Air-Con Saturn Series Service Manual
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Air-Con Saturn Series Service Manual

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Service Manual
2023.3

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Summary of Contents for Air-Con Saturn Series

  • Page 1 Service Manual 2023.3...
  • Page 2 Part 1 General Information 1. Indoor and Outdoor Units ..............2 2. External Appearance ................2...
  • Page 3 1. Indoor and Outdoor Units Series Capacity Outdoor units Indoor units ATSCV4C4T18 ATSEM4H4T18 ATSFR4H4T18 ATSCV4H4T18 ATSCV4C4T24 ATSEM4H4T24 ATSFR4H4T24 ATSCV4H4T24 ATSCV4C4T30 ATSEM4H4T30 ATSFR4H4T30 ATSCV4H4T30 ATSCV4C4T36 15 SEER ATSEM4H4T36 ON/OFF ATSFR4H4T36 ATSCV4H4T36 ATSCV4C4T42 ATSEM4H4T42 ATSCV4H4T42 ATSCV4C4T48 ATSEM4H4T48 ATSCV4H4T48 ATSCV4C4T60 ATSEM4H4T60 ATSCV4H4T60 2. External Appearance Indoor Unit Outdoor Unit...

  • Page 4: Table Of Contents

    Part 2 Engineering Data 1. Specifications ..................4 2. Dimensions ..................11 3. Installation Space Requirements ............. 14 4. Piping Diagrams ................16 5. Wiring Diagrams ................17 6. Capacity Tables ................. 21 7. Accessories ..................25...

  • Page 5: Specifications

    1. Specifications 1.1 Outdoor Units Model ATSCV4C4T18 ATSCV4C4T24 ATSCV4C4T30 Outdoor power supply V/Ph/Hz 208/230/1/60 Capacity Btu/h 17500 23400 28000 Input 1550 2000 2350 Cooling EER2 Btu/(h·W) 11.7 11.7 11.7 SEER2 (AHRI Certified) Btu/(h·W) 14.3 14.3 14.3 Capacity Btu/h － － －...
  • Page 6 ATSCV4C4T36 ATSCV4C4T42 ATSCV4C4T48 ATSCV4C4T60 Model Outdoor power supply V/Ph/Hz 208/230/1/60 Capacity Btu/h 33000 40000 45000 55500 Input 2750 3440 3800 4920 Cooling EER2 Btu/(h·W) 11.7 11.7 11.2 11.2 SEER2 (AHRI Certified) Btu/(h·W) 14.3 14.3 13.8 13.8 Capacity Btu/h － － －...
  • Page 7 Model ATSCV4H4T18 ATSCV4H4T24 ATSCV4H4T30 Outdoor power supply V/Ph/Hz 208/230/1/60 Capacity Btu/h 17500 22000 28000 Input 1550 2000 2370 Cooling EER2 Btu/(h·W) 11.5 11.2 11.5 SEER2 (AHRI Certified) Btu/(h·W) 14.3 14.3 14.3 Capacity Btu/h 17500 22000 26000 Heating HSPF2(AHRI Certified) Btu/(h·W) Max.
  • Page 8 ATSCV4H4T36 ATSCV4H4T42 ATSCV4H4T48 ATSCV4H4T60 Model Outdoor power supply V/Ph/Hz 208/230/1/60 Capacity Btu/h 33000 40000 45000 56000 Input 2780 3400 3770 4870 Cooling EER2 Btu/(h·W) 11.5 11.5 11.5 11.5 SEER2 (AHRI Btu/(h·W) 14.3 14.3 14.3 14.3 Certified) Capacity Btu/h 33000 40000 44000 53000 Heating...
  • Page 9 1.2 Indoor Units Model ATSEM4H4T18 ATSEM4H4T24 ATSEM4H4T30 Power supply V/Ph/Hz 208/230/1/60 Capacity Btu/h 17500 22000 28000 Cooling SEER2 Btu/(h·W) 14.3 14.3 14.3 Indoor external static pressure Throttle type Orifice Orifice Orifice Number of row 3(row)×2(piece) 4(row)×2(piece) 4(row)×2(piece) Tube pitch(a) x row pitch(b) 0.83×0.53 0.83×0.53 0.83×0.53...
  • Page 10 ATSEM4H4T36 ATSEM4H4T42 ATSEM4H4T48 ATSEM4H4T60 Model Power supply V/Ph/Hz 208/230/1/60 Capacity Btu/h 33000 40000 45000 55500 Cooling SEER2 Btu/(h·W) 14.3 14.3 13.8/14.3 13.8/14.3 Indoor external static pressure Throttle type Orifice Orifice Orifice Orifice Number of row 4(row)×2(piece) 4(row)×2(piece) 4(row)×2(piece) 5(row)×2(piece) Tube pitch(a) x row 0.83×0.53 0.83×0.53 0.83×0.53...
  • Page 11 ATSFR4H4T18 ATSFR4H4T24 ATSFR4H4T30 ATSFR4H4T36 Model Power supply V/Ph/Hz 208/230/1/60 Capacity Btu/h 17500 22000 28000 33000 Cooling SEER2 Btu/(h·W) 14.3 14.3 14.3 14.3 Indoor external static pressure Throttle type Orifice Orifice Orifice Orifice Number of row Tube pitch(a) x row 0.83×0.53 0.83×0.53 0.83×0.53 0.83×0.53...

  • Page 12: Dimensions

    2. Dimensions 2.1 Outdoor Units Dimensions Model name “W” mm (in.) “D” mm (in.) “H” mm (in.) ATSCV4C4T18 ATSCV4H4T18 ATSCV4C4T24 600 (23-5/8) 600 (23-5/8) 635 (25) ATSCV4H4T24 ATSCV4C4T30 ATSCV4H4T30 ATSCV4C4T36 740 (29-1/8) 740 (29-1/8) 635 (25) ATSCV4H4T36 ATSCV4C4T42 ATSCV4H4T42 ATSCV4C4T48 740 (29-1/8) 740 (29-1/8) 835 (32-7/8)
  • Page 13 2.2 Indoor Units Supply Air High voltage Flanges provided connection for field installation 10-1/2 Low voltage connection Gas pipe connection (Sweat) Liquid pipe connection (Sweat) Auxiliary drain connection 3/4” Female pipe thread (NPT) Primary drain connection 3/4” Female pipe thread (NPT) Upflow unit shown;...
  • Page 14 Supply Air High voltage connection Vapor line connection 1-2/25"(7/8") dia knock outs copper (Sweat) (3/4"dia pipe) Liquid line connection Low voltage connection copper (Sweat) (3/8"dia pipe) High voltage connection High voltage connection 7/8"(1-3/8") dia knock outs 7/8"(1-3/8") dia knock outs Primary drain connection 3/4”...

  • Page 15: Installation Space Requirements

    3. Installation Space Requirements 3.1 Outdoor Units 3.2 Indoor Units Regular Air Handler: Horizontal position: Vertical position:...
  • Page 16 Front Return Air Handler:...

  • Page 17: Piping Diagrams

    4. Piping Diagrams Cooling only models: Heat pump models:...

  • Page 18: Wiring Diagrams

    5. Wiring Diagrams 5.1 Outdoor Units Cooling only models 18K-60K: Heat pump models 18K-48K:...
  • Page 19 Heat pump models 60K:...
  • Page 20 5.2 Indoor Units Regular Air Handler: 18K, 24K: 30K, 36K, 42K, 48K, 60K:...
  • Page 21 Front Return Air Handler: 18K, 24K, 30K, 36K:...

  • Page 22: Capacity Tables

    6. Capacity Tables 6.1 Cooling Capacity Tables ATSCV4C4T18 ATSCV4H4T18 ATSEM4H4T18 - Orifice Conditions: 80 °F IDB, 67 °F IWB @ 580 CFM Outdoor Total Sensible Latent Total Tem. °F. Btu/h Btu/h Btu/h Watts 20909 14491 6417 1273 20371 14511 5861 1344 19816 14496...
  • Page 23 ATSCV4C4T36 ATSCV4H4T36 ATSEM4H4T36 - Orifice Conditions: 80 °F IDB, 67 °F IWB @ 1150CFM Outdoor Total Sensible Latent Total Tem. °F. Btu/h Btu/h Btu/h Watts 37813 26847 10966 2262 36925 26734 10191 2379 35982 26699 9283 2500 35023 26617 8406 2624 34059 26566...
  • Page 24 ATSCV4C4T60 ATSEM4H4T60- Orifice Conditions: 80 °F IDB, 67 °F IWB @ 1570 CFM Outdoor Total Sensible Latent Total Tem. °F. Btu/h Btu/h Btu/h Watts 61905 40424 21481 4039 60466 40331 20135 4241 58991 40232 18759 4450 57486 40068 17418 4673 56267 39950 16318...
  • Page 25 ATSCV4C4T24 ATSCV4H4T24 ATSFR4H4T24 - Orifice Conditions: 80 °F IDB, 67 °F IWB @ 805CFM Outdoor Total Sensible Latent Total Tem. °F. Btu/h Btu/h Btu/h Watts 27084 18742 8342 1636 26359 18557 7802 1720 25649 18442 7207 1809 24949 18337 6611 1900 24154 18336...

  • Page 26: Accessories

    7. Accessories 7.1 Standard Accessories Items Quantity Installation manual Drain pipe Drain plug 7.2 Optional Accessories Items Accessories Electric heater...
  • Page 27 Part 3 Outdoor Unit Installation 1. Safety 27 2. Unit Location Considerations ............29 3. Unit Preparation ................31 4. Setting the Unit .................. 31 5. Refrigerant Line Considerations ............32 6. Refrigerant Line Routing ..............33 7. Refrigerant Line Brazing ..............34 8.

  • Page 28: Safety

    1. Safety Important - This document contains a wiring diagram and service information. This is customer property and is to remain with this unit. Please return to service information pack upon completion of work.  CAUTION This information is intended for use by individuals possessing adequate backgrounds of electrical and mechanical experience.
  • Page 29  WARNING SERVICE VALVES! Failure to follow this warning will result in abrupt release of system charge and may result in personal injury and/orproperty damage. Extreme caution should be exercised when opening the Liquid Line Service valve. Turn valve stemcounterclockwise only until the stem contacts the rolled edge.

  • Page 30: Unit Location Considerations

    2. Unit Location Considerations 2.1 Unit Dimensions and Location Restrictions When mounting the outdoor unit on a roof, be sure the roof will support the unit’s weight. Properly selected isolation is recommended to prevent sound or vibration transmission to the building structure. Ensure the top discharge area is unrestricted for at least 60 inches above the unit.
  • Page 31 2.2 Refrigerant Piping Limits Considering the allowable pipe length and height drop to determine the installation position. Make sure the distance and height drop between indoor and outdoor unit not exceed the data in the following table. Model Max. length ft(m) Max.

  • Page 32: Unit Preparation

    3. Unit Preparation Check for damage and report promptly to the carrier any damage found to the unit. The charge port can be used to check to be sure the refrigerant charge has been retained during shipment. 4. Setting the Unit When installing the unit on a support pad, such as a concrete slab, consider the following: The pad should be at least 1-2”...

  • Page 33: Refrigerant Line Considerations

    5. Refrigerant Line Considerations 5.1 Refrigerant Line and Service Valve Connection Sizes Line Sizes Service Valve Connection Sizes Suction Line Liquid Line Model Suction Line Liquid Line Connection Connection 18K/24K/30K/36K/42K 48K/60K 5.2 Refrigerant Line Length and Insulation Determine required line length. IMPORTANT: The Suction Line must always be insulated.

  • Page 34: Refrigerant Line Routing

    6. Refrigerant Line Routing Important: Take precautions to prevent noise within the building structure due to vibration transmission from the refrigerant lines. Comply with National, State, and Local Codes when isolating line sets from joists, rafters, walls, or other structural elements. For Example: When the refrigerant lines have to be fastened to floor joists or other framing in a structure, use isolation type •...

  • Page 35: Refrigerant Line Brazing

    7. Refrigerant Line Brazing Remove caps or plugs. Use a deburring tool to deburr the pipe ends. Clean both internal and external surfaces of the tubing using an emery cloth. Remove the pressure tap cap from both service valves. Purge the refrigerant lines and indoor coil with dry nitrogen. This pipe must have a thimble.
  • Page 36 Replace the pressure tap caps after the service valves have cooled.

  • Page 37: Refrigerant Line Leakage Check

    8. Refrigerant Line Leakage Check Pressurize the refrigerant lines and evaporator coil to 150 PSIG using dry nitrogen. Check for leaks by using a soapy solution or bubbles at each brazed location. 9. 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 38: Service Valves

    10. Service Valves  WARNING Extreme caution should be exercised when opening the Liquid Line Service Valve. Turn counterclockwise until the valve stem just touches the rolled edge. No torque is required. Failure to follow this warning will result in abrupt release of system charge and may result in personal injury and /or property damage.

  • Page 39: Electrical Wiring

    12. Electrical Wiring  WARNING LIVE ELECTRICAL COMPONENTS! During installation, testing, servicing, and troubleshooting of this product, it may be necessary to work with live electrical components. Failure to follow all electrical safety precautions when exposed to live electrical components could result in death or serious injury.
  • Page 40 Part 4 Indoor Unit Installation 1. Safety ....................40 2. Applications ..................42 3. Electrical Wiring ................45 4. Airflow Performance ................. 47 5. Ductwork .................... 49 6. Refrigerant Connections ..............50 7. Air Filter (not factory-installed) ............52 8. Filter Installation Dimensions............53 9.

  • Page 41: Safety

    1. Safety Important - This is an attention alert symbol. When you see this symbol on labels or in manuals, be alert to the potential for personal injury.  WARNING Disconnect all power to unit before installing or servicing. More than one disconnect switch may be required to de-energize the equipment.
  • Page 42  WARNING PROPOSITION 65: This appliance contains fiberglass insulation. Respirable particles of fiberglass are known to State of California to cause cancer. All manufacturer products meet current federal OSHA Guidelines for safety. California Proposition 65 warnings are required for certain products, which are not covered by the OSHA standards. California’s Proposition 65 requires warnings for products sold in California that contain or produce any of over 600 listed chemicals known to the State of California to cause cancer or birth defects such as fiberglass insulation, lead in brass, and combustion products from natural gas.

  • Page 43: Applications

    2. Applications Regular Air Handler: 2.1 Vertical Upflow Vertical Upflow configuration is the factory set on all models. • If return air is to be ducted, install duct flush with floor. • Use fireproof resilient gasket 1/8 to 1/4 in. thick between the ducts, unit and floor. Set unit on floor over opening. IMPORTANT NOTE Torque applied to drain connections should not exceed 15.ft.lbs.
  • Page 44 2.3 Horizontal Horizontal right is the default factory configuration for the units. Conversion to Horizontal left: A vertical upflow unit may be converted to horizontal left by removing indoor coil assembly and reinstalling coil as shown for left hand air supply. Rotate unit into the downflow position, with the coil compartment on top and the blower compartment on bottom.
  • Page 45 2.5 Frame Mount The air handler comes with 8 clearance holes (4 on each side). These holes are used to mount the air handler inside of a frame structure. When mounting in this fashion, make sure that the wood screws are mounted from within the air handler and not from outside the unit in order to avoid damaging the coil.

  • Page 46: Electrical Wiring

    3. Electrical Wiring Field wiring must comply with the National Electric Code and any applicable local ordinance.  WARNING Disconnect all power to unit before installing or servicing. More than one disconnect switch may be required to de-energize the equipment. Hazardous voltage can cause severe personal injury or death. 3.1 Power Wiring It is important that proper electrical power is available for connection to the unit model being installed.
  • Page 47 3.4 Electrical Data Circuit Maximum Series Model Voltage Speed Amps. circuit protector 3(A) 3(A) 3(A) Regular Air 6(A) Handler 6(A) 208/230V 6(A) 6(A) 3(A) 3(A) Front Return Air Handler 6(A) 6(A)

  • Page 48: Airflow Performance

    4. Airflow Performance Airflow performance data is based on cooling performance with a dry coil and no filter in place. Select performance table for appropriate unit size external static pressure applied to unit allows operation within the minimum and maximum limits shown in table below for both cooling and electric heater operation.
  • Page 49 Front Return Air Handler: External Static Pressure (in.w.c.) Blower Model Speeds 2-Factory Default 1005 1122 1096 1061 1036 1002 1239 1214 1182 1158 1127 1088 1051 3-Factory 1005 Default 1122 1096 1061 1036 1002 1239 1214 1182 1158 1127 1088 1051 1059 1009...

  • Page 50: Ductwork

    5. Ductwork Field ductwork must comply with the National Fire Protection Association NFPA 90A, NFPA 90B and any applicable local ordinance.  WARNING Do not, under any circumstances, connect return ductwork to any other heat producing device such as fireplace insert, stove, etc.

  • Page 51: Refrigerant Connections

    6. Refrigerant Connections Keep the coil connections sealed until refrigerant connections are made. See the Installation Instructions for the outdoor unit for details on line sizing, tubing installation, and charging information. Coil is shipped with “No charge”. Evacuate the system before charging with refrigerant. Install refrigerant tubing so that it does not block service access to the front of the unit.
  • Page 52 and line. Check to make sure drain pan is draining completely, no leaks are found in drain line fittings, and water is draining from the termination of the primary drain line. Front Return Air Handler The unit is supplied with primary and auxiliary condensate drains that have 3/4” NPT connections. Both drains must be trapped outside the unit and piped in accordance with applicable materials and building codes.

  • Page 53: Air Filter (Not Factory-Installed)

    7. Air Filter (not factory-installed) External filter or other means of filtration is required. Units should be sized for a maximum of 300 feet/min. Air velocity or what is recommended for the type filter installed. Filter application and placement are critical to airflow, which may affect the heating and cooling system performance. Reduced airflow can shorten the life of the system’s major components, such as motor, limits, elements, heat relays, evaporator coil or compressor.

  • Page 54: Filter Installation Dimensions

    8. Filter Installation Dimensions Dimension data FILTER SIZE SERIES MODEL IN [mm] 18/24/30/36/42 18.1×21.4 [460×544] Regular Air Handler 48/60 20.5×23.8 [521×605] 18/24 15×19 [381×483] Front Return Air Handler 30/36 20×20 [508×508] NOTE: The thickness of the filter should be within 1"[25mm]. AIR FILTER REMOVAL / INSTALLATION Remove bolts manually, remove air filter recover;...

  • Page 55: Wiring Diagram

    9. Wiring Diagram To avoid the electrical shock, please connect the air conditioner with the ground lug. The main power plug in the air conditioner has been joined with the ground wiring, please don't change it freely. The power socket is used as the air conditioner specially. Don't pull the power wiring hard.

  • Page 56: Electrical Wiring Gauge

    10. Electrical Wiring Gauge NOTE: The cross-section areas of wires or lines should not be less than the corresponding ones listed in the table below; besides, if the power wires is quite long from the unit, please choose the windings with lager cross-section area to guarantee the normal power supply.
  • Page 57 Part 5 Troubleshooting 1. Control logic description ..............57 2. Sensor ....................57 3. Exploded views ................. 57 4. Main PCB Ports ................. 61 5. Fault code table ................. 64 6. Troubleshooting ................65...

  • Page 58: Control Logic Description

    1. Control logic description The fixed speed system adopts the same control communication command as that of common heat pump and air conditioning unit, it is the 24V control command. 2. Sensor ● T3 (Outdoor coil temperature) ● T4 (ambient temperature) ●...
  • Page 59 Heat pump outdoor unit: Part Name Quantity Part Name Quantity Top air outlet grille Fan capacitor Fan motor Brass binding post Axial-flow fan Ambient temperature sensor Top cover Upper side panel Right side panel 4-way valve assembly Condenser assembly Gas return pipe assembly Condenser component Lower side panel Shunt components...
  • Page 60 Regular Air Handler: Part Name Quantity Part Name Quantity Base pan cotton sticking Connecting plate assembly Drain pan support plate cotton Evaporator water baffle 3 sticking assembly Evaporator gas collector pipe Wind wheel fixing plate assembly Left side panel of air duct Evaporator shunt pipe assembly Right side panel of air duct Evaporator connecting plate...
  • Page 61 Front Return Air Handler: Part Name Quantity Part Name Quantity Electric control cover cotton Volute fixing plate cotton sticking assembly sticking assembly Upper side panel cotton sticking Air duct panel assembly Sealing plate cotton sticking Wind wheel volute assembly Lower reinforcement plate Evaporator Lower side panel cotton sticking Motor clamp...

  • Page 62: Main Pcb Ports

    4. Main PCB Ports For 18K-48K heat pump models: Content Content Power (L1) 24VAC common AC fan motor T4 temperature sensor Crankshaft heating belt T3 temperature sensor 4-way valve coil T5 temperature sensor Compressor High pressure switch Defrost signal Low pressure switch 24V control port...
  • Page 63 For 60K heat pump model: Content Content Power (L2) 24VAC power DC fan motor Power (L2) Temperature sensor group Crankshaft heating belt High pressure switch 4-way valve coil Low pressure switch Compressor 24V control port Power (L1)
  • Page 64 For indoor units: Content Content Power 24VAC power E-heater Reserved 24V control port Reserved 24VAC common ECM fan motor 24VAC common AC fan motor...

  • Page 65: Fault Code Table

    5. Fault code table Dispay Description No Fault: Green light flashes slowly Normal standby Green light flashes Green light normally on Normal running Red light off (T3) Temperature sensor fault Green light flashes twice every 8 seconds (T4) Temperature sensor fault Green light flashes 9 times every 8 seconds (T5) Temperature sensor fault Green light flashes 8 times every 8 seconds...

  • Page 66: Troubleshooting

    6. Troubleshooting (T3) Temperature sensor fault: (T4) Temperature sensor fault:...
  • Page 67 (T5) Temperature sensor fault: Low pressure fault:...
  • Page 68 High pressure fault: (T3) High temperature protection:...
  • Page 69 (T5) High exhaust temperature protection: DC fan not connected fault: DC fan motor fault Error Check whether the fan motor Connect the terminal well terminal connection is loose Error Check whether outdoor unit is Remove impurities around sheltered outdoor unit Check whether there is Error Check whether wiring is correct,...

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