleshooting： NOTE: Please refer to Appendix 1 for temperature and resistance of temperature sensor. the relation between 3.4.6 “F4”...
  • Page 37 SERVICE MANUAL Possible reason: Poor contact between temperature sensor and terminal in mainboard interface Temperature sensor is abnormal Detecting circuit is abnormal Troubleshooting： Malfunction of discharge temperature sensor Check if the Correctly insert the discharge temperature sensor on temperature sensor mainboard is inserted on the on the needle stand needle stand correctly...
  • Page 38 SERVICE MANUAL Possible reason: Poor contact between temperature sensor and terminal in mainboard interface Temperature sensor is abnormal Detecting circuit is abnormal Troubleshooting： Malfunction of discharge temperature sensor Check if the Correctly insert the discharge temperature sensor on temperature sensor mainboard is inserted on the on the needle stand needle stand correctly...
  • Page 39 SERVICE MANUAL Troubleshooting: Malfunction of ODU memory chip error Replace the outdoor mainboard 3.4.9 “H4” Overload Error display: ODU mainboard LED displayer Error judgment condition and method: When condensing pressure is higher than the protection value, system will report overload protection. Possible reason: Cooling ODU heat exchanger is blocked or heat exchange is bad.
  • Page 40 SERVICE MANUAL Troubleshooting： Overload Outdoor heat exchanger is blocked Remove the obstacle Indoor heat exchanger is blocked . Remove the obstacle Ambient temperature is out of the Normal protection . No operation range need to handle it . Release a proper amount Too much charging quantity .
  • Page 41 SERVICE MANUAL Drive board IPM module’s 15V power supply is lower than 13.5V. Drive board 6-line PWM signal and the corresponding element are abnormal. Drive board compressor current sampling circuit element is damaged or drive chip current sampling AD terminal is abnormal.
  • Page 42 SERVICE MANUAL Possible reason: Outdoor fan wiring terminal is not correctly connected to the mainboard. Outdoor fan is damaged. If it is a new unit or a new motor has been replaced in the unit and the wire connection is correct, then probably it is the program that goes wrong.
  • Page 43 SERVICE MANUAL Drive board compressor current sampling circuit element is damaged or drive chip current sampling AD terminal is abnormal. Compressor is damaged. Troubleshooting：...
  • Page 44 SERVICE MANUAL 3.4.13 “HC” PFC Protection Error display: ODU mainboard LED displayer Error judgment condition and method: After power is connected, and drive chip received PFC lead F0 that is of low level, than it is PFC module malfunction. System will shut down for protection. Possible reason: Power grid voltage is abnormal.
  • Page 45 SERVICE MANUAL 3.4.14 “Lc” Startup Failure Error display: ODU mainboard LED displayer Error judgment condition and method: Check the error code on nixie tube of ODU main control board. If PJ is displayed, it indicates inverter compressor startup failure Possible reason: Poor contact of compressor UVW wire;...
  • Page 46 SERVICE MANUAL 3.4.15 “P0” Driver Reset Protection Error display: ODU mainboard LED displayer Error judgment condition and method: Drive board chip resets and starts initialization. After the drive board is energized for 5s, it detects that the chip resets again. In this case, it can be judged as drive chip reset protection. Possible reason: 3.3V drive chip supply voltage drop.
  • Page 47 SERVICE MANUAL Drive board current sampling circuit element is damaged or drive chip current sampling AD terminal is abnormal. Compressor is damaged. Troubleshooting： 3.4.17 “P6” Master Control and Driver Communication Error Error display: ODU mainboard LED displayer Error judgment condition and method: If there is no other malfunction and the communication between master control and driver is cut off for 30s, then it can be judged that the communication between master control and driver is faulted.
  • Page 48 SERVICE MANUAL The switch power of drive board is abnormal, therefore, the 3.3V power voltage is abnormal. Communication circuit of the drive board or the master control board is abnormal. Troubleshooting： 3.4.18 “P7” Driver Module Sensor Error Error display: ODU mainboard LED displayer Error judgment condition and method: If IPM or PFC module temperature is lower than the set protection value, then it can be judged that driver module sensor error occurs and system will shut down for protection.
  • Page 49 SERVICE MANUAL Troubleshooting： P7 Driver module sensor error Replace the drive board 3.4.19 “P8” Driver Module High Temperature Protection Error display: ODU mainboard LED displayer Error judgment condition and method: If IPM module temperature or PFC module temperature exceeds the set protection value, then it can be judged that driver module temperature is too high and system will shut down for protection.
  • Page 50 SERVICE MANUAL 3.4.20 “PA” AC Current Protection Error display: ODU mainboard LED displayer Error judgment condition and method: If input current value exceeds the set protection value, then it can be judged that AC current protection occurs and system will shut down for protection. Possible reason: System is heavy-loaded and compressor current is too large.
  • Page 51 SERVICE MANUAL Possible reason: Current detection (or current sensor) sampling circuit element is abnormal. Drive chip compressor current sampling AD terminal is badly welded or short-circuited. Troubleshooting： Current detection (or current sensor) circuit error Replace the drive board . 3.4.22 “PL” Bus Low-Voltage Protection Error display: ODU mainboard LED displayer Error judgment condition and method: When compressor is running and there is no other malfunction, if busbar voltage is lower than the set value...
  • Page 52 SERVICE MANUAL 3.4.23 “PH” Bus High-Voltage Protection Error display: ODU mainboard LED displayer Error judgment condition and method: If there is no other malfunction and the busbar voltage is higher than the set value for high voltage protection, then it can be judged that bus high-voltage protection occurs. System will shut down for protection. Possible reason: Voltage of power grid is abnormal.
  • Page 53 SERVICE MANUAL Troubleshooting： Charge loop error Grid voltage is too low ? Normal protection Replace the drive board 3.4.25 “ee” Drive Memory Chip Error Error display: ODU mainboard LED displayer Error judgment condition and method: If power is connected but the drive board with memory chip cannot detect the memory chip or read the memory chip data correctly, then it can be judged that drive memory chip error exists.
  • Page 54 SERVICE MANUAL 3.4.26 “e1” High Pressure Sensor Error Error display: ODU mainboard LED displayer Sample the AD value of pressure sensor through pressure sensor detecting circuit and judge the range of AD value, If the sampling AD value exceeds upper limit and lower limit in 30 seconds continuously, report the error.
  • Page 55 SERVICE MANUAL Possible reason: Jumper cap is not installed Jumper cap model is wrong Detecting circuit is abnormal Troubleshooting：...

  • Page 56: Failures Not Caused By Errors

    SERVICE MANUAL 3.5 Failures Not Caused by Errors (1) If your air conditioner fails to function normally, please first check the following items before maintenance: Problem Cause Corrective measure If you turn off the unit and then immediately turn it on, in order to protect the compressor and avoid Please wait for a while.
  • Page 57 Check the above items and adopt the corresponding corrective measures. If the air conditioner continues to function poorly, please stop the air conditioner immediately and contact Innovair's authorized local service center. Ask our professional service staff to check and repair the unit.

  • Page 58: Maintenance

    SERVICE MANUAL 4 Maintenance 4.1 System Diagram 4.2 Connection Pipe Vacuum Pumping NOTICE ① Make sure the outlet of vacuum pump is away from fire source and is well-ventilated. ② Before vacuum pumping, make sure the unit cut-off valves are closed. ③...
  • Page 59 SERVICE MANUAL (6) Wait for 10min to see if the system pressure can remain unchanged. If the pressure increase, there may be leakage. (7) Slightly open the liquid valve and let some refrigerant go to the connection pipe to balance the pressure inside and outside of the connection pipe, so that air will not come into the connection pipe when removing the hose.

  • Page 60: Refrigerant Charging

    SERVICE MANUAL 4.3 Refrigerant Charging Pre-charging Step 1: Connect the high pressure gauge line to the valve of liquid pipe and connect the low pressure gauge line to the valve of gas pipe. Connect the middle gauge line to the vacuum pump. Power on the vacuum pump and perform vacuum drying.
  • Page 61 SERVICE MANUAL Refrigerant charging when unit is turned on: Step 1: Close the valve of refrigerant tank. First remove the pressure gauge lines and connect the outdoor unit to the indoor unit. Then reconnect the pressure gauge lines. Connect the low pressure gauge line to the other joint of gas valve and connect the high pressure gauge line to the liquid valve.

  • Page 62: Maintenance Of Major Components

    SERVICE MANUAL 4.4 Maintenance of Major Components 4.4.1 Replacement of thermostat Please refer to the instruction manual of thermostat XE70-00/E1. 4.4.2 How to replace the compressor 4.4.2.1 Diagnosis of compressor failure A. On condition that the unit can be started up Step 1: If the unit can be started up, then start it up to check the current of the faulted compressor.
  • Page 63 SERVICE MANUAL Step 2: Judge whether the operating noise of the compressor is normal, and whether there is a sharp noise or obvious scraping. If there is a normal compressor working nearby, compare their operating noise. Step 3: Examine whether the electronic expansion valve of the outdoor unit is active and whether the 4-way valve works or not.
  • Page 64 SERVICE MANUAL This is the position of the 4-way valve. Do not touch it directly with your hands. There is hot refrigerant at the exhaust pipe, so be careful not to be scalded. D- Connect to the exhaust side Caution! High temperature! Labels on the 4-way valve: D-connect to the exhaust side;...
  • Page 65 SERVICE MANUAL Please refer to the IPM checking method in the section of troubleshooting. B．On condition that the unit cannot be started up Step 1: Cut off the power supply and detach the cover of the wiring box of the compressor. Check the wiring of the compressor.
  • Page 66 SERVICE MANUAL balance mouth. The suction and exhaust openings of the compressors must be sealed. If a rubber seal is missing, user adhesive tape to seal the opening. This is to prevent the compressor oil from contacting the air. Make sure the rubber seals of the suction and exhaust openings of the compressor are in good condition.
  • Page 67 SERVICE MANUAL (2) Prepare relevant tools 1) Prepare nitrogen. Please strictly follow the nitrogen welding standards during the welding process. Make sure there is sufficient nitrogen. The nitrogen pressure should be above 2.0MPa; 2) Prepare welding rods. Prepare some welding rods of common specifications and some special welding rods that contain more than 5% silver.
  • Page 68 SERVICE MANUAL (2) Place the compressor at a position above the ground level and then pour out the oil from the air outlet of the compressor. Collect the oil in a transparent container. The amount of oil should be over 150ml. NOTE: 1) The axial direction of the compressor should not slant at an angle larger than 20°...
  • Page 69 SERVICE MANUAL 1. Remove the screw bolt of the separator. 2. Remove the screw bolt of the separator. 3. Remove the separator. When the separator is detached, check whether there are impurities inside. Below is the checking method: NOTE: When pouring the liquid from the separator, make sure the discharge pipe is at the lower position.Slant at an angle not larger than 20°...
  • Page 70 SERVICE MANUAL Step 8: Replace the compressor For the removal of compressor, please refer to the section: Removal of Major Components. Step 9: Check/Replace the gas-liquid separator NOTE: If a compressor is damaged and needs to be replaced, its gas-liquid separator should also be replaced. This is to avoid the abnormal condition of the separator from affecting the safe and reliable operation of the system.
  • Page 71 SERVICE MANUAL 4.4.3 How to replace the drive module of compressor Step 1: First, make sure that power is cut off. Set the universal meter at the AC voltage and measure the voltage between L1, L2, L3, and N. If each time the voltage is 0V (Errors may occur to the universal meter, sometimes the voltage may not be 0V), proceed with the next step and put a sign on the power switch that reads “Under maintenance, don’t switch on”.

  • Page 72: Removal Of Major Components

    SERVICE MANUAL 4.5 Removal of Major Components 4.5.1 Removal of ODU Major Components Picture Name Function Through compression, the low pressure refrigerant occupies a less space. Compressor As its pressure and temperature both rise, it becomes high pressure and high temperature refrigerant. It is the power drive of the system. 4-way valve It is used to change directions, the flow of refrigerant in cooling/heating.
  • Page 73 SERVICE MANUAL Picture Name Function Accumulator Flash refrigerant from liquid to gas It is used to transfer partial heat of the hot flow to the cold flow so that the Condenser flow temperature can reach the specified index. It is an energy exchanging device.
  • Page 74 SERVICE MANUAL Model: SEV2040H2R18 Removal of front panel NOTE: Before removing the front panel, make sure power is cut off. Step Picture Work instruction Unscrew the screws of the 1. Remove the upper cover upper cover plate with a plate. screwdriver.
  • Page 75 SERVICE MANUAL Removal of front panel NOTE: Before removing the front panel, make sure power is cut off. Step Picture Work instruction Unscrew the screws that connect the right side plate 5. Remove the right side plate. to the electric box and the screws around the right side plate.
  • Page 76 SERVICE MANUAL Removal of front panel NOTE: Before removing the front panel, make sure power is cut off. Step Picture Work instruction Fix the clasps on both sides 9. Install the front side plate. of the plate and tighten up the screws.
  • Page 77 SERVICE MANUAL Removal of compressor/gas liquid separator NOTE: Before removing the compressor/gas liquid separator, make sure there is no refrigerant in the pipeline and power is cut off. Step Picture Work instruction Weld the pipes that are connected to the compressor/gas liquid 2.
  • Page 78 SERVICE MANUAL Removal of compressor/gas liquid separator NOTE: Before removing the compressor/gas liquid separator, make sure there is no refrigerant in the pipeline and power is cut off. Step Picture Work instruction After replacing the 5. Install the new compressor/gas liquid compressor/gas liquid separator, tighten up the separator onto the chassis.
  • Page 79 SERVICE MANUAL Model: SEV2040H2R18 Removal of 4-way valve NOTE: Before removing the 4-way valve, make sure refrigerant is fully discharged from the unit and power is cut off. Step Picture Work instruction Carefully unscrew the 1. Take off the coil of the screws of electromagnetic 4-way valve.
  • Page 80 SERVICE MANUAL Removal of 4-way valve NOTE: Before removing the 4-way valve, make sure refrigerant is fully discharged from the unit and power is cut off. Step Picture Work instruction Tighten the screws of the 4. Install the coil of 4-way coil of 4-way valve with a valve.
  • Page 81 SERVICE MANUAL Removal of fan and motor Note: Before removing the fan, make sure power is cut off. Step Picture Work instruction Use a screwdriver to unscrew the bolt of motor. 3. Remove motor. NOTE: Motor wire should be first removed from the electric box.
  • Page 82 SERVICE MANUAL Model: SEV2040H2R18 Removal of condenser NOTE:Before removing the condenser, make sure there is no refrigerant in the pipeline and power is cut off. Step Picture Work instruction Remove the upper, lower and 1. Remove the panels. front panels. Loosen the wire clamp at the bottom of the electric box.
  • Page 83 SERVICE MANUAL Removal of condenser NOTE:Before removing the condenser, make sure there is no refrigerant in the pipeline and power is cut off. Step Picture Work instruction Heat up the welding points of connection pipes through gas welding until the pipes break off.
  • Page 84 SERVICE MANUAL Removal of condenser NOTE:Before removing the condenser, make sure there is no refrigerant in the pipeline and power is cut off. Step Picture Work instruction Put the electric box in place 7. Secure the electric box and tighten up the screws of and arrange the wires electric box.
  • Page 85 SERVICE MANUAL Model: SEV2040H2R18 Removal of electronic expansion valve NOTE:Before removing the electronic expansion valve, make sure there is no refrigerant in the pipeline and power is cut off. Step Picture Work instruction Remove the upper, lower and front panels. Loosen the wire clamp at the bottom of the electric Unscrew the screws of...
  • Page 86 SERVICE MANUAL Removal of electronic expansion valve NOTE:Before removing the electronic expansion valve, make sure there is no refrigerant in the pipeline and power is cut off. Step Picture Work instruction Take off the coil of electronic expansion valve. Loosen the connection 3.
  • Page 87 SERVICE MANUAL Removal of electronic expansion valve NOTE:Before removing the electronic expansion valve, make sure there is no refrigerant in the pipeline and power is cut off. Step Picture Work instruction 6. Secure the Put the electric box back electric box in place and tighten up and arrange the screws.
  • Page 88 SERVICE MANUAL Removal of front panel NOTE: Before removing the front panel, make sure power is cut off. Step Picture Work instruction Unscrew the screws of the 2. Remove the front plate. front plate with a screwdriver. Unscrew the screws of the 3.
  • Page 89 SERVICE MANUAL Removal of front panel NOTE: Before removing the front panel, make sure power is cut off. Step Picture Work instruction Attach the grill back in place 6. Install the grill. and tighten up the screws. Unscrew the screws of the 7.
  • Page 90 SERVICE MANUAL Removal of front panel NOTE: Before removing the front panel, make sure power is cut off. Step Picture Work instruction Attach the grill back in place 10. Install the grill. and tighten up the screws. Tighten up the screws 11.
  • Page 91 SERVICE MANUAL Model: SEV4060H2R18 Disassembly of compressor NOTE:Before removing the compressor, make sure there is no refrigerant in the pipeline and power is cut off. Step Picture Work instruction Loosen the securing screws of the wires with a screwdriver. Remove the wires. 1.
  • Page 92 SERVICE MANUAL Disassembly of compressor NOTE:Before removing the compressor, make sure there is no refrigerant in the pipeline and power is cut off. Step Picture Work instruction Take out the compressor and replace it. 4. Remove the compressor NOTE:When replacing the from the chassis.
  • Page 93 SERVICE MANUAL Disassembly of compressor NOTE:Before removing the compressor, make sure there is no refrigerant in the pipeline and power is cut off. Step Picture Work instruction Connect the compressor wires to the wire terminals on the top of compressor. 7.
  • Page 94 SERVICE MANUAL Removal of 4-way valve NOTE:Before removing the 4-way valve, make sure refrigerant is fully discharged from the unit and power is cut off. Step Picture Work instruction Use a soldering gun to loosen the 4 joints on the 4-way valve and then remove the connection pipes.
  • Page 95 SERVICE MANUAL Model: SEV4060H2R18 Removal of fan and motor NOTE: Before removing the fan, make sure power is cut off. Step Picture Work instruction Use a screwdriver to unscrew the two screws on 1. Remove the grill. the upper left and lower right corners.
  • Page 96 SERVICE MANUAL Removal of fan and motor NOTE: Before removing the fan, make sure power is cut off. Step Picture Work instruction Replace with a new motor. 4. Install the motor. Then tighten up the screw bolt. Install the fan in place. Put on the gasket and use a wrench to secure the screw nut.
  • Page 97 SERVICE MANUAL Model: SEV4060H2R18 Removal of gas liquid separator NOTE: Before removing the gas liquid separator, make sure there is no refrigerant in the pipeline and power is cut off. Step Picture Work instruction Remove the upper, lower and 1. Loosen the wire clamp at the front panels.
  • Page 98 SERVICE MANUAL Removal of gas liquid separator NOTE: Before removing the gas liquid separator, make sure there is no refrigerant in the pipeline and power is cut off. Step Picture Work instruction Install the gas liquid separator by referring to the positions of entering and leaving pipes.
  • Page 99 SERVICE MANUAL Model: SEV4060H2R18 Removal of electronic expansion valve NOTE:Before removing the electronic expansion valve, make sure there is no refrigerant in the pipeline and power is cut off. Step Picture Work instruction Remove the upper, lower and 1. Loosen the wire clamp at the front panels.
  • Page 100 SERVICE MANUAL Removal of electronic expansion valve NOTE:Before removing the electronic expansion valve, make sure there is no refrigerant in the pipeline and power is cut off. Step Picture Work instruction 4. Take out the electronic Take out the electronic expansion valve.
  • Page 101 SERVICE MANUAL Removal of electronic expansion valve NOTE:Before removing the electronic expansion valve, make sure there is no refrigerant in the pipeline and power is cut off. Step Picture Work instruction Check whether each component and connection wire is well 7.
  • Page 102 SERVICE MANUAL Disassembly and Assembly of the Electric Box Step Picture Work instruction Disconnect the electric element from the wiring terminal. Loosen screws around th e electric 3. Remove the electric element. element with a screwdriver. Remove the electric element from the electric box.
  • Page 103 SERVICE MANUAL Disassembly and Assembly of the Fan Motor Step Picture Work instruction Disconnect the wires of the fan from the wiring terminal and draw them out. 2. Remove the fan. Loosen screws located at the front of the fan with a screwdriver. R emove the fan from the unit.
  • Page 104 SERVICE MANUAL Disassembly and Assembly of the Evaporator and Drain Pan Step Picture Work instruction Loosen screws round the lower panel 2. Remove the lower panel (1) with a screwdriver. and panel (2). Remove the lower panel from unit. Remove the screws from enhanced 3.
  • Page 105 SERVICE MANUAL Disassembly and Assembly of the Evaporator and Drain Pan Step Picture Work instruction 6. Remove the secondary drain Remove the secondary drain pan from pan. the unit. Remove the evaporator away from the 7. Remove the evaporator. primary drain pan. Reassemble the unit as before.
  • Page 106 SERVICE MANUAL Disassembly and Assembly of the Filter Step Picture Work instruction Remove the filter screen away from the unit. 2. Remove the filter screen. After replacing the filter screen, reassemble the unit as before.

  • Page 107: Explosive View And Lists Of Parts

    SERVICE MANUAL 4.6 Explosive View and Lists of Parts 4.6.1 ODU Explosive View and Lists of Parts SEV2040H2R18 29 30 31 34 35 36 37 Material name Coping Electric Box Assy PFC Inductance Filter Board Reactor Sub-Assy Power Switch Main Board...
  • Page 108 SERVICE MANUAL Material name Inductance Terminal Board Terminal Board Radiator Main Board Condenser Assy Filter Sub-Assy Electromagnetic Valve Sub-Assy Magnet Coil (Electromagnetic Valve) Electromagnetic Valve Strainer Brushless DC Motor Axial Flow Fan Cabinet Diversion Circle Front Grill Front Side Plate Compressor And Fittings Handle Chassis Assy...
  • Page 109 SERVICE MANUAL Material name Filter Pressure Protect Switch 4-Way Valve Pressure Sensor Rear Grill SEV4060H2R18 27 28 29 30 31 36 37 Material name Coping Rear Grill Left Side Plate Electric Box Assy Drive Board Radiator...
  • Page 110 SERVICE MANUAL Material name Main Board Filter Board Terminal Board Terminal Board Inductance Box Assy Handle Axial Flow Fan Cabinet Brushless DC Motor Gas-liquid Separator Sub-Assy Front Grill Front Side Plate Pressure Protect Switch Brushless DC Motor Electromagnetic Valve Electric Expand Valve Fitting Electric Expansion Valve Sub-Assy Compressor and Fittings Accumulator...
  • Page 111 SERVICE MANUAL 4.6.2 IDU Explosive View and Lists of Parts DEV36H2R18 DEV60H2R18 Material name Coping Left Side Plate Electric Box Assy Terminal Board Transformer Terminal Board Main Board Terminal Board Pinboard...
  • Page 112 SERVICE MANUAL Material name Rear Side Plate Centrifugal Fan Assy Motor For Centrifugal Fan Brushless DC Motor Top Cover Board Sub-Assy Bottom Cover Plate Assy Right Side Plate Bottom Cover Plate Assy Water Tray Strainer Cut-Off Valve 3/8(N) Thermal Expansion Valve Cut Off Valve Evaporator Assy Evaporator Assy...

  • Page 113: Appendices

    SERVICE MANUAL Appendices 1 Resistance/Temperature Lists of Temperature Sensors 1.1 Voltage List of 15 KΩ Temperature Sensors (including ODU temperature sensors) Temperature (°C) Resistance (kΩ) Voltage (V) Temperature (°F) Resistance (kΩ) Voltage (V) 0.311 2.523 2.825 138.1 0.323 2.439 2.838 128.6 0.345 2.358...
  • Page 114 SERVICE MANUAL Temperature (°C) Resistance (kΩ) Voltage (V) Temperature (°F) Resistance (kΩ) Voltage (V) 23.6 1.282 0.848 3.123 22.53 1.319 0.825 3.128 21.51 1.356 0.802 3.133 20.54 1.393 0.779 3.137 19.63 1.429 0.758 3.141 18.75 1.467 0.737 3.145 17.93 1.503 0.717 3.15 17.14...

  • Page 115: Voltage List Of 20 Kω Pipeline Temperature Sensors

    SERVICE MANUAL Temperature (°C) Resistance (kΩ) Voltage (V) Temperature (°F) Resistance (kΩ) Voltage (V) 3.579 2.664 0.266 3.242 3.454 2.682 0.261 3.244 3.333 0.254 3.245 3.217 2.717 0.248 3.246 3.105 2.734 0.243 3.247 2.998 2.75 0.237 3.249 2.898 2.766 0.232 3.25 2.797 2.781...
  • Page 116 SERVICE MANUAL Temperature (°C) Resistance (kΩ) Voltage (V) Temperature (°F) Resistance (kΩ) Voltage (V) 68.79 0.743 1.561 3.061 65.37 0.773 1.515 3.068 62.13 0.804 1.47 3.074 59.08 0.835 1.427 3.08 56.19 0.866 1.386 3.086 53.46 0.898 1.346 3.092 50.87 0.931 1.307 3.098 48.42...

  • Page 117: Voltage List Of 50 Kω Discharge Temperature Sensors

    SERVICE MANUAL Resistance (kΩ) Voltage (V) Temperature (°F) Resistance (kΩ) Voltage (V) Temperature (°C) 9.42 2.243 0.4727 3.224 9.054 2.272 0.4613 3.226 8.705 2.299 0.4502 3.227 8.37 2.326 0.4394 3.229 8.051 2.353 0.4289 3.231 7.745 2.379 0.4187 3.232 7.453 2.404 0.4088 3.234 7.173...
  • Page 118 SERVICE MANUAL Temperature (°C) Resistance (kΩ) Voltage (V) Temperature (°F) Resistance (kΩ) Voltage (V) 362.99 0.088 6.9882 1.943 342.83 0.094 6.7608 1.969 323.94 0.099 6.542 1.995 306.23 0.104 6.3315 2.021 289.61 0.11 6.1288 2.046 274.02 0.116 5.9336 2.071 259.37 0.123 5.7457 2.096 245.61...
  • Page 119 SERVICE MANUAL Temperature (°C) Resistance (kΩ) Voltage (V) Temperature (°F) Resistance (kΩ) Voltage (V) 41.313 0.643 1.9123 2.77 39.61 0.665 1.8652 2.781 37.958 0.688 1.8158 2.793 36.384 0.711 1.7698 2.804 34.883 0.735 1.7253 2.814 33.453 0.759 1.6821 2.825 32.088 0.784 1.6402 2.835 30.787...

  • Page 120: Temperature/Pressure List Of Refrigerant

    SERVICE MANUAL 2 Temperature/Pressure List of Refrigerant R410A Temperature Pressure Temperature Pressure Temperature Pressure °C °C °C 1880 1910 1960 2030 2080 2130 2180 2240 1020 2290 1050 2350 1090 2410 1110 2460 1150 2510 1180 2580 1220 2650 1250 2710 1280 2770...
  • Page 121 SERVICE MANUAL The design and specifications are subject to change without prior notice for product improvement. Consult with the sales agency or manufacturer for details. Any updates to the manual will be uploaded to the service website, please check for the latest version. w w w .

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