CENTRAL AIR CONDITIONERS MINI CHILLER SERVICE MANUAL

Transcription

1 CENTRAL AIR CONDITIONERS MINI CHILLER SERVICE MANUAL T/R40A/50Hz (GC2004)

2 CONTENTS PRODUCT...2 MODELS LIST...2. Split Type Integral Type NOMENCLATURE...3. Split Type Integral Type FUNCTION PRODUCT DATA Product Data at Rated Condition Operation Range Electrical Data PIPING DIAGRAM...7 UNITS CONTROL...9 OPERATION FLOWCHART...9. Cooling Operation Heating Operation MAIN LOGIC Cooling Mode Heating Mode Defrosting Mode WIRED CONTROLLER Dimension Function Installation CONTROL WIRING DESIGN...6 UNITS INSTALLATION...8 UNITS INSTALLATION...8. Installation Positions Matters need Attention DIMENSION DATA INSTALLATION CLEARANCE DATA WATER PIPING WORK Installation Procedure...23

3 2.2 Matters of Attention Antifreeze ELECTRIC WIRING WORK Wiring Principle SPECIFICATION OF POWER CORD & AIR SWITCH WIRING DIAGRAM...23 UNITS MAINTENANCE...28 ERROR CODE LIST FLOW CHART OF TROUBLESHOOTING DISASSEMBLY AND ASSEMBLY PROCEDURE OF MAIN PARTS Split Type Integral Type EXPLODED VIEWS AND PART LIST Exploded Views and Parts List- Split Type Exploded Views and Parts List- Integral Type...52

4 PRODUCT

5 PRODUCT MODELS LIST. Split Type Model Product Code Nominal Capacity Power Supply Appearance Refrigerant Model Name kw (V,Ph,Hz) Outdoor Unit Indoor Unit HLR8WZNa-M I EM3N0030 HLR8WZNa-M HLR8WZNa-M O EM3W0030 EM3W HLR0WZNa-M I EM3N0020 R40A HLR0WZNa-M HLR2.5WZNa-M HLR0WZNa-M O HLR2.5WZNa-M I HLR2.5WZNa-M O EM3W0020 EM3W002 EM3N0040 EM3W V 3Ph 50Hz HLR5WZNa-M I EM3N000 HLR5WZNa-M 5.0 HLR5WZNa-M O EM3W000 EM3W00 Note:Ton =2000Btu/h = 3.57kW 2

6 .2 Integral Type Model Product Code Nominal Capacity Power Supply Appearance Refrigerant Model Name kw (V,Ph,Hz) HLR22SNa-M EM HLR25SNa-M EM6N R40A HLR35SNa-M EM6N0260 EM6N V 3Ph 50Hz HLR45SNa-M EM EM Note:Ton =2000Btu/h = 3.57kW 2 NOMENCLATURE. Split Type HL R 5 W Z Na - M NO. Description Options Mini chiller - 2 Product type R=Heat pump 3 Nominal Cooling Capacity 4 Struct type 8=8kW 0=0 kw 2.5= 2.5kW 5= 5kW Default=Vertical type W=Horizontal type 5 Z=Combination 6 Refrigerant Na=R40A, Default=R22 7 Voltage M=380 45V 3Ph 50Hz 3

7 .2 Integral Type HL R 35 S Na - M NO. Description Options Mini chiller - 2 Product type R=Heat pump 3 Nominal Cooling Capacity 4 Refrigeration Circuits 22=22kW 25=25kW 35=35kW 45=45kW Default=One circuit S=Twin circuit 5 Refrigerant Na=R40A, Default=R22 6 Voltage M=380 45V 3Ph 50Hz 3 FUNCTION Indoor Unit Type Function Description Split Type Integral Type Heating/Cooling Interface kit for up to 6 indoor units Memory restart Two circuits optimized design Low noise design Safety and reliability thanks to advance compressor balance control 4

8 4 PRODUCT DATA 4. Product Data at Rated Condition 4.. Split Type Models HLR_WZNa-M Product Code Indoor unit EM3N0030 EM3N0020 EM3N0040 EM3N000 Outdoor unit EM3W0030 EM3W003 EM3W0020 EM3W002 EM3W0040 EM3W000 EM3W00 kw Cooling Btu/h Nominal Capacity RT kw Heating Btu/h RT Power Consumption Cooling kw Heating kw Refrigerant Compressor Power Supply Safeties Type 380~45V,3Ph,50Hz High/Low pressure switch, compressor thermal protection, over current protection, lose of R40A Charge kg Type scroll NO. Evaporator Condenser Heat Exchanger Water In/Out Pipe Diameter Heat Exchanger Tube-in-Tube Inch " " " " Fan Motor Power Input kw Fan quantity Pump L/s Water Flow GPM Delivery Lift m Power Input kw Expansion Vessel Volume L Indoor Unit Unit / Packing Dimension Height mm 288/ / / /385 Width mm 00/285 00/285 00/285 00/285 Depth mm 450/ / / /682 Net/Gross Weights 84/96 84/96 84/96 84/96 Outdoor Unit Unit / Packing Dimension Height mm 840/ / / /385 Width mm 950/0 950/0 950/0 950/0 Depth mm 42/450 42/450 42/450 42/450 Net / Gross Weights 90/00 2/23 5/26 23/34 5

9 4..2 Integral Type Models Product Code EM EM6N0270 HLR_SNa-M EM6N0260 EM6N026 EM EM kw Cooling Btu/h Nominal Capacity RT kw Heating Btu/h RT Power Consumption Cooling kw Heating kw Power Supply Safeties 380~45V 3Ph 50Hz High/Low pressure switch, compressor thermal protection, over current protection, lose of phase/anti- Refrigerant Compressor Type R40A Charge kg Type scroll NO Heat Exchanger Tube-in-Tube Tube-in-Tube Shell in tube Shell heat exchanger Evaporator Condenser Pump Water In/ Out Pipe Diameter Heat Exchanger Fan Motor Power Input Water Flow Inch " " -/2" -/2" Fin sleeve Heat exchanger kw L/s GPM Delivery Lift m Power Input kw Expansion Vessel Volume L Unit / Packing Dimension Height mm 850/ / / /970 Width mm 460/ / /90 750/90 Depth mm 530/60 530/60 800/ /960 Net/Gross Weights kg 370/ / / /765 Notes a. Cooling capacity is based on the following conditions leaving chilled water temp.7,outdoor air temp.35 b. Heating capacity is based on the following conditions leaving warmed water temp.45, outdoor air temp.7 c. d. The maximum allowable pressure for water pipe is 0.9MPa. 6

10 4.2 Operation Range Mode Range of Outdoor Temperature ( ) Cooling 6~48 Heating -5~ Electrical Data 4.3. Split Type Model HLR8WZNa-M Rated Power Supply NO. Compressor LRA each A MRC each A NO. Fan Motor Outdoor MRC A Pump MRC A MRC A Total NRC A HLR0WZNa-M HLR2.5WZNa-M 380~45V 3Ph 50Hz HLR5WZNa-M Integral Type Model HLR22SNa-M Rated Power Supply NO. Compressor Fan Motor Pump Total LRA each A MRC each A NO. MRC A MRC A MRC A MRC A HLR25SNa-M` 380~45V HLR35SNa-M 3Ph 50Hz HLR45SNa-M Notes: a. LRA: Locked rotor amps (A). b. MRC: Maximum running current (A). c. NRC: Nominal running current (A). 5 PIPING DIAGRAM High-pressure switch Outlet Shell and tube heat exchanger Pump Relief valve Flow Expansion switch drum F Inlet Compressor Low-pressure switch Four-way valve Cooling circuit Heating circuit High pressure tank Liquid-gas separator Aluminum fin-copper tube coil 7

11 CONTROL 8

12 UNITS CONTROL OPERATION FLOWCHART. Cooling Operation N Y N Y Y N 9

13 .2 Heating Operation N Y N Y Y N 0

14 2 MAIN LOGIC 2. Cooling Mode When pressing ON button, if the outdoor temperature is above 6 outlet water temperature meets the cooling running requirements, the fans of outdoor unit will start. Then the compressor will run in 5s. During the period of cooling, the unit will be turned off if the outlet water temperature meets the stopping requirements and the running time of compressor is over the shortest running time required. The fans of outdoor unit will stop in5s. If the outdoor temperature is below 6, the unit will stop, and all loads except the water pump will be turned off. Turn on Turn off Pump 30S 3min 5S Fan 30S 5S When it is turned off 3min 5S Fan 2 5S 5S Check if flow switch is ok When it is turned off Flow Switch 5S Compressor 0min Compressor 2 5>Tout>2 Four-way valve Four-way valve 2 4>Tout>7 5>Tout>8 2.2 Heating Mode When pressing ON button, if the outdoor temperature is below 28 outlet water temperature meets the heating running requirements, the fans of outdoor unit will start. Then the compressor will run in 5s. During the period of cooling, the unit will be turned off if the outlet water temperature meets the stopping requirements and the running time of compressor is over the shortest running time required. The fans of outdoor unit will stop in5s. If the outdoor temperature is over 28, the unit will stop, and all loads except the water pump will be turned off.

15 Turn on Turn off Pump 5S 5S Check if flow switch is ok Flow Switch Fan 5S 3min When it is turned off 5S Compressor 5S 30S Four-way valve 30S 3min Fan 2 5S When it is turned off Compressor 2 5S 5S Four-way valve 2 48<Tout<54 46<Tout<52 2S 5S 2.3 Defrosting Mode The condition of start defrosting mode: Under heating mode, if the accumulative running time of compressor is over the set interval time of defrosting default 45min and the defrosting temperature is lower than the set starting temperature(default -4 ),the unit will start running defrosting mode, and the 4-way valve will shut off and the outdoor fan will stop after 2s. The condition of quit defrosting mode: Under defrosting mode, if the continual defrosting time is over the set continual time of defrosting default 8min and the defrosting temperature is over the set stopping temperature(default 20 ),the unit will restart running heating mode, and the 4-way valve will turn on and the outdoor fan will run. 3 WIRED CONTROLLER 3. Dimension installation dimension outline dimension 2

16 3.2 Function 3.2. Operation View NO. Name Function description MODE button It can switch between cooling and heating. This button is available only on heat pump unit. 2 CHECK button Press it once under normal state to enter check mode. Under check mode, pressing this button when 7 is displayed can change the value of 7. Under parameter setting mode, pressing this once can switch the adjusting objection between parameter and value, and pressing this button for long (about 5s) can save and quit this parameter setting. 3 Increasing button To increase present set value or change set/check object. 4 Decreasing button To decrease present set value or change set/check object. 5 QUIT button Under Set and Check mode, press it once to quit this mode. Under parameter set mode, this set value would not be saved. Press this button for long (about 5s) to set sound, and make sound switch between always on and always off. 6 ON button To turn on the unit; when under compel operation, press it once to quit compel operation. 7 OFF button To turn off the unit; press it once to quit compel operation when the unit is under compel operation. 8 LCD display Display information of the unit. Notes a. Turn On, Off Auxiliary Heater: It is only available for heat pump unit. Press CHECK once to enter Check mode. switches between 0/03 (auxiliary heater on) and 00/02 (auxiliary heater off). That is 00 Off >0 On >00 Off, or 02 Off >03 On >02 Off. b. mode, Auxiliary display area shows the checking object, and Main display area displays the value for the checking object. 3

17 3.2.2 Display View NO. Name Function description Running mode display : cooling mode, : heating mode, : reserved 2 Temp display It shows temperature value at main display area. 3 Auxiliary display area 4 Main display area It contains 2 numbers and a comma, for showing temperature and number of parameter at main display area. It only displays when under Check mode and Parameter checking mode. It contains a minus, 2 numbers and temperature unit, for displaying value of temperature and parameter (temperature or time value) and error code. When temperature value is displayed, it shows value in algorism and temperature unit; when time is displayed, it shows algorism value but without temperature unit temperature unit. Individual temperature or parameter may exceed 99, then adopt AX for 00 09, bx for 0 9, CX for 20 29, dx for 30 39, EX for 40 49, FX for 50 59, and X stands for a number between 0 9. Under normal state, it shows temperature for back water. 5 Parameter display It means the value shown at present main display area is parameter. It shows only under Parameter Check mode. 6 Defrost display It displays when defrosting; otherwise it doesn t displays. 7 System ID It displays when system or compressor orders, for showing which system is defrosting. 8 Testing display For testing, it displays under compel operation. It shows the error code displayed on Main Display Area. It displays when there is error at system or 9 Error code display communication. Caution: ) When unit is off, it displays only temperature of back water. When unit is on, under normal state, if there is no error, it displays temperature of back water, if there is error, it displays error code; when there is no operation after 60s of pressing the button, it quit back to normal state display automatically. 2) Auto antifreeze operation display (only for heat pump unit) 4

18 this time, LCD main display area displays code d2 (if there is error it displays error code). 3.3 Installation ) First select an installation position. According to the size of the communication line of the wire controller, leave a recess or an embedded wire hole to bury the communication line. 2) If the communication line between the wire controller ( ) and the indoor unit is surface-mounted, use # PVC pipe and make matching recess in the wall (refer to Figure 6); If concealed installation is adopted, # PVC pipe can be used (Refer to Figure 7). 3) No matter if surface mounting or concealed mounting is selected, it is required to drill 2 holes (in the same level) which distance shall be the same as the distance (60mm) of installation holes in the bottom plate of the wire controller. Then insert a wood plug into each hole. Fix the bottom plate of the wire controller to the wall by using the two holes. Plug the communication line onto the control panel. Lastly install the panel of the wire controller. Caution: During the installation of the bottom plate of the wire controller, pay attention to the direction of the bottom plate. The plate s side with two notches must be at the lower position, and otherwise the panel of the wire controller cannot be correctly installed. PVC pipe Fig6 Surface Mounting of Cable Fig7 Concealed mounting of Cable Fig 8 Schematic Diagram of Installation Caution: No. Name Wall Surface 2 Bottom Plate of Wire Controller 3 Screw M4X0 4 Panel of Wire Controller ) The communication distance between the main board and the wire controller can be as far as 20m (The standard distance is 8m). 2) The wire controller shall not be installed in a place where there is water drop or large amount of water vapor. 5

19 4 CONTROL WIRING DESIGN Indoor Unit Controller CN CN2 twisted-pair twisted-pair J Manual Unit Controller X7 Outdoor Unit Controller The controllers of the split type unit include manual controller, indoor unit controller and outdoor unit controller. The indoor unit controller communications with manual controller and outdoor unit controller in RS485. The indoor unit controller connects manual controller with 4-line twisted-pair. Similarly, the indoor unit controller connects outdoor unit controller with 4-line twisted-pair. Indoor Unit Controller Manual Unit Controller J twisted-pair X7 Outdoor Unit Controller The controllers of the Integral type unit include manual controller and outdoor unit controller. The manual controller communications with outdoor unit controller in RS485. The manual controller connects outdoor unit controller with 4-line twisted-pair. 6

20 INSTALLATION 7

21 UNITS INSTALLATION UNITS INSTALLATION. Installation Positions For indoor unit: ) Fix the indoor unit bracket to the wall using appropriate plugs and screws. 2) Hang the indoor unit on the top wall mounting bracket. 3) Fix the indoor unit at the bottom side using appropriate plugs and screws. For outdoor unit: ) The installation is frost-free. 2) The space around the unit is adequate for servicing. 5) All piping lengths and distances have been taken into consideration..2 Matters need Attention 2) At delivery, the unit should be checked and any demage should be reported immediately to the carrier claims agent. 3) Check if all indoor unit accessories are enclosed. 4) The indoor unit is heavy and should be lifted by two persons..3 DIMENSION DATA ) Split type HLR8WZNa-M(O) Unit: mm

22 HLR0WZNa-M(O) HLR2.5WZNa-M(O) Unit: mm HLR5WZNa-M(O) Unit: mm

23 HL(R)8WZNa-M(I) HL(R)0WZNa-M(I) HL(R) 2.5WZNa-M(I) HL(R)5WZNa-M(I) Unit: mm ) Integral Type HLR22SNa-M HLR25Na-M Unit: mm 850 G" outlet G" inlet G/2" Water-filled vavle Basement 260 fixing hole Diameter 2mm

24 HLR35Na-M.HLR45Na-M Unit: mm.2 INSTALLATION CLEARANCE DATA ) Split type Outdoor unit air inlet L L3 L4 air outlet L2 unit mm demonstration L L2 L3 L4 distance >500 >000 >500 >500 2

25 2) Split type Indoor unit L3 L Seismic Spring Isolators L2 unit mm demonstration L L2 L3 distance >250 >800 >200 Integral Type 22

26 2 WATER PIPING WORK 2. Installation Procedure outdoor unit please refer to the outdoor unit installation manual. The units are equipped with a water inlet and water outlet for connection to a water circuit, which must be provided by a licensed technician and must comply with all relevant national regulations. 2.2 Matters of Attention Air vents must be provided at all high points of the system. The vents should be located at points which are easily accessible for servicing. An automatic air purge should be used. Check the valve is not tightened too much so that automatic release of air in the water circuit remains possible. 2.3 Antifreeze Freezing Point 0(32) -5(23) -0(4) -5(5) -20(-4) -30(-22) Ambient Temperature 8.3(47) 3.3(38) -.7(29) -6.7(20) -.7() -6.7(2) Cooling Capacity Correction Factor Water Flow Correction Factor Pressure Drop Correction Factor ELECTRIC WIRING WORK 3. Wiring Principle POWER SUPPLY The electrical characteristics of the available power supply must agree with the unit nameplate rating. Supply voltage must be within the limits shown. See 3.3 for electrical and configuration data. FIELD POWER circuit fused disconnect(s) of a type that can be locked off or open. Disconnect(s) must be located within sight and readily accessible. 3.2 SPECIFICATION OF POWER CORD & AIR SWITCH Model Power Supply Capability of Air Switch(A) Minimum Sectional Area of Earth Wire(mm 2 ) Minimum Sectional Area of Power Cord(mm 2 ) HLR8WZNa-M V,3, HLR0WZNa-M V,3, HLR2.5WZNa-M V,3, HLR5WZNa-M V,3, HLR22SNa-M V,3, HLR25SNa-M V,3, HLR35SNa-M V,3, HLR45SNa-M V,3,

27 3.3 WIRING DIAGRAM 3.3. Wiring Diagram-Split Type Outdoor Units Model: HLR8WZNa-M(O) - N PE W3 BK W BU W9 RD W4 BU W2 RD W5 BU XT2 2 W6 WH W7 W9 RD WH X7 2 2 W8 WH KM TC AP C2 4 2 W20 W RD BU C W3 BU 6 W22 BN W2 YE 8 Electric heater 0 KM 2 EH W2 BU WHBUBK C2 BN BN M W0WH AP2 indoor unit W8 W7 RD RD XT3 2 W5 BN W6 BN TC C XT2 XT3 XT E W4 YEGN compressor E Fan motor YEGN PE PE Model: HLR0WZNa-M(O) HLR2.5WZNa-M(O) POWER XT N XT X9 X0 X7 X8 PE KM KM2 C3 2 C4 2 TC KM T C 2 KM2 T C W W43 X3 X32 W W W48 X33 X34 W56 W33 W34 W37 W38 W35 W36 W49 W50 W5 W52 M M2 W30 W27 W32 W3 W28 W29 XT3 E E W24 E E PE PE PE PE COMPONENT POSITION DIAGRAM C4 C3 XT2 2 AP2 TC C2 C AP KM KM2 XT XT3 24

28 Model: HLR5WZNa-M(O) W33 W3 W37 W3 W3 W3 W W W W W W W3 W3 W3 W Indoor Units POWER XT N L PE PE N L BN 7BU L N 2RD 8BU A9BU A KM KM2 A2 A2 3OG 4GN XT-2 HT XT- 5 OG heat pump 5RD L KM T EH HEATER end_switch 3YE L KM2 T 4BU 6YE W2 U M W pump 6 YEGN PE TC CN3 CN CN2 OVERLOAD W_FLOW +2V AP2 CN2 flow CN4 in CN5 flow out CN6 anti-ice CN Water-Inlet Temp.Sensor Water-Outlet Temp.Sensor Frost-proof Temp.Sensor OUTDOOR UNIT X7 AP 2WH FL 0BK BK 4 AP3 X controller COMPONENT POSITION DIAGRAM AP2 TC KM KM2 XT 25

29 3 3 Mini Chiller Service Manual Wiring Diagram- Integral Type Model: HLR22SNa-M HLR25SNa-M R S T PE E M M2 M3 E E E E 723 PE PE PE PE PE 724 TC Specification:.Auxiliary electric heater is optional part for heat pump unit, once it is used, please connect the temp. restricter HT with XT2.- and XT Cooling only type unit do not have below parts: KM5, Auxiliary electric heater, LP2, LP22, Defrost temp. sensor. 3. if the chiller is connected with fancoil units, please remove the wire between AC-L and X6 on PC, then connect X6 to X on fancoil unit patching board. 4. Remarks: " " means terminals on XT2. or XT2.2 patching board. Model: HLR35SNa-M HLR45SNa-M M M2 M3 E E E E E 26

30 MAINTENANCE 27

31 UNITS MAINTENANCE ERROR CODE LIST Code Indication Error Name Control Description E Comp. High-pressure protection Press ON/OFF key to clear E2 System antifreeze protection Auto resume E3 Comp. Low pressure protection Press ON/OFF key to clear E4 Comp. Discharge temp. protection Press ON/OFF key to clear E5 Comp. overload protection Press ON/OFF key to clear E6 Pump overload protection Press ON/OFF key to clear E7 Flow switch failure Press ON/OFF key to clear E8 Fan overload protection Press ON/OFF key to clear E9 System outlet water temp. too high Auto resume b Comp. 2 High-pressure protection Press ON/OFF key to clear b2 System 2 antifreeze protection Auto resume b3 Comp. 2 Low pressure protection Press ON/OFF key to clear b4 Comp. 2 Discharge temp. protection Press ON/OFF key to clear b5 Comp. 2 overload protection Press ON/OFF key to clear b8 Fan 2 overload protection Press ON/OFF key to clear b9 System 2 outlet water temp. too high Auto resume F Antifreeze temp. sensor failure Auto resume F2 Antifreeze temp. sensor 2 failure Auto resume F3 Defrost temp. sensor failure Auto resume F4 Defrost temp. sensor 2 failure Auto resume F5 Discharge temp. sensor error Auto resume F6 Discharge temp. sensor 2 error Auto resume F7 Outdoor ambient temp. sensor failure Auto resume F8 Inlet water temp. sensor failure Auto resume F9 Outlet water temp. sensor failure Auto resume EC Communication malfunction Auto resume 28

32 2 FLOW CHART OF TROUBLESHOOTING The unit cannot start Power off Yes Stop and restart No If the power supply is normal Yes If fuse burnt Yes Replace the fuse No If three-phase unit Yes If phase sequence protection Adjust any two phases No No If the power of mainboard is failure No If the power cable is fallen Yes Cut off the power, restart after the power is resumed Yes No Replace the mainboard Yes Mainboard is broken If the fuse is burnt Yes Replace the fuse No No Reconnect Yes The connection wire between display board and mainboard is loosened If the transformer is burnt Yes Replace the transformer No If The display board is broken No Replace the display board 29

33 E7 failuer The Power cable is loosened Yes No If the pump start No If the contactor failure Yes Replace the contactor No No Adjust the phase sequence Yes If the pump rotates in reverse direction Yes No If three-phase unit No If the pump failure Yes Replace the pump If the flow switch failure Yes If the wire is fallen Cut off the power, restart after the wire is resumed No No Clean the filter Yes The filter is blocked Clamp the target to pipe Yes Adjust the size and angle of the target No No Replenish the water No The replenish is sufficient The target is broken Yes Replace the target Yes The valve open too small Yes Adjust the openness of the valve 30

34 3 DISASSEMBLY AND ASSEMBLY PROCEDURE OF MAIN PARTS 3. Split Type 3.. Outdoor Unit Operation Procedure Illustration ) Remove the front case a) Remove the panel Loosen the two tapping screws fixing the front grill. Pull down and remove the front grill. See Fig. 2 Fig. b) Remove the cover. Loosen the two tapping screws fixing the cover. Remove the cover See Fig. 3 Fig. 2 Fig. 3 3

35 c) Remove the front plate. Loosen the two tapping screws fixing the front plate. Remove the front plate. See Fig. 5 Fig. 4 grill d) Remove the grill Loosen the two tapping screws fixing the grill. Remove the grill. See Fig. 6 Fig. 5 Fig. 6 32

36 2) Remove the axial fan and remove the washer. See Fig. 7 Pull outward to remove the impeller. See Fig. 7 Ball Nut Fig. 7 3) Remove the motor Remove the motor support. See Fig.8 & Fig.9 Motor support Fig. 8 Fig. 9 33

37 Loosen the two screws fixing the motor. Pull backward and remove the motor. See Fig.0 Loosen the wire of motor, and pull it through the hole. Fig. 0 4) Remove the 4-way valve and capillary tube a Remove the 4-way valve Remove the coil of 4-way valve Welding out the tubes connected to the 4-way valve. Remove the 4-way valve. See Fig. Note When welding, the valve should be covered by wet cloth in order to avoid the high temp. hurt b Remove the capillary tube Welding out the tubes connected to the capillary tube. Remove the capillary See Fig.2 Fig. Fig. 2 34

38 5) Remove electric box pressure switches and temp. sensor. See Fig.3 Noise-absorbing cover Fig.3 6) Remove compressor and gas-liquid separator Remove the connection wire of compresso See Fig.4 welding out the suction pipe and discharge pipe. See Fig.4 Loosen the bolts fixing the compressor and Remove the compressor and gas-liquid separator. Gas-liquid separator Fig.4 Compressor 35

39 7) Remove gas and liquid valve a) Remove gas valve welding out the pipe connected to the gas valve (See Fig.5 Note When welding, the valve should be covered by wet cloth in order to avoid the high temp. hurt Gas valve bolts b) Remove liquid valve welding out the pipe connected to the liquid valve (See Fig.6 Note When welding, the valve should be covered by wet cloth in order to avoid the high temp. hurt liquid valve Fig.5 bolts Fig.6 36

40 3..2 Indoor Unit Operation Procedure Illustration ) Remove the Cover the cover. See Fig. Remove the cover See Fig. 2 Fig. Fig. 2 2) Remove electric box pressure switches and temp. sensor. See Fig.3 3) Remove the water pump the water pump. See Fig. 4 Electric box Fig. 3 Fig. 4 Water pump 37

41 4) Remove the tube in tube heat-exchanger welding out the pipes connected to the tube in tube heat-exchanger. Remove the tube in tube heatexchanger. See Fig. 5 See Fig. 6 Tube in tube heat-exchanger Fig. 5 6) Remove the expansion gas tank Remove the expansion gas tank. See Fig. 7 Flow switch Fig. 6 Expansion gas tank Fig. 7 38

42 3.2 Integral Type ) Remove the front case See Fig. Pull down and remove the front case. See Fig. 2 Fig. Fig. 2 39

43 2) Remove electric box pressure switches and temp. sensor. See Fig.3 3)Remove compressor and gas-liquid separator Remove the connection wire of compressor See Fig.4 welding out the suction pipe and discharge pipe. See Fig.4 the compressor and gas-liquid separator. Electric box Fig. 3 Gas-liquid separator Fig. 4 Compressor 40

44 4 Remove the water pump water pump. See Fig. 5 5 Remove the expansion gas tank Loosen the joints fixing the expansion gas tank. Remove the expansion gas tank. See Fig. 6 Expansion gas tank Water pump Fig. 5 Fig. 6 4

45 6 See Fig. 7 7 Remove the shell and tube heat-exchanger welding out the pipes connected to the shell and tube heat-exchanger. Remove the shell and tube heatexchanger. See Fig. 8 Flow switch Fig. 7 Shell and tube heat-exchanger Fig. 8 42

46 4 EXPLODED VIEWS AND PART LIST 4. Exploded Views and Parts List- Split Type 4.. Outdoor Units Model HLR8WZNa-M(O) Exploded Views: Model HLR8WZNa-M(O) for EM3W0030 EM3W003 No. Name of Part Part Code Quantity Front Grill Cabinet P 3 Protection Grill Top Cover P 5 Rear Side Plate Sub-Assy Handle Valve Support Metal Base P 9 Front Side Plate Axial Flow Fan Condenser Assy Motor Support Motor LW92D Isolation Plate way Valve (SHF-20H) Magnet Coil Compressor C-SBN303H8D Cut off Valve

47 9 Cut off Valve Pressure Switch Temp Sensor Electric Box Sub-Assy Terminal Board Transformer 57X25D Terminal Board MainPCB WZ Capacitor CBB6 4uF/500V AC Contactor GC3-8/0KK/3TF Insulation Gasket Wire Clamp Note: is only used in EM3W0030 is only used in EM3W003 Model: HLR0WZNa-M(O) HLR2.5WZNa-M(O) HLR5WZNa-M(O)) Exploded views: 44

48 Model HLR0WZNa-M(O) for EM3W0020 EM3W002 NO Name of Part Part Code Quantity Front Grill Front Plate Protection Grill Top Cover P 5 Back Side Plate Handle Valve Support Metal Base P 9 Front Side Plate Protection Grill Gasket 0 Axial Flow Fan Condenser Assy Motor Support Sub-Assy Motor FW68G Isolation Plate Gas-liquid Separator Sub-Assy way Valve Compressor C-SBN373H8D Cut-off Valve Cut-off Valve Ambient Sensor(5K) G 22 Temperature Sensor (20K) G 23 Temp. Limiter 0 24 Electric Box Sub-Assy Wire Clamp Terminal Board Terminal Board Terminal Board AC Contactor GC3-8/0KK/3TF Over current Protector Phase Reverse Protector 0 33 Insulation Gasket Magnet Coil Compressor Gasket 0 36 Capillary Sub-Assy pressure switch Capacitor Clamp 0 39 Transformer 57X25D Main PCB WZ Note: is only used in EM3W0020 is only used in EM3W002 45

49 Model HLR2.5WZNa-M(O) for EM3W0040 NO Name of Part Part Code Quantity Front Grill Front Plate Protection Grill Top Cover Back Side Plate Handle Valve Support Metal Base Front Side Plate Protection Grill Gasket 0 Axial Flow Fan Condenser Assy Motor Support Motor FW68G Isolation Plate Liquid-gas Separator way Valve Compressor C-SBN373H8D Gas Valve Liquid Valve Ambient Sensor(5K) Temperature Sensor (20K) Temp. Limiter 0 24 Electric Box Wire Clamp Terminal Board Terminal Board Terminal Board AC Contactor GC3-8/0KK/3TF Over current Protector Phase Reverse Protector 0 33 Isolation Washer D way Valve Coil Compressor Gasket 0 36 Capillary Assy Pressure Switch Capacitor Clamp 0 39 Transformer 57X25D Main PCB WZ

50 Model HLR5WZNa-M(O) for EM3W000 EM3W00 NO Name of Part Part Code Quantity Front Grill Front Plate Protection Grill Top Cover Back Side Plate Handle Valve Support Metal Base P 9 Front Side Plate Protection Grill tub Axial Flow Fan Condenser Assy Motor Support Motor LW92C Isolation Plate Liquid-gas Separator Sub-Assy way Valve Compressor C-SBN453H8D Cut-off Valve Cut-off Valve Ambient Sensor(5K) G 22 Temperature Sensor (20K) G 23 Temp. Sensor G 24 Electric Box Wire Clamp Terminal Board Terminal Board Terminal Board 0 29 Capacitor 4uF/500V AC Contactor LCD250M7C Over current Protector Phase Reverse Protector 380V Isolation Washer C Magnet Coil Compressor Gasket Capillary Assy pressure switch Capacitor Clamp 0 39 Transformer 57X25D Main PCB WZ Note: is only used in EM3W0020 is only used in EM3W002 47

51 4..2 Indoor Units Model HLR8WZNa-M(I) HLR0WZNa-M(I) HLR2.5WZNa-M(I) HLR5WZNa-M(I) Exploded views: Model HLR8WZNa-M(I) for EM3N0030 NO Name of Part Part Code Quantity Water Pump Vertical Pillar Assy Pedestal Parts Front Panel Assy Electric Box cover Electric Box Temperature Sensor Temperature Sensor Temperature Sensor Terminal Board AC Contactor CJX9B-25S/D Transformer 57X25D Main Board Electric Component Mounting Plate Wiring Display Board Left Side Plate Double Pipe Heat Exchanger Expansion Drum Cross Beam Sub-Assy Rear Panel Assy

52 22 Cross Beam Sub-Assy Top Cover Collecting Gas Pipe Sub-Assy Liquid Divider Sub-Assy Gas Pipe Sub-Assy Liquid Sub-Assy Outlet Water Pipe Sub-Assyv Big Handle Relief Valve Tube Clip Enter Water Pipe Sub-Assy Right Side Plate Water switch FSF50P-2G/ Auto Water Replenishing Valve Right Side Plate Water tube jam Model HLR0WZNa-M(I) for EM3N0020 NO Name of Part Part Code Quantity Water Pump MHI Vertical Pillar Assy Pedestal Parts Front Panel Assy Electric Box cover Electric Box Temperature Sensor Temperature Sensor Temperature Sensor Terminal Board AC Contactor CJX9B-25S/D Transformer 57X25D Main Board Z Electric Component Mounting Plate Wiring Display Board Z Left Side Plate Double Pipe Heat Exchanger Expansion Drum Cross Beam Sub-Assy Rear Panel Assy Cross Beam Sub-Assy Top Cover Collecting Gas Pipe Sub-Assy Liquid Divider Sub-Assy

53 Mini Chiller Service Manual 26 Gas Pipe Sub-Assy Liquid Sub-Assy Outlet Water Pipe Sub-Assyv Big Handle Relief Valve Tube Clip Enter Water Pipe Sub-Assy Right Side Plate Water switch FSF50P-2G/ Auto Water Replenishing Valve Right Side Plate Water Tube Jam Model HLR2.5WZNa-M(I) for EM3N0040 NO Name of Part Part Code Quantity Water Pump MHI Vertical Pillar Assy Pedestal Parts Left Side Plate Electric Box cover Electric Box Temperature Sensor Temperature Sensor Temperature Sensor Terminal Board AC Contactor CJX9B-25S/D Transformer 57X25D Main Board Z Electric Component Mounting Plate Wiring Display Board Z Left Side Plate Double Pipe Heat Exchanger Expansion Drum Cross Beam Sub-Assy Rear Panel Cross Beam Sub-Assy Top Cover Collecting Gas Pipe Sub-Assy Liquid Divider Sub-Assy Gas Pipe Sub-Assy Liquid Sub-Assy Outlet Water Pipe Sub-Assyv Big Handle Relief Valve Tube Clip

54 32 Enter Water Pipe Sub-Assy Right Side Plate Water switch FSF50P-2G/ Auto Water Replenishing Valve Right Side Plate Water Tube Jam Model HLR5WZNa-M(I) for EM3N000 NO Name of Part Part Code Quantity Water Pump MHI Vertical Pillar Assy Pedestal Parts Left Side Plate Electric Box cover Electric Box Temperature Sensor Temperature Sensor Temperature Sensor Terminal Board AC Contactor CJX9B-25S/D Transformer 57X25D Main Board Z Electric Component Mounting Plate Wiring Display Board Z Left Side Plate Double Pipe Heat Exchanger Expansion Drum Cross Beam Sub-Assy Rear Panel Cross Beam Sub-Assy Top Cover Collecting Gas Pipe Sub-Assy Liquid Divider Sub-Assy Gas Pipe Sub-Assy Liquid Sub-Assy Outlet Water Pipe Sub-Assyv Big Handle Relief Valve Tube Clip Enter Water Pipe Sub-Assy Right Side Plate Water Switch FSF50P-2G/ Auto Water Replenishing Valve Right Side Plate Water Tube Jam

55 4.2 Exploded Views and Parts List- Integral Type Model HLR22SNa-M HLR25SNa-M Exploded views Model HLR22SNa-M HLR25SNa-M for EM EM6N0270 No Name of Part Part Code Quantity Front Panel Encloser Sub-assy Fan Grill Outlet Pipe Sub-assy Fan Motor SW200B Motor Support Sub-assy Condenser Components Windshield Rear Side Plate 032 Right Side Plate Sub-assy Transition Pipe Sub-assy (Four-way Valve-condenser) Water Tray Sub-assy Vertical Shaft Transition Pipe Sub-assy 3 (Condenser-Capillary for heating) Four-way Valve Sub-assy Base Frame Sub-assy Discharge Pipe Sub-assy Base Plate Sub-assy

56 Mini Chiller Service Manual 20 Suction Pipe Sub-assy Capillary Sub-assy (Heating) Two-direction Liquid Vessel Compressor and Fittings C-SBN373H8D Gas-liquid Separator Vertical Shaft Sub-assy Tube-in-tube Heat Exchanger Water Pump MHI V Expansion Vessel Inlet Pipe Sub-assy Auto Water Replenishing Valve Emergency Valve Water Flow Switch FSF50P-R Left Side Board Sub-assy Electric Box Sub-assy Front Panel Wind Shield Condenser Components Capillary Sub-assy (Cooling) Four-way Valve Sub-assy Model HLR35SNa-M Exploded views 53

57 Model HLR35SNa-M for EM6N0260 EM6N026 No Name of Part Part Code Quantity Centrifugal Fan Fan Motor Front Grill Water Collecting Tray Sub-Assy Back Side Plate Back Side Plate P 7 Pipe Connector Electric Box Assy Right Side Plate Dry Evaporator Magnet Coil way Valve Current Divider Thermal Expansion Valve One way Valve Thermal Expansion Valve One way Valve Discharge Tube Sub-Assy Pressure Protect Switch Gas-liquid Separator Base Frame Assy Pressure Protect Switch Inhalation Tube Sub-Assy Compressor Gasket Pressure Protect Switch Compressor Gasket Electric heater(compressor) Pressure Protect Switch Pressure Protect Switch Inhalation Tube Sub-Assy Accumulator Pressure Protect Switch Discharge Tube Sub-Assy One way Valve Front Side Plate Thermal Expansion Valve Water Pump Thermal Expansion Valve Expansion Drum Current Divider way Valve Left Side Plate

58 44 Magnet Coil One way Valve Strainer Condenser Assy Condenser Assy Front Grill In-line Sheet Jacket Connecter (fork shape) In-line Lock Sheet Pinboard Display Board Auto Water Replenishing Valve Relief Valve Auto Air Outlet Valve Sensor sub-assy Terminal Board Main Board Terminal Board Single-phase Air Switch Phase Reverse Protector AC Contactor AC Contactor AC Contactor AC Contactor Terminal Board Receiver Board Transformer Terminal Board Note: is only used in EM6N0260 is only used in EM6N026 55

59 Model: HLR45SNa-M Exploded views Model HLR45SNa-M for EM EM No Name of Part Part Code Quantity Axial Flow Fan Mesh Enclosure Front Side Plate Column Column Electric Cabinet Sub-assy P 7 Side casing Clapboard Sub-Assy Right Side Plate Clapboard way Valve Sub-Assy 2 2 Discharge Tube Sub-Assy Inhalation Tube Sub-Assy Gas-liquid Separator Capillary Sub-Assy Capillary Sub-Assy Supporting Strip P 8 Accumulator Back Side Plate 03226P 20 Shell pipe Sub-Assy Base Plate Sub-Assy P 22 Base Frame Assy P 23 Condenser bottom border P 24 Water Collecting Tray Assy P

60 25 Front Brace Capillary Sub-Assy Capillary Sub-Assy Inhalation Tube Sub-Assy way Valve Sub-Assy Water pump Support Sub-Assy for Water Pump Small Spider Compressor and Fittings Big Spider Sub-Assy Front Brace Water Pipe Sub-Assy Condenser Outlet Pipe Expansion vessel Connection Pipe Expansion Drum Fixed Mount Sub-Assy Discharge Tube Sub-Assy Brace Clapboard Sub-Assy Left Side Plate Cross Beam Sub-Assy P 47 Condenser Assy Motor Retaining Plate Sub-Assy Condenser Assy Cross Beam Motor Retaining Plate Sub-Assy Top Cover Plate P 53 Motor Support Sub-Assy Fan Motor Top Cover Plate 02520P 56 Electric Box Cover P 57 AC Contactor AC Contactor Anti-phase Protector Single-phase Air Switch Main Board Terminal Board Terminal Board Terminal Board Transformer Receiver Board Fixed Clamp Terminal Board Note: is only used in EM is only used in EM

61 JF