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Sinclair ASE-76AH Service Manual

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SERVICE MANUAL
CONDENSING UNITS
ASE-76AH, ASE-96AH, ASE-120AH

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Summary of Contents for Sinclair ASE-76AH

  • Page 1 SERVICE MANUAL CONDENSING UNITS ASE-76AH, ASE-96AH, ASE-120AH...
  • Page 3 Content Part 1 General Information .......... 2 Part 2 Outdoor Units ............ 5 Part 3 Installation ............25 Part 4 Control ............. 49...

  • Page 4: Part 1 General Information

    Part 1 General Information 1. Model Names of Outdoor Units ......... 3 2. External Appearance ............3 3. Nomenclature ..............4...
  • Page 5 1. Model Names of Outdoor Units 1.1 Model Names of Outdoor Units: Outdoor unit Capacity Power Model Btu/h supply ASE-76AH 380~415V- ASE-96AH 3N-50Hz ASE-120AH 2. External Appearance 2.1 Outdoor Unit ASE-76AH ASE-120AH ASE-96AH Btu/h...
  • Page 6 3. Nomenclature 3.1 Outdoor unit: A S E - 76 A Heating Refrigerant R410A Cooling capacity (76 kBtu/h) External Split MOV 120C(H) Air conditioner...

  • Page 7: Table Of Contents

    Part 2 Outdoor Units 1. Specifications ..............6 2. Dimension ................ 8 3. Service Space ..............10 4. Wiring Diagrams ..............12 5. Electric Characteristics ...........13 6. Operation Limits ..............13 7. Sound Levels ..............14 8. Exploded View ..............15 9. Troubleshooting ...............21 10. Malfunctions ..............22...
  • Page 8 1. Specifications ASE-76AH ASE-96AH Model Power supply 380~415V-3N-50Hz 380~415V-3N-50Hz Ambient temp range -7～52 -7～52 Rated input 11700 14400 Rated current 19.3 23.7 Noise level dB(A) Type scroll scroll Brand Copland Copland Model ZP90KCE-TFD-522 ZP120KCE-TFD-522 Qty. Compressor 74500 Capacity Btu/h 100000...

  • Page 9: Specifications

    Model ASE-120AH Power supply 380~400V-3N-50Hz -7～52 Ambient temp range Rated input 17300 Rated current 28.6 Noise level dB(A) Type scroll Brand Danfoss Model SH140A4ALC Qty. Compressor Capacity Btu/h 118000 Input 10862 Rated current 21.4 Locked rotor Amp Type R410A Refrigerant Charge 7200 Type...
  • Page 10 Outdoor heat-exchanger Cooling Heating HP Switch 4-way valve Indoor unit Discharge temp. sensor Capillary LP Switch Capillary Compressor Liquid-gas seperator Indoor heat-exchanger...

  • Page 11: Dimension

    2. Dimension (Units: mm) 2.1 ASE-76AH, ASE-96AH...
  • Page 12 2.2 ASE-120AH...

  • Page 13: Service Space

    3. Service Space 3.1 ASE-76AH, ASE-96AH, ASE-120AH Air outlet Air inlet Air inlet ≥1000 mm ≥500 mm ≥1000 mm ≥1000 mm ≥1000 mm Note: 1. In case any obstacles exist above the outdoor unit, such obstacles must be 2000mm above the outdoor unit.
  • Page 14 Foundation of the outdoor unit ≥500 mm ≥500 mm M12 foundation bolt 4 screws for 1 unit...

  • Page 15: Wiring Diagrams

    4. Wiring Diagrams 1 - Compressor Output 2 - S.V.O (4 Way Valve Output) 4.1 ASE-76AH, ASE-96AH, ASE-120AH 3 - FAN Output 4 - N Item Name Item Name Item Name Item Name COMP Compressor HEAT(A) Crank RT3A Pipe temp. sensor...

  • Page 16: Electric Characteristics

    5. Electric Characteristics Outdoor Unit Power Supply Compressor Model Voltage Min. Max. TOCA ASE-76AH 380-415 17.5 20.5 16.5 0.573 2.613 ASE-96AH 380-415 23.8 1.373 6.26 ASE-120AH 380-400 28.6 21.4 1.373 6.26 Remark: MCA: Min. Current Amps. (A) TOCA: Total Over-current Amps. (A) MFA: Max.

  • Page 17: Sound Levels

    7. Sound Levels Standard of testing Front Note: H = (h+1) / 2 Model Noise level (dB(A)) ASE-76AH ASE-96AH ASE-120AH...

  • Page 18: Exploded View

    8. Exploded View 8.1 ASE 76AH...
  • Page 19 Part Name BOM Code Part Name BOM Code top cover welding part 201275990072 12.9 Wire joint 202301450121 four-way valve ass'y 201675990299 12.10 Wire joint 202301450122 Pressure controller 202301820042 12.11 Wire joint 202301450130 Three-phase power 4-way valve 201600600110 12.12 202301600518 protection devices 4-Ways valve solenoid 201600600179 front-right support pillar...
  • Page 20 8.2 ASE-96AH...
  • Page 21 Part Name BOM Code Part Name BOM Code Welding together pieces 201275990102 12.8 Wire joint 202301450130 of roof Three-phase power Four-way valve assembly 201675990271 12.9 202301600518 protection devices Pressure controller 202301820042 12.10 Compressor capacitor 202401000410 4-way valve 201600600110 Front right column 201275990109 4-Ways valve solenoid 201600600113...
  • Page 22 8.3 ASE...
  • Page 23 Part Name BOM Code Part Name BOM Code Bottom mounting plate of The partition 201275990085 201275990079 electronic control box Outdoor electronic control The air grille 201275990062 203375990015 box components Welding together pieces 201275990102 22.1 electric box welding ass'y 201275990107 of roof wiring base installation Axial fan 201200300035...

  • Page 24: Troubleshooting

    9. Troubleshooting Type LED1 LED2 Remarks Standby ☆ ☆ Cooling mode ◆ ◇ Heating mode ◆ ◆ Defrosting mode ◇ ◆ Phase sequence protection Manual reset ◆ ●★ Communication failure Manual reset ◆ ●●★ Outdoor condenser temp. sensor error Manual reset ◆...

  • Page 25: Malfunctions

    10. Malfunctions: About the Fault of T3A or T3B, High pressure protection, low pressure protection. Please refer to the following: Fault of T3A or T3B Judge 1: Whether the sensor is break Connects it well. off. Judge 2: Whether the sensor is malfunction.
  • Page 26 Low pressure protection Judge 1: The wiring between the low pressure switch and main control board is connected well or correctly Connect it well Judge 2: Whether the low pressure switch is broken Validate: Short connect the low pressure switch socket, check whether the system can run normally Replace low pressure switch Check whether the refrigerant system is ok...
  • Page 27 High pressure protection Judge 1: Whether the wiring between the high pressure switch Connect it well and main control board is connected well or correctly Judge 2: Whether the high pressure switch is broken Validate: Short connect the high pressure switch Replace high pressure switch socket, check whether the system can run normally Check whether the refrigerant system is ok...

  • Page 28: Part 3 Installation

    Part 3 Installation 1. Note ................26 2. Installation of Outdoor Units ........27 3. Heat Insulation of the Pipe ..........35 4. Installation of Connective Pipe ........36 5. Installation of Drain Pipe ..........41 6. Electric Connection .............42 7. Methods of configuring and selecting installation ..45...

  • Page 29: Note

    1. Note CAUTION:  Install the unit where enough space of installation and maintenance is available.  Install the unit where the ceiling is horizontal and enough for bearing the weight of the indoor unit.  Install the unit where the air inlet and outlet are not baffled and are the least affected by external air. ...

  • Page 30: Installation Of Outdoor Units

    2. Installation of Outdoor Units 2.1 Important: Construction Checkpoints 1). Installation Check the model and name to avoid mistaken installation. 2). Refrigerant pipe  The refrigerant pipes must have the specified diameter.  Nitrogen of a certain pressure must be filled into the refrigerant pipe before welding. ...
  • Page 31 Air outlet Air inlet Air inlet Fig-14 ≥1000 mm ≥500 mm ≥1000 mm ≥1000 mm ≥1000 mm Fig-15 NOTE: 1. In case any obstacles exist above the outdoor unit, such obstacles must be 2000mm above the outdoor unit. 2. If miscellaneous articles are piled around the outdoor unit, such articles must be 400mm below the top of the outdoor unit. As shown in Fig-16, leave an interval of 500mm between the outdoor units.
  • Page 32 The distance of the foundation bolt is shown in Fig-17. Fig-17 2.3 Convey Outdoor Unit  Use 4 steel ropes of a Ф6mm or bigger size to hoist the outdoor unit and convey it into the room.  In order to prevent scratch and deformity the outdoor unit, apply a guard board to the surface of contact between the steel ropes and the air conditioner.
  • Page 33 Snow protection Snow protection shed at the air outlet shed at the air inlet Snow protection shed at the air inlet Fig-19 2.5 Installation of Refrigerant Pipe  The refrigerant pipe adapter is located inside the outdoor unit. When the pipe is connected from the front side, the pipe can be let out through the right front board.

  • Page 34: Outdoor Unit

    When welding the refrigerant pipe, in order to prevent internal oxidation of the pipe, nitrogen must be filled in. Otherwise, the oxidized chips may block refrigerating circulatory system. 2.5.1 Size of Outdoor Unit Pipes and Piping Methods 1) Size of outdoor unit pipes and piping methods Model Gas side Liquid side ASE-76AH Φ22 Φ9.52 ASE-96AH Φ25 Φ9.52 ASE-120AH Φ28.6...
  • Page 35 Table 1: 76000, 96000 120000 Btu/h Btu/h Max. equivalent length of pipe (L) Outdoor upper Height difference between Max. height difference indoor unit and outdoor unit (H) Outdoor lower 3) Connection between indoor unit and outdoor unit (Fig Fig-23...
  • Page 36 2.6 Airtight Test After the pipes between the indoor unit and the outdoor unit are connected, replenish compressed nitrogen to perform airtight test. NOTE: 1. The airtight test is performed by using the compressed nitrogen [2.94MPa (30kg/cm G)]. 2. Tighten the spool of the gas valve and liquid valve before compressing the nitrogen. 3.
  • Page 37 Outdoor unit Room in which refrigerant is leaked (All refrigerant is leaked) Fig-24 Fig-25 In case multiple systems are set, in order to identify the connection system of the indoor unit and outdoor unit, it is necessary to give name to each system, and mark it onto the nameplate on the electric control box cover of the outdoor unit.

  • Page 38: Heat Insulation Of The Pipe

    3. Heat Insulation of the Pipe 3.1 Heat Insulation of the Pipe In order to prevent faults caused by condensate of the refrigerant pipe and drain pipe, perform condensate prevention and heat insulation properly. CAUTION: If it is forecast that high humidity/temperature environment (condensate temperature is over 23℃) may exist in the ceiling, e.g., inside the ceiling with slab, ceiling which is in the same environment as the outdoor air), it is necessary to apply 10mm or thicker adiabatic wool (16~20kg/m2 ) to the refrigerant pipe and the drain pipe in addition to applying the general heat insulation materials.

  • Page 39: Installation Of Connective Pipe

    4. Installation of Connective Pipe 4.1 Preparation before Installation Check the height difference between the indoor unit and the outdoor unit, and check the length and number of bends of the refrigerant pipeline, which must meet the following requirements:  Max. Height difference..30m (If the height difference is greater than 5m, it is better to put the outdoor unit above the indoor unit).
  • Page 40 Fig-27 4.2.2 Deploy the pipelines  Drill a porthole on the wall, and put the hole sheath and hole cover through the wall.  Place the connective pipe together with the indoor & outdoor connection wires. Use wrapping tape to tie them tight.
  • Page 41 Fig-29  Tighten the nut Align with the connective pipe Screw up the connection pipe nut manually, and use a spanner to tighten it as shown in Fig-38 Fig-30 NOTE: According to the installation conditions, too large torque will damage the flaring, and too small torque will lead to looseness and leakage.
  • Page 42 4.3 Expelling Air 4.3.1. From the following table, select a method of expelling air. Table 4: Length of connective pipe Procedure of expelling air (single pass) Less than 5m Use refrigerant in the outdoor unit 5～15m Use vacuum pump or refrigerant tank. If the air conditioner is relocated, be sure to use a vacuum pump or refrigerant tank to expel air.
  • Page 43 Manifold valve Multimeter manometer -76cmHg -handle Lo-handle Filler hose Filler hose Lo pressure valve Fig-32  Loosen and remove the maintenance orifice nut of valve A, and connect the filler hose of the manifold valve to the maintenance orifice of valve A (tighten both valve A and valve B). ...

  • Page 44: Installation Of Drain Pipe

    4.4 Leak Detection Use soap water or a leak detector to check whether gas leakage exists at the adapters. 4.5 Heat Insulation  Use heat insulation materials to wrap the part protruding outside the flared pipe joint and the refrigerant pipe of the liquid pipe and the gas pipe, and ensure that no gap exists between them.

  • Page 45: Electric Connection

    6. Electric Connection 6.1 Electric field wiring CAUTION:  Use special power supply for the air conditioner. Design power supplies specific to the indoor unit and outdoor unit. The supply voltage must comply with the nominal voltage.  The external supply circuit of the air conditioner must have a ground wire, and the power supply ground wire of the indoor unit must be connected with the external ground wire firmly.
  • Page 46 6.1.1 Duct type - 76 kBtu/h; 96 kBtu/h; 120 kBtu/h: 6.1.2 Floor standing type - 76 kBtu/h; 96 kBtu/h:...
  • Page 47 Outdoor unit: Model ASE-76AH ASE-96AH ASE-120AH 380~415V- 380~415V- 380~415V- Power supply 3N-50Hz 3N-50Hz 3N-50Hz Capacity of power 60/40 60/40 60/40 supply/ fuse (A) Power supply YCW-450/750 YCW-450/750 YCW-450/750 4*6.0 mm 4*6.0 mm 4*6.0 mm cable YCW-450/750 YCW-450/750 YCW-450/750 Grounded wire 6.0 mm...

  • Page 48: Methods Of Configuring And Selecting Installation

    7. Methods of configuring and selecting installation Material name Characteristics, advantages and other contents 1. Install the filter at the main body grille in case the storey height is low, and at the main body of the indoor unit in case the storey height is high.
  • Page 49 1. Fixed model that diffuses air at a 360 angle. 2. The outline size should increase when the air volume is over 350CMH. (For above 303), i.e., when about 9 diffusers are required, the outline size should increase. 3. The diffuser pipes should preferably have the same length after branching, and the minimum length of the ventilation pipes is 5m.
  • Page 50 1. Low noise compared with other air outlets. Applicable to tall buildings that require a long distance of air conditioning. 2. Select the ventilation pipe connection caliber according to the distance and the air speed. 3. Applicable to storey height of over 5m (for design of tall stores such as temple, consult Midea).

  • Page 52: Part 4 Control

    Part 4 Control 1. Central Control Monitor (Optional) ......50...
  • Page 54 Liquid Crystal Display:...
  • Page 55 2) Installation Note: To differentiate each centralized controller, the controllers in the same RS-485 net should be with different address with each other. NOTE: 1. Never turn screws too tightly, otherwise the cover would be dented, or the Liquid Crystal would be broken. 2.
  • Page 56 Appendix 1: Indoor Temp. and Pipe Temp. 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...
  • Page 57 185/2001 Coll., in the wording of later regulations. In case of incorrect disposal of this waste, a fine can be imposed according to national regulations. Manufacturer: Sinclair Corporation Ltd., 1-4 Argyll Street, London W1F 7LD, UK Supplier and technical support: Nepa, spol.s.r.o.

This manual is also suitable for:

Ase-96ahAse-120ah

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