Service Manual & Installation Manual

Transcription

1 GE Consumer & Industrial Appliances Service Manual & Installation Manual Split System Air Conditioner Model numbers: GE AIR 116 GE AIR 121

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4 1 Summary and Features MODEL REMARK GE AIR 116 IN / GE AIR 116 OUT GE AIR 121 IN / GE AIR 121 OUT 1PH 220V-230V 50Hz R407C 1

5 2 Technical and Specification Model GE AIR 116 IN / GE AIR 116 OUT GE AIR 121 IN / GE AIR 121 OUT Function Cooling Heating Cooling Heating Rated Voltage 230V~ 230V~ Rated Frequency 50Hz 50Hz Capacity (W) Nominal Power (W) Rated Power (W) Rated Current (A) Air Volume (m 3 /h) 700/670/ Dehumidity Volume (L/h) C.O.P/ EER (W/W) Model GE AIR 116 IN GE AIR 121 IN Fan Speed(r/min)(H/M/L) 1250/1150/ /1200/1100 Output Power of Fan(W) Assistant Electric Heater Power / / Fan Capacitor 1 1 Fan Motor Running Current 0.091/0.067A 0.091/0.087A Fan Type-piece Cross-flow Fan 1 Cross-flow Fan 1 Diameter-Length(mm) φ90 X723 φ90x723 Evaporator Aluminum Fin-Copper tube Aluminum Fin-Copper tube Indoor Pipe Diameter Φ7 Φ7 Unit Row-Fin Gap(mm) 3-1.6/ /2-1.5 Developeed Area of Heat Exchanger(I X H X L)(mm 2 ) 730X400X40 606X230X25.4 Swing Motor Model MP28GD MP28GD Output Power of Swing 2 2 Fuse(A) PCB3.15A Transformer 0.2A PCB3.15A Transformer 0.2A Sound Pressure Level db (A) Sound Power Level db (A) Dimension (W/D/H)(mm) X290 X X290 X195 Dimension of Package 1058X366 X X366 X317 Net Weight/Gross Weight (kg)

6 Outdoor unit Connection Pipe Model of Outdoor Unit Compressor Model Compressor Type L.R.A. (A) Compressor RLA Compressor Power Input Overload Protector Throttling Method Starting Method Working Temp Range ( ) Condenser Pipe Diameter (mm) Rows-Fin Gap(mm) Developed Area of Heat Exchanger(I X H X L)(mm2) Fan Motor Speed (rpm) Output of Fan Motor (W) Fan Motor RLA Fan Motor Capacitor (uf) Air Flow Volume of Outdoor Fan Type-Piece Fan Diameter (mm) Defrosting Method Climate Type Isolation Moisture Protection Permissible Excessive Permissible Excessive Sound Pressure Level db (A) Sound Power Level db (A) Dimension (W/D/H)( mm) Dimension of Package Net Weight /Gross Weight (kg) Refrigerant Charge (kg) Length (m) Outer Diamete Max Distance GE AIR 116 OUT GE AIR 121 OUT CHZ33LC4-U CHW33TC4-U Rotary Rotary A W 2050W Build in Build in Capillary Capillary Capacitor Capacitor -7 T 43-7 T 43 Aluminum fin-copper tube Aluminum fin-copper tube φ9.52 φ mm X 650X47mm 683mm X 813X44mm A 0.31/0.30A Axial fan 1 Axial fan 1 φ460 φ460 Auto defrost Auto defrost T1 T1 I I IP24 IP X700 X X840 X X755 X X920 X R407C/1.8 R407C/ Liquid (mm) φ9.52(3/8 ) φ9.52(3/8 ) Gas (mm) φ16(5/8 ) φ16(5/8 ) Height (m) 5 5 Length (m)

7 3 Parts Name Indoor Unit Air Inlet Front Panel Wraping Tape Air Guide Louver Air Outlet Power Plug Outdoor Unit Remote Controller Air Inlet Connecting Pipe and Connecting Wire Water Drainage Pipe Air Outlet Grill Air Outlet 4

8 4 4.1 OutLine and Installation Dimension Outline and Installation Dimension of Indoor Unit Air Inlet 290 Left Outlet Pipe Hole Rear View Ceiling >7cm Left >20cm >20cm Right Installation Dimension 5

9 Unit: mm Above 600 Less than600 Above 600 Above600 Bolt Nut Spanner 6

10 Cross-flow Fan 5 System Diagram 5.1 Circuit Diagram of Cooling / Heating System Evapoarator Check Valve Main Capillary Strainer Assistant Capillary Condenser Refrigenrant Flow Direction when Heating Refrigenrant Flow Direction when Cooling Gas-liquid Separator Compressor When the power is on, indoor and outdoor units will start to run. When the system operates in cooling mode, the compressor sucks low-temperature, low-pressure refrigerant gas from indoor evaporator, compresses and then discharges high-temperature, high-pressure refrigerant gas into outdoor heat exchanger. With the help of axial-flow fan, the gas transfers heat with environment and becomes high-pressure refrigerant liquid. The liquid is throttled by the capillary and changes into low-temperature and low-pressure liquid and then flows into indoor heat exchanger. With the help of centrifugal fan, the liquid evaporates into low-temperature refrigerant gas and indoor air is cooled down. The refrigerant gas is sucked into the compressor and the cycle introduced above goes on and on, and the demanded low temperature environment is maintained. When the system operates in heating mode, 4-way valve changes its way and the refrigerant flows into the reversible cycle as the cooling mode. The refrigerant transfers heat in the indoor heat exchanger, and sucks heat from outdoor heat exchanger and forms the heat pump cycle. This cycle goes on and on, and the demanded high temperature environment is maintained. 7

11 6 Circuit Diagram GE AIR 116 IN / GE AIR 116 OUT GE AIR 121 IN / GE AIR 121 OUT 8

12 7 Function Manual of Remote Controller 7.1 Remote Controller Function Manual Temperature Parameter The room set temperature (Tset) The room ambient temperature (Tamb) System Fundamental functions Cooling mode If Tamb Tset+1, COOL mode will act, the compressor and the outdoor fan will run, the indoor fan will run at the setting speed. If Tamb Tset-1, Compressor and outdoor fan will have a delay of 15 seconds and stop, indoor fan will run at the setting speed If Tset-1 Tamb Tset+1, the unit will keep running in the old mode. In this mode, the 4-way valve will not power on, the setting temp. range:16 ~30. set amb Start Cooling Original Running State set Min. Min. Min. Stop Cooling Compressor Outdoor Fan Indoor Fan Setting Fan Speed Running Stop Protection Function Anti Freezing Protections When the system tested anti-freezing protection, the compressor will stop, the outdoor fan will delay 15 seconds and stop running. During anti-freezing Compressor Min. Outdoor Fan Indoor Fan Setting fan speed Running Stop Over Current protection When the system is tested, the compressor will stop, the outdoor fan will delay 15 seconds and stop running. The indoor fan will run at the set speed. When antifreezing protection is eliminated and compressor has stopped for 3min, the system will resume operation Dry Mode The condition and processes of dehumidifying When Tamb Tset+2, Dry and Cooling modes will act,compressor, outdoor fan will run at setting fan speed. When Tset-2 Tamb Tset+2, Dry mode will act, at this time indoor fan runs at low fan speed,compressor will run 6mins and will stop running, outdoor fan will delay 15s and stop mins later, compressor, outdoor fan and indoor fan motor restart 9

13 When T amb T set -2, compressor outdoor/indoorfan will stop. In this mode, the 4-way valve won t power on, the temperature range is 16 ~30. amb Cooling SET Dehumidifying SET Min. Min. Min. Min. Stop Compressor Outdoor Fan Indoor Fan Seeting Fan Speed Low Fan Speed Running Stop Protection Function Antifreezing protection If the anti-freezing protection is detected, compressor,outdoor fan stop to run, indoor fan runs at low fan speed; When antifreezing is eliminated and compressor had stopped 3mins, the whole unit will back to original running state. When it isfit for the dry mode running for 6mins and stop running for 4mins, and system anti-freezing protection is detected, thatthe compressor, outdoor fan stop running, indoor fan runs at low fan speed, when anti-freezing is eleminated and compressorhad stopped for 4mins, that will back to original running status. During anti-freezing Compressor Outdoor Fan Indoor Fan Low Fan Speed Min Running Stop Heating Model Heating Running Condition and procedures If Tamb Tset+2, Heating mode will act, compressor, outdoor fan and 4-way valve will run, but indoor fan will run after 3minutes delay. If Tset+2 T amb T set +4, the unit will keep running in the original mode. In this mode, the 4-way valve will be powered on, the setting temp. range:16 ~30. If Tamb>Tset+4, compressor, outdoor fan stop running, the 4-wayvalve is power on, indoor fan will stop after 60s In this mode, the 4-way valve will be powered on, the setting temp. range:16 ~30. set Stop Heating Original Running State set amb Start Heating Min. Min. Min. Compressor Outdoor Fan Min. Min. Indoor Fan Setting Fan Speed Setting Fan Speed 4-way valve Running Stop Defrosting Condition and procedures If frost is detected with the condenser, the system enters defrost mode.in this case, the compressor goes on running, outer fan, 4-way valve and inner fan stop running, the running indicator flash; If Swing is started, that the swing motor will stop torun at the same time. After the condenser is detected with defrost completed, the outer fan, four-way valve will start torun at the same time, indoor fan will go into running after a delay of 3mins. The swing motor will resume to run after indoorfan is running, compressor keeps on original running mode, the running indicator stops flashing. 10

14 The defrosting time is 10min for the first time power on and the defrosting time afterwards depends on the practicalfrost condition, the more the frost, the longer the defrosting time(max. 12min. Min. 3min), Exit from the defrostingmode if the frost removal is ended. Druing Defrosting Compressor Outdoor Fan Min. Min. Indoor Fan Min. 4-way Valve Running Stop Protection Function Anti-high temperature protection when detecting evaporator tube is very high, outdoor fan will stop running; when detecting temperature is normal, outdoor fan will return to run. Electrical Noise protection When "RUN/STOP" is used to turn off the unit, the 4-way valve will delay 2min to stop, or there will be 2 minutes of delay in the mode switching. Over current protection Over current protection is the same with the over current in Cool mode Fan mode In Fan mode, only the indoor fan is running AUTO mode In this mode, the system will automatically select its running mode based on the change of the ambient temperature (cooling, dry, heating and air supply) The protection function as HEAT/COOL mode Other control Sleep Function In Cooling or Dry mode, when the set sleeping has run for 1 hour, Tset will rise 1 ; 2 hours later, Tset will rise 2. Setting Temperature Set Set Set Set hour hour Above hours In Heating mode, when the set sleeping has run for 1 hour, Tset will decrease 1 ; 2 hours later, Tset will decrease 2. The temp. has decreased 2 within two minutes. Then the unit will run at this setting temperaure. Hour Hour Above Hour Set Set Setting temperature Set Set The set temperature of the sleep function of the auto mode does not change Swing motor control After the power is turned on, the stepping motor will return back to 0 position and close the air outlet vent;after the power is turned on, if there is no Swing function be set, the up and down guide louvers will turnto horizontal position. In case when unit is turned on, Sing function is set at the same time, that the guide louver will swing between L and D. When unit is turned off, the guide louver will be turned off. Indoorfan will stop to run, guide louver will stop at once at the current position, and stop swing; after indoor fan resumed to runthe guide louver will continue to swing. 11

15 Buzzer When controller is power on or receives the signal from the wireless remote control, the buzzer will send out the sound once Indicator light The running indicator is red, when unit is turned on, red indicator will be turned on, when defrosting, the indicatorwill flash. When Timer is set, the yellow indicator will flash Auto fan control In this mode, according to ambient temperature, indoor fan will select High, Middle, Low fan speed automatically. the interval of each speed is 3 minutes and 30 seconds Auto button When pressing this button, unit will run in Auto mode, indoor fan will run at Auto fan speed, the indoor fan is working,the swing motor is running, when repressed this button, the unit will be turned off. 12

16 7.2 Operation method of remote controller Note: Be sure that there are no obstructions between receiver and remote controller. Swing button When it is pressed, the louvers start to swing at the stated angle and stop when repressed. FAN speed button Press this button to change the fan speed Auto Fan (Note:in mode, fan speed cannot be adjusted. COOl mode DRY mode FAN mode HEAT mode TEMP button When pressing the Button, the setting temperature willbe increased by 1 degree centigrade,when pressing the button, the setting temperature will be decreased 1 degree centigrade, In mode, the temperature could be adjusted in 16 degree centigrade-30 degree centigrade MODE button Press down the mode buttons in turn the running modes will be changed as follows: Auto ON/OFF button Press this button, the unit will start to run, when repressed it, it will stop running. 13

17 7.3 Names and functions of remote controller (with the cover removed) Note:This type of remote controller is new current control. Some buttons AIR, HUMID, ANION, SAVE, LIGHT of the control are not available for this type of air conditioner Liquid crystal display It shows all set contents SLEEP button Press this button to set SLEEP operation and stop when repressed. Remarks: there is no SLEEP function inauto and FAN mode. T-OFF button At operating mode, press this button to set TIMEROFF in the range of 0-24h 0 24h Cancel Light button The display will be lit each time the button is pressed and the display will be distinguished when the button is pressed once more. T-OFF button At operating mode, pressthis button to set TIMEROFF in the range of 0-24h 0 24h Cancel 14

18 7.4 Installation of battery for remote controller Guide for operation procedure The general procedure: 1.Plug to power supply and press ON/OFF button to start the unit. 2.Press MODE button to select the suitable operation mode. 3.Press SWING button to swing according to a certain direction and stop whenpressing it again. 4.Press FAN button to set desired fan speed. 5.Press button to set desired temperature. The selected procedure: 6.Press SLEEP button to set the sleep. 7.Press TIMER button, then press The selected procedure:button to set scheduled time. Note: In AUTO mode, the unit will automatically adjust its running modes accordingto the room temperature changes. How to insert batteries The remote control adopts two 7# alkaline dry-cell batteries. 1.Remove the cover from the back of the remote control and insert two newbatteries (Pay more attention to the polarity.) 2.Re-attach the cover. Note: Cover of Batteries Don t mix new and used ordifferent types of batteries. Remove batteries away whenthe remote control is not inuse for a long time. The remote control should beplaced about 1m or more awayfrom the TV set or any otherelectric appliances. Reset Button Insert two 7# batteries + _ + _ It should be in it's receivingrange. 15

19 8 Disassembly procedures 8.1 Disassembly procedures for indoor unit Operation procedures/pictures Disassemble the front panel Along the direction of arrow head,to take out the panel. As show in Fig.8-1 Front panel Fig Disassemble the filter Push the filter inward, then pull the filterupward can disassemble the filter.loosen each movable latch of the guidelouver, can disassemble the guide louver. As show in Fig.8-2 Filter Air guide louver Fig Disassemble the front panel body Screw off the screw on the electric box cover Open the 3pcs screw cover of front panel body, then screw off 3pcs screw, then to pull out the movable latch on the front panel, can disassemblethe front panel. As show in Fig.8-3 Screw Electric box cover Screw Fig

20 Operation procedures/pictures Disassemble water tray To take the movable latch of water tray and the wire terminal that connect withelectric box, then lift up the water tray,take out the swing motor wire, can dis-assemble the water tray. As show in Fig.8-4 Movable latch Fig.8-4 Water tray Motor wire Disassemble electric box Remove the grounding wire of the evaporator, and remove the temperature sensor for the pipe. Remove the socket/plug connector for the indoor motor and swing motor of the electric box. Screw off the screws fixing the electric box with a screw driver. Remove the electric box. As shown in Fig.8-5, 8-6 Tube sensor Screw Room sensor Fig.8-5 Hook Screw Fig

21 Operation procedures/pictures Disassemble evaporator Movable latches The clamp plate can be removed by just pulling away the movable latches in a direction as shown by arrow. Screw off screws at the left and the right of the evaporator and take out the Rear pipe clamp plate evaporator with hand, so that the side board latch of the evaporator is disengaged from thegroove. Fig.8-7 Remove the evaporator carefully and take care to protect the connection pipe. As shown in Fig.8-7, 8-8, 8-9 Screw Fig.8-8 Screw Fig

22 Operation procedures/pictures Disassemble the motor Loose the screw fixing the motor clamp plate with a screw driver and remove the motor clamp plate. Screw off 1 M4 fastening screw at the axle sleeve and remove the motor. As shown in Fig.8-10 Motor clamp plate Motor Fastening Screw Screw Cross flow fan Fig Disassemble Cross Flow Fan The cross flow fan can be removed after removing the bearing rubber gasket from the left. As shown in Fig.8-11 Bearing rubber Fig

23 8.2 Disassembly Procedures of the Outdoor Unit Operation procedures/pictures Disassemble front side plate Screw off 4 screws around the front side plate to remove the front side plate. As shown in Fig.8-12 Former side plate Screw Fig Disassemble the top cover Screw off the taping screws around the top cover around and then pull upward to take off the top cover. As shown in Fig.8-13 Screw the top cover Fig Disassemble the grill Screw off 4 screws around the grill to remove the grill. As shown in Fig.8-14 Screw Grill Fig

24 Operation procedures/pictures Disassemble the Housing Screw off the surrounding screws of the housing with a screw driver, and take off the housing. As shown in Fig.8-15 Screw Housing Fig Disassemble electric box Screw off 2 screws fixing the top cover of the electric box with a screw driver and pull upward to remove the electric assembly. As shown in Fig.8-16 Screw Electric Box Fig Disassemble right side plate Screw off 7 screws fixing the right side board and condenser side board and valve frame, pull upward to remove the right side board assembly. As shown in Fig.8-17 Screw Right side Fig

25 operation procedures/pictures Disassemble axial flow fan Screw off the nuts of fan blade by spanner, and could take off the fan blade. As shown in Fig.8-18 Firm Nut AxialFlow Fan Fig Disassemble the outdoor motor Screw off 4pcs tapping screws fixing the motor, and pull out the motor lead wire connection insert, and disassemble the motor. Screw off 2pcs tapping screws from the motor support, and lift it upward, disassemble the motor support. As shown in Fig.8-19 Motor Motor Fixing Screw Motor Wire Motor Support Fixing Screw Fig Disassemble 4-way valve (Only for cooling and heating unit) Screw off the fixing nuts for fixing the solenoid of 4-way valve and remove the solenoid. Wrap the 4- way valve with wet cotton gauze. It is recommended to solder as quickly as possible and the cotton gauze should always be wet. Make sure not to burn the leads of compressor by the fame. As shown in Fig way valve Solder Point Fig

26 Operation procedures/pictures Disassemble the capillary Solder off soldering points of capillary and valve and condenser outlet pipe to remove the capillary. It should be noted not to block the capillary during the soldering. As shown in Fig.8-21 Capillary Fig Disassemble the valve Screw off 2 screws fixing the big valve, and then solder off the connecting points of the big valve and the gas return pipe to remove the big valve. (It is recommended to wrap completely the big valve with wet cotton gauze to avoid damaging the valve with high temperature.) Screw down 2 bolts fixing the small valve, and solder off the soldering points connecting the Small valve Screw Big valve big valve and the cross type pipe to remove the big valve. Fig.8-22 As shown in Fig Disassemble the compressor Firstly Solder off pipes connecting the compressor and then screw off 3 base screws of compressor to remove the compressor. As shown in Fig.8-23 Bottom Nut Fig

27 9 Exploded View 9.1 Exploded View - Indoor unit spare part 24

28 9.2 Spare Parts List of Indoor Unit No. Parts Name Code of Parts GE AIR 116 IN GE AIR 121 IN Qty 1 Wall Mounting Frame Pipe Clamp Right Gate of Rear Case Motor FN20X Shield of Electric Box Drainage Pipe Right Fixer of Evaporator Electrical box Wire Clip Terminal Board T595A Transformer SC Tube Sensor Main PCB 5D52CJ Room Sensor Receiver Board Wire Clip Right Linkage Right Swing Louver Connecting Cable Upper Guide Louver Signal Cable Front Case Electric Box Cover Screw Cover Right filter Left filter Front Panel Remote Controller Power Cord Left Swing Louver Left Linkage Pendular Lever Bush of Guide Louver Motor Holder Motor MP28GD Water Tray Air Cleaner Frame Air Cleaner B Air Cleaner A Air Cleaner holder Left Fixer of Evaporator Evaporator Assy Ring of Bearing Fan Bearing Left Gate of Rear Case Cross Flow Fan Rear Case Drainage Plate

29 9.3 Exploded View-Outdoor Unit Spare parts 26

30 9.4 Spare parts List of Outdoor Unit No. Parts Name Code of Parts GE AIR 116 OUT GE AIR 121 OUT Qty 1 Axial Flow Fan Motor LW68B Motor Support Condenser Assy Condenser Clamp Top Cover Rear grill Underlay Of Rear Grille 9 Electrical Box Capacitor Clamp Capacitor AC Contactor Capacitor 3uF/450V Terminal Board Terminal Board Capillary Assy Handle Rear Side Plate way Valve Assy way valve coil Valve Assy 5/8" Valve Assy 3/8" Valve support Compressor Gasket Compressor Overload Protector Built in Built in 1 26 Drainage Connecter Mid Clapboard Chassis Front Side Plate Front Grill Cabinet

31 10 Care and maintenance! Warning Turn the power off and pull out the power plug before cleaning the air conditioner. Or it may cause electric shock. Never dampen the air conditioner, it can cause the electric shock. And never flush the air conditioner with water in any condition. Volatile liquid like thinner or gasoline would damage the appearance of air conditioner (only adopting soft dry cloth and wet cloth with neutral scour when cleaning air conditioner appearance) Clean the Front Panel 1 Take Down the Front Panel Pull the grooves on both sides of panel at the same time with force in the direction as shown by arrow, then take out the panel. 2 Clean the Front Panel Use brush, water and neutral detergent to clean, then dry it in the shadow. 3 Install the Front Panel Put the props on both ends of panel into fulcrum groove, then cover the panel cover properly in the direction as shown by arrow 10.2 Cleaning the air filters 1 Take Down the air filter Pull with force the front panel away an angle at the grooves of both ends of front panel in the direction as shown by arrow, and then pull downward the filter to take it out as shown in the diagram at the right. 2 Cleaning the air filter To clear the dust adhering to the filters, you can either use a dust collector, or wash them with warm water (the water with the neutral detergent below 45 Centidegree) when the filters are very dirty (such as oil stain), and dry it in the shadow as shown in the diagram at the right. 3 Install the air filters Install air filter properly in the direction as shown by arrow, let its side that marked "Front" faces you, then cover and buckle the panel properly. NOTE: Don't dry the panel or air filter directly under sun burn; don't wash them by hot water which is hotter than 45 degree centigrade or burn it on fire (For these would cause 28

32 11 Installation Instruction 11.1 Select of Installation Location 1 Indoor unit The inlet/outlet vents should be far away from the obstacles so that the air can flow all over the room; Select the place where it is easy to drain condensed water or easy to connect with outdoor unit; Be far away from heat source, steam and inflammable gas; Select the place where it is possible to stand the weight of indoor unit without increasing the running noise and vibration; Ensure that the installation of indoor unit meets requirements in installation dimensions diagram; Ensure that there should be enough space for maintenance or repair, distance between indoor unit and floor should be over 200cm; Place the unit to where 1m or more away from TV, Hi-fi and other electric appliances; Place the unit to where air filter will be taken out easily; 2 Outdoor Unit It should be located at a place not affecting the neighbors with noise and air generated by discharging; It should be installed in where with good ventilation; No obstacles affecting the air inlet/outlet of the unit should be allowed around the outdoor unit; The installation location should be able to bear the weight and vibration of outdoor unit and should enable the safe installation; It should be installed in a location free from leakage of inflammable or corrosive gas; It is required that the installation of indoor unit meeting requirements on install dimensions diagram; Note: Install in the following place may cause failure. If it is unavoidable, contact with service center please Place where oil (machine oil) is used The place where a lot of salinities such as coast exists Place where a sulfured gas such as the hot spring zones is generated Place where high-frequency waves are generated from radio equipment, welders and medical equipment Other place with special circumstance. 29

33 11.2 Install the Indoor Unit 1 install the wall mounted frame Measure horizon position by hanging line method. The left side is a little bit lower when adjusting the hang plate since the drainage hose outlet is at the left side. Fix rear plate on wall by bolts. Pull the rear panel after installation to see if it is firm enough. The rear panel afterinstalled should be able to stand the weight of an adult (60kg), and the weight should beevenly shared on each screw. Rear Left Piping Fig.11-1 Rear Right Piping 2 Install the piping hole As shown in fig.11-2, pipe can go out from 6 directions, choose one in necessary. Right As shown in fig. 11-1, after deciding the location of piping hole, and drill a hole withdownward slant (Diameter 55). Rear Right Left In order to protect pipe and cable from damage when going through the wall, install piping hole sleeve. 3 Install Drainage Hose Low Right Rear Left Low Left Fig.11-2 Drainage hose must be placed at a downward slant for smooth drainage Convex Wrenched Do not wrench, bend or heave the drain hose or flood its end into water (as shown in fig. 11-3) Heat insulation material should be wrapped on the elongated drainage hose whenpassing through the indoor unit. 4 Install connect pipe Fig.11-3 Flood into water Connect the connecting pipe with the 2 leading pipes from indoor unit correspondingly, and tighten joint nuts on connecting pipe (refer to the Installation of connecting pipes in the later section) Notes: Connect the connecting pipe with indoor unit first, and then outdoor unit Be careful when bending connecting pipe, avoid damaging it Don't tighten the joint nut too much, or leakage would occur 30

34 5 Electric Wiring 1 Open the panel upwardly; 2 Disassemble the electric box cover, screw off the wire clip"as shown in Fig 11-4"; 3 Lead power connecting wire goes through bottom case and wire hole at bottom of electric box from below to up; 4 The blue power wire is connected to "N(1)" of terminal board, and black wire to "2"; the brown to "3" and theviolet to "4", orange to "5", the yellow-green(viz. ground wire ) on the evaporator. (As show in Fig.11-4); 5 For the heat pump unit, connect one signal wire to the indoor unit via the connector"as shown in Fig 11-4", then use thewire clip to fix the signal wire to the bottom of the case; 6 Install the wire clip back to the original position screw tight the bolt to ensure that the wire clip presses the power connection wire tightly, then put the electric box cover back to the original position and fix it with bolts; 7 Cover the panel back. Terminal Board Wire Clip Black Blue Yellow-Green Orange Violet Power Connection Cord Fig.11-4 Electric Box Cover Note: All electrical installations must be carried out by specialized personnel in accordance with local laws, regulations and this manual; Rated voltage and special circuit for air conditioner must be adopted for the power supply Be sure to install leakage circuit-breaker and air switch with adequate capacity.(the capacity of the air switch is 20A) The linear diameter of the power cord should be great enough and damaged power cord and connecting wire must be replaced by special flexible cord Ground wire of socket must be connected with the ground reliably. Do not connect the ground wire to gaspipe, tap water pipe, lightning rod ground wire or telephone ground wire. Installation must be carried out in accordance with the national wiring regulations. 31

35 6 Install indoor unit When routing the piping and wiring from the left or right side of the indoor unit (as shown in the following Fig.11-5, cut off the sections at the distribution pipe at t he pipe board of the unit base. 1 When only the power cord is led, pass through the hole 2 When the connection pipe and wire are led, pass through the hole Wrap the connecting piping and electric cable properly (as shown in Fig. 11-6) and pass them through the piping hole; Hang the claw at the back of the indoor unit to the clasp on the wall-mounting frame and move the unit body left and right to see if it's secured; Guarantee that the install height of the indoor unit should above 2.0m from the floor; Take out two purifier filters from the auxiliary bag and install them in the unit; Low material 2 Low material 1 Hole Power Connection Cable Signal Control line not Drainage for cooling only unit Hose Connect Pipe Pipe outlet Plate Fig.11-5 Fig.11-6 Banding Tape 32

36 11.3 Install Outdoor Unit 1 Install connecting pipe The flare end of the connecting pipe coincides with the flare end connector of the corresponding valve Tighten nuts on connecting pipe forcibly then tighten it by spanner (as shown in Fig.11.7) Note: Too great of torque would damage nuts. Refer the following list for tightening torque Torque Spanner Hex nut diameter Tighten torque(n-m) Diameter Diameter Diameter Diameter Spanner Connect pipe nut Joint Fig Distribution line connection Earthing Copper wire Disassemble the right side board of the outdoor unit, drill hole for connection of the outdoor unit and sheath with line passing rubber ring; Disassemble line clamp, connect the power lines to the terminal board and fix them as shown in Fig Take off the clamp, connect and fix the power connect lines to the wiring terminal board (as shown in Fig.11.8); Blue Black Brown Line Clamp Orange Yellow-Green Purple Power Cable With line clamp, fix the power lines and signal control line. Connect the corresponding connectors properly Ensure that wire has been fixed firmly Front side plate Install Front side plate Rear side Plate Line Passing hole for outdoor unit Interconnection Cable Control Cord (Fig.11-8) Remark Wrong wiring connection will cause failure of some electric components The lead between the connecting and the fixed should be a little freedom when fixing it with wire clamp. 33

37 3 Evacuation and Leakage Detection Take off the nut cover on stop valve in outdoor unit Align the center of piping, tighten properly the flare nut by hand Tighten taper nut by spanner Remove the valve caps of liquid and gas valves and freon filling nozzle nut Screw off the core of liquid valve with socket hexagon spanner and at the same time top the air core at the gas valve with a screw driver. In this case, there should be gas coming out GE AIR 116 OUT Screwdriver Gas Pipe Freon Filling Nozzle Screwdriver Liquid Pipe Turn off the gas core and screw tightly freon filling nozzle nut when gas discharging for 15s and when there appears refrigerant GE AIR 121 OUT Socket Hexagon Turn on core valve of both liquid and gas valve completely (Fig. 11-9) Liquid valve Gas valve Check valve Tighten valve cover, and then check if leakage happens in the connecting part between pipeline and both indoor and outdoor unit by soup water or leakage detector InnerHaxagon spanner Screwdriver Valve Rod bonnet If possible, exhaust air in unit from core of air valve with a vacuum pump (Fig.11-10). 4 Drainage of condesed water of outdoor unit Not for cooling only unit When heating, condensed water and defrost water produced when defrosting by outdoor unit can be drained to proper place through drainage hose. bonnet Fig.11-9 Vacuum meter Install Method: Vacuum Pump As shown in Fig insert the drainage joint of outdoor unit to the base Diameter thin pipe thick pipe Fig hole and then connect the drainage hose to the drainage port to condensed water and defrost water to a proper location. Base Plate of Outdoor Unit Joint of Outdoor Unit Fig

38 11.4 Check Items for Trial Run and after Installation 1 Trial Running 1.Preparation for trail running Before completing the entire installation, power cannot be turned on Control circuit should be connected correctly, all wire be connected firmly Open stop valves of both thick and thin pipes All scattered things, especially scrap and wire etc., should be taken out from the unit Open the front panel and set the manual switch to Run mode. 2.Trial running method (1) Turn on the power (2) Press ON/OFF button of remote controller. Press mode button to select working mode such as COOL, DRY, HEAT and FAN to see if operations are normal. (3) Emergency running 2 Check Items after Installation Check Items Is the installation firm enough? Is leakage test done? Is heat insulation sufficient? Is drainage smooth? Is power voltage the same as that listed in nameplate? Is installation of circuit and pipeline correct? Is unit grounded safely? Is wire model fits relative regulation? Is air inlet or outlet vent of indoor and outdoor unit blocked? Are the length of refrigerant pipe and the charge amount of refrigerant recorded? Items to be checked. Possible failure Unit may drop, shake or emit noise. It may cause insufficient of refrigerating (heating) Capacity. Condensation or drop may occur. Condensation or drop may occur. Failure or burn out of parts may occur. Failure or burn out of parts may occur. Leakage may occur Failure or burn out of parts may occur. It may cause insufficient of refrigerating (heating) Capacity. Cannot handle the charging amount of refrigerant. 35

39 12 Malfunction Analysis Breaker tripped When set the breaker to ON, it will trip off at once. Test the insulative resistance for earthing to confirm whether the unit has current leakage or not or fuse burnt out When turn on the unit, the breaker will trip in a few minutes The circuit or the part of the air conditioner has malfunction. They heat and break the insulation and lead to short circuit or creepage. Measure the insulation resistance or eliminate the malfunction one by one. If the breaker itself has malfunction, then replace the breaker. No power supply circuit Check the power supply circuit. Air conditioner can not start up The air conditioner does not react after it is powered(after the plug is inserted, the buzzer does not sound and the remote startup has no response) The power plug is not inserted well or has bad contact The controller fuse blows. The transformer connection is loose or has bad contact or the transformer has malfunction Check and insert the plug well and make the contact firm. Replace the controller fuse. Fasten the connection wire and measure the output voltage of the transformer. If it is defective, then replace the transformer. The controller is damaged. Replace the controlle The remote control- The power of the remote controller is not enough. Replace the battery ler does not receive signals(after it is powered, the buzzer will sound, unless it has malfunction) The remote controller has malfunction. The receiver is loose or has bad contact. First, press the manual switch button AUTO, if there is no response, check based on the above methods. If it runs normally after pressing the button, check again whether the installation position and the connection wire of the reception head is correct. If it is correct, then replace the receiver The receiver is damaged. or the remote controller. The voltage is too low. Check the voltage. If it is lower than 10 of the rated voltage, check the cause, improve the power supply condition and add the stabilized voltage power supply. Water Leakage Blockage or crack of water discharge pipe Wrap of refrigerant pipe joint is not close enough Replace the water discharge pipe. Re-wrap and make it tight 36

40 Improper set of temperature Adjust set temperature If cooling (heating) load is proper Check the forecasted load of cooling (heating) The secondary refrigerant has leakage or is insufficient Check and fill the leakage, then vacuumize it and supplement the refrigerant as required Malfunction of refrigerant flow Leakage between the high pressure and the low pressure inside the compressor Malfunction of four-way valve Replace the compressor Replace the four-way valve Local block of capillary Replace the capillary operation Poor COOL(HEAT) Blockage of cooling system Judge whether the system is blocked by observing the condensation of evaporator and the pressure value of the high pressure manometer and take measures to deal with the system. Make sure that heat insulation for the thick and thin pipes is Heat insulation for the connection pipes of good. Heat insulation must also be provided for the joint and the indoor unit and the outdoor unit is bad. the exposed part of the copper pipe. Block of outdoor heat exchanger Clean the dust accumulated on the surface of the heat exchanger. Air filter were blocked Clean the filter Air circulation is insufficient Fan speed was set too slow Fan rotation speed becomes low To set the fan speed to high or middle speed Capacitor damage Replace the capacitor Motor damage Replace the motor The installation position of the outdoor unit is not appropriate. Good ventilation must be provided for the installation position of the outdoor unit. The outdoor temperature is too high. Properly install the rainproof plate or the sunproof plate. If the maximum cool air still can not meet the requirement, it is suggested to replace the air conditioner. The air tightness is not enough. People come in and out too frequently. There are heating devices indoors. Keep certain air tightness indoors, try not to use electrical appliance with large quantity of heat 37

41 The indoor fan motor is burned or breaks or has the heat protector malfunction. Replace the fan motor or the defective part. The fan does not run when it is set to supply air. The built-in heat protector of the motor breaks frequently because the motor is abnormal. Wrong connection The fan capacitor has open circuit or is damaged. Replace the fan motor Make the correction connection based on the circuit drawing. Replace the fan capacitor of the same type and same specification. In the cooling and heating mode, the compressor runs, but the outdoor fan does not run. The outdoor fan motor is damaged. ½ÓÏß íîó The outdoor fan capacitor is damaged. Replace the fan motor Make the correct connection based on the circuit drawing. Replace the fan capacitor Malfunction of compressor Replace the compressor In Cooling and Herting mode,outdoor Fan runs but compressor don t run Breakage of running capacitor of compressor The voltage is too low or too high. Wrong wire connection Replace the capacitor Manostat is recommended. Connect the circuit diagram correctly The protector itself has malfunction The refrigerant is not enough or is too much. Use the multimeter to check whether the contact of the compressor is on when it is not overheated. If it is not on, then replace the protector Adjust the volume of the refrigerant The compressor is too hot and leads to the action of the protector. The capillary is blocked and the temperature rises. The compressor does not run smoothly or is stuck. The air discharge valve is damaged Replace the capillary Replace the compressor The protector itself has malfunction. Replace the protector The swing fan does not run. The torque of the swing motor is not enough wrong connection The controller is damaged(ic2003 is damaged, the swing relay can not close, etc) First, check whether the connection is wrong. If no, replace the parts 38

42 Indoor Fan Contact other part Re-wrap and make it tight. Foreign object in indoor unit Adjust fan location. compressor vibrate to much Take out the foreign object. Water leakage pipes of outddor unit touch each other Touch of inner metal plate Adjust support washer of compressor, and tighten loosen screws. 1. Tighten connect screw. 2. Stick absorbing clay between plates. Blade of outdoorunit touch the housing Adjust location of louver. abnormal sound inside compressor Change compressor. abnormal electromagnetic sound from 4- way valve when heating Circuit-short inside solenoid of the valve and change the solenoid valve. 39