SPLIT TYPE AIR CONDITIONER SERVICE MANUAL KFR-7002GW CONTENTS 1.PART NAMES AND FUNCTIONS... 2.SPECIFICATION... 3.OUTLINES AND DIMENSIONS... 4.WIRING DIAGRAM... 5.REFRIGERANT SYSTEM DIAGRAM... 6.PERFORMANCE DATA... 7.CONTROL MODE... 8.SERVICE FLOW CHART... 9.SENSOR PARAMETER... 10.DISASSEMBLY INSTRUCTIONS... 11.PARTS LIST...
1. PART NAMES AND FUNCTIONS INDOOR UNIT Front Panel Horizontal Vane Display panel Switch button Power plug OUTDOOR UNIT Air inlet (rear and side) Tubes and cable Air outlet Drainage hose Drainage hole (bottom) 1
1. PART NAMES AND FUNCTIONS REMOTE CONTROL UNIT Sensor Testing the ambient temperature of the remote control unit Transmitter Transmitting signals to the indoor unit, the symbol will appear on the top of LCD. LCD Displaying the running condition. AUTO SET TEMP C On/Off button Press the button to run, press again to cease. 1 HR.TIMER button 1HOUR 1 HOUR ON OFF AUTO AUTO Temperature setting button Press the button marked " " " to increase or decrease the temperature. "or HI-power running button 1HR ON/OFF TEMP Mode selection button Flap Up-down adjustment Timer on/off button Setting the time of appliance on/off. Set/cancel timer button Set or cancel the time of appliance on/off. HIGH POWER FLAP ON OFF FAN SPEED MODE SET CANCEL SLEEP Auto heating dehumidification Fan cooling Fan speed selection button A/C sensor button Press the button if the remote control unit is liable to be affected by the heat resource, such as electric blanket, radiator or sunlight, this will use the sensor of indoor unit, the symbol will appear on the LCD. BATTERY A/C SENSOR ACL Sleep button Press the button, the appliance enter sleep mode. ACL button Press the button after batteries are loaded and indication appears on LCD. Sliding cover Battery compartment COMMONSENSE Remove the batteries in the remote controller when it is not used for a long period. Replace the batteries when the indication on the LCD of the remote controller is feint, or the remote controller cannot be set or operated. Properly dispose of used batteries. Keep the remote controller away from cold or hot air, sunlight or heat sources. Contact the local distributor if the receiver in the appliance does not work in a room illuminated by fluorescent tubes. Remote controller must be used within its effective range or the timer and the temperature control will not function properly. Control will fail if two of the same model appliances are installed in the same room. If the remote controller is fixed on the wall, press the On/Off button to ensure that the appliance is receiving a signal from the device. 2
2.SPECIFICATION Model KFR-7002GWE Function Cooling Heating Power supply a.c 220V~ 50Hz Capacity KW 7.0 8.0 Capacity Dehumidification l /h 2.5 Air flow m 3 /h 1200 Power outlet A 16 Running current A 13/14 Power input W 2600/2800 Electrical data Auxiliary heater A(KW) Power factor % 97.5/97.9 Starting current A Compressor motor current A Fan motor current A Coefficient of performance(c.o.p) 2.7/2.9 Model THU33WC6-U Compressor Output W 2670 Winding resistance (at20 Ñ) 2.19 Indoor Model fan motor Winding resistance (at20 Ñ) Outdoor Model fan motor Winding resistance (at20 Ñ) Width mm 1150 Indoor unit Height mm 197 Dimensions Depth mm 330 Width mm 950 Outdoor unit Height mm 840 Depth mm 340 Weight Indoor unit kg 17.0 Outdoor unit kg 72.0 Refrigerant Liquid pipe mm 9.52 piping Gas pipe mm 15.88 Connection method Air direction Sound level Indoor unit db 48 (Hi) Outdoor unit db 52 Fan speed Indoor unit rpm 1400 (Hi) Outdoor unit rpm 830 Special remarks Fan speed Indoor unit regulator Outdoor unit Refrigerant filling capacity(r-22) kg 2.20 RT1(at25 Ñ) k Thermitstor RT2(at25 Ñ) k RT3(at0 Ñ) k TE :Test conditions Cooling : Indoor: DB27 Ñ / WB19 Ñ Heating: Indoor: DB20 Ñ / WB15 Ñ Outdoor: DB35 Ñ / WB24 Ñ 3 Outdoor DB7 Ñ / WB 6 Ñ
5.REFRIGERANT 3.OUTLINES AND SYSTEM DIMENSIONS DIAGRAM 1150 196. 5 330 4
5.REFRIGERANT 3.OUTLINES AND SYSTEM DIMENSIONS DIAGRAM 380 410 100 498 840 340 580 950 1010 Inhale direction 100mm above Inhale direction 100mmabove Exhale direction 500mmabove Front 5 300mm above
4.WIRING DIAGRAM INDOOR UNIT CONECTION WITH OUTDOOR UNIT TO OUTDOOR TEMP SENSOR OF EVAP TEMP SENSOR OF EVAP TEMP SENSOR OF INDOOR 1( ) 2(N) 3(L) 1(CM) 2(FM) 3(VA) (N) (L) TERMINAL PANEL RED WHT BLU BLU BRN CONNECTOR CN13 N BLU CN14 BRN L CN11 WHT CN10 RED CN9 BLK POWER BOARD CONTROL BOARD CN12 CN7 CN4 CN15 BLK BLU YEL BRN RED FM POWER SWITCH M FAN MOTOR DISPLAY STEP MOTOR CONECTION WITH INDOOR UNIT TEMINAL PANEL SENSOR (N) 1( ) 2(N) 3(L) 1(CM)2(FM)3(VA)4(AX) YEL/GRN OUTDOOR UNIT WHT FM OUTDOOR TEMP SENSOR OF EVAP BLK BLK BLU CAPACITOR RED FAN MOTOR RED BLK CAPACITOR S WHT YEL/GRN BLK R BLK COMPRESSOR CONTACTOR RED C BLU RED BLK 4-WAY VALVE ASSY CONNECTOR BLU WHT CN23 RED CN20 RED RED CONTROL BOARD HIGH PRESS SWITCH 6
5.REFRIGERANT SYSTEM DIAGRAM OUTDOOR UNIT Capillary tube 2.0*475 INDOOR UNIT 4-way valve Refrigerant pipe ( 15.88) Service valve Indoor heat exchanger (with heat insulator) Flared connection Indoor coil sensor Accumulator Outdoor coil sensor Outdoor heat exchanger Check valve Capillary tube 2.0*275 High pressure switch Indoor temperature sensor 7 Compressor Flared connection Strainer Service valve Refrigerant pipe ( 9.52) (with heat insulator)
5.REFRIGERANT SYSTEM DIAGRAM Modles Refrigerant Piping Piping size O.D : mm Length of connecting pipe : m Max. Length : m A Gas Liquid Indoor unit Outdoor unit KFR-7002GWE 15 15.88 9.52 MAX. HEIGHT DIFFERENCE Indoor ` unit Max. Height difference 7m Refrigerant piping Max. length A Outdoor unit ADDITIONAL; REFRIGERANT CHARGE(R-22 : g) Modles Outdoor unit precharged Refrigerant piping length (one way) (up to 7m) 7m 10m 15m KFR-7002GWE 2200 0 150 400 Canculation :Xg=50g/m * (A-7)m 8
5.REFRIGERANT SYSTEM DIAGRAM EVACUATION PROCEDURES Connect the refrigerant pipes (both the liquid and gas pipes) between the indoor and the outdoor units. Remove the service port cap of the stop valve on the sid e of the outdoor unit gas pipe. (The sto p valv e will not wor k in i ts initial state fresh out of the factory (totally closed with cap on). Connect the gage manifold valve and the vacuum pump side of the outdoor unit. to the service port o f the stop valve on the ga s pipe Run the vacuum pump for more than 15 minutes and at this time confirm that the pressure gage indicates -0.1 Mpa (-76 cmhg). Check the vacuum with the gage vacuum pump. manifold valve, then close the gage manifold valve, and stop the Leave it as is for one or two minutes.make sure the pointer of the gage manifold valve remains in the. same position. Ope n Close Hexagonal wrench Stop valve Connection pipe Gage manifold valve Stop valve Liquid pipe Hexagonal wrench Gas pipe Service port Stop valve Caps Vacuum pump Remove the gage manifold valve quickly from the ser vice port of the stop valve. After refrigerant pipes a re connected and evac uated, fully open all sto p valves on gas and liquid pipe sides. Operating without fully opening lowers the per formance and causes tr ouble. Pipe length : 7m maximum No gas charge is needed. Pipe length exceeding 7m Charge the prescribed amount of gas. Tighten the cap to th e service port to obtain the initia l status. Retighten the cap. Leak test 9
10 COOLING CAPACITY model Indoor Intake Air(WB Ñ) Outdoor intake air DB Ñ 20 25 30 35 40 45 CA PC CA PC CA PC CA PC CA PC CA PC KFR-7002GWE (220V) 16 6880 2116 6543 2245 6291 2414 6135 2589 5574 2779 5210 2976 18 7182 2138 6856 2277 6745 2448 6529 2633 6072 2829 5665 3037 20 7539 2162 7168 2297 7152 2476 6877 2672 6547 2878 6099 3092 22 7976 2166 7520 2315 7509 2504 7255 2705 6956 2919 6522 3156 6.PERFORMANCE DATA HEATING CAPACITY model KFR-7002GWE (220V) Indoor Outdoor intake air WB Ñ Intake Air(DB Ñ) -10-5 0 5 10 15 CA PC CA PC CA PC CA PC CA PC CA PC 15 5604 2052 6814 2283 7197 2381 8823 2727 9843 3000 10597 3298 20 5303 2177 6544 2387 7248 2557 8584 2900 9445 3157 10154 3319 25 5094 2258 6348 2529 6909 2652 8466 3083 8722 3140 8547 3045
7.CONTROL MODE CONTROL SYSTEM INTRODUCTION 1 Working conditions of the contr ol panel 1) Working voltage: 170VAC 262VAC 50/60 Hz 2) Working environment: Working temperature: -10 ~ +60 Storage temperature: -20 ~ +70 3)Temperature measuring precision: ±0.5 4)Temperature contr ol precision: ±1 5)Clock precision: ±30S/24H 6)Capable of suppressing disturbance from power voltage fluctuation 7)Capable of suppressing outside electromagnetic disturbance 2 Outgoing control signal processing unit of the main control panel 1) Indoor stepmotor (air flap motor): to control operation of the air grille between the 6 positions 2) Indoor fan (tapped motor): to control by a 3A relay, inductive loading 3) Four-way valve: to control by a 3A relay, inductive loading 4) Outdoor fan: to control by a 3A relay, inductive loading 5) Compressor: to control by a 3A relay, inductive loading 3 Incoming signals of the main control panel 1) Temperature signals detected by the indoor coil temperature sensor 2) Temperature (indoor ambient temperature) signals detected by the indoor air inlet temperature sensor 3) Temperature signals detected by the outdoor coil temperature sensor 4) Infrared remote control signals sent from the remote controller 5) Control signals from buttons 6) Compressor current signals 7) High pressure detecting signals 4 Outgoing signals of the main control pa nel 1) Indicator panel 2) Buzzer 5 Installation size of the main control panel complies with electrical installation requirements 6 Connector pins are designed for easy connection 7 Insulation resistor between high field and weak field is larger than 10M 8 No breakdown occurs under 1500VAC/1min when the moisture conditions between high field and weak field are in agreement with the international standards (when the striking current exceeds 10mA, it will be taken as a breakdown.) 9 The safety parameters of the product comply with the existing national standards. CONTROL MODE This unit has five running modes auto, heating, cooling, dehumidifying and ventilation(fan mode). By pressing the MODE key, the modes will change by the following or der: Auto heating dehumidifying cooling ventilation 11
7.CONTROL MODE T indoor represents indoor ambient temperature T setting represents setting temperature T indoor coil represents indoor coil temperature T outdoor coil represents outdoor coil temperature 1. Cooling 1) During cooling run, the temperature setting and control range is 16 ~ 30. The compressor cannot be restarted until after 3 minutes protection. The four-way valve relay remains off. 2) Working conditions and process es a. When T indoor - T setting 1, the compressor will run and the outdoor fan will run after 2 seconds. The indoor fan and the swinging grille will run by the setting. b. When T indoor T setting, both the compressor and the outdoor fan will stop running. The indoor fan and the swinging grille will still run by the setting. c. When T setting T indoor T setting +1, the unit will run as before. d. Grille control: The grille movement can be set using the FLAP key. When the indoor fan stops running, the grille will stop swinging. Refer to 3. Protection section for protection in this mode. 2. Dehumidification 1) In this mode, the temperature setting and control range is 16 ~ 30. The compr essor cannot be restarted until after 3 minutes protection. 2) Working conditions and process es a. When T indoor T setting +2, it goes into cooling run. The compressor will run and the outdoor fan will run after 2 seconds. The fan speed can be changeable between auto, high, mid and low. The swinging grilles will run according to the set parameters. b. When T setting 1 T indoor < T setting +2, it goes into dehumidifying run. The compressor will continue running and the indoor fan will automatically change to low gear run. c. When 15 T indoor T setting 1, it goes into dehumidifying run. The compressor will run and stop, i.e. run for 6 minutes and stop for 4 minutes, alternatively. When the compressor runs, the indoor fan will run at the low speed. d. When T indoor 15, it goes into monitoring run. All the indoor and outdoor fans and the grille stop wor king. In this mode, the indoor fan s peed cannot be controlled through the remote controller. 3) Once the compressor stops running, the indoor fan will stop accordingly. 4) The control of the swinging grille is the same as cooling run. 3. Automatic 1) If T indoor 27 when the unit is switched on (by pressing the power button), it will go into cooling run. The set temperature is 27. 2) If 25 T indoor 27 when the unit is switched on (by pressing the power button), it will go into airing run. The set temperature is 25. 3) If T indoor 25 when the unit is switched on (by pressing the power button), it will go into heating run. The set temperature is 25. Once the system goes into heating run, it will remain in this mode. Once it goes into cooling run, it will remain in cooling mode. If remote control is used, do as the information on the remote controller indicates. The Auto mode of the remote controller has the same function as started by pressing the power button. 4. Heating The temperature setting and control range is 16 ~ 30. The four-way valve is in operation except for defrosting 12
7.CONTROL MODE run. The grille moves according to the setting. 1) When T indoor T setting 1, the compressor and the four-way valve will run and the outdoor fan will run after 2 seconds. The indoor fan runs as in cold air prevention run. 2) When T indoor T setting, both the compressor and the outdoor fan will stop running. The indoor fan will go into remaining-heat-sending run and the four-way valve will remain in the original working status. 3) When T setting 1 T indoor T setting, the compressor and the indoor and outdoor fans will remain in the original working status. 4) Cold air prevention During temperature rise of the indoor coil, the indoor fan is controlled by the indoor coil temperature, so that cold air will be prevented. a. When T indoor coil 30, the indoor fan will not run. b. When 30 T indoor coil 35, the indoor fan will run at low speed. c. When T indoor coil 35, the indoor fan will run at the preset speed. After the compressor runs for 30 seconds, the T indoor coi l value will be ignored and the indoor fan will run using the preset parameters. 5) Remaining heat sending During heating run, the indoor fan will operate on the indoor coil temperature. In this way, the remaining heat in the coil will be sent out while the compressor is off. a. When T indoor coil 33, the indoor fan will run at the preset speed. b. When 28 T indoor coil 33, the indoor fan will run at low speed. c. When T indoor coil 28, the indoor fan will stop running. 6) High-temperature protection a. When the indoor coil temperature continues to go up to T indoor coil 55, the outdoor fan will stop running. b. When the indoor coil temperature continues to go up to T indoor coil 70, the compressor will stop running. c. When the indoor coil temperature goes down to T indoor coil 60, the compressor will resume operation. d. When the indoor coil temperature goes down to T indoor coil 48, the outdoor fan will resume operation. During high temperature protection, the compressor should be restarted after a delay of 3 minutes when the ambient temperature meets the shutdown conditions. 7) Defrosting a. Defrosting trigger conditions When the outdoor unit runs for 45 minutes, defrosting run will be started if T outdoor coil -8 and T indoor coil 40. The compressor and the outdoor fan will stop simultaneously. 30 seconds later, the four-way valve will be off and the indoor fan will stop. After another 32 seconds, the compressor will start again (the four-way valve will be off 2 seconds before the compressor is switched on again). b. After the defrosting run, it will resume operation at the original speed. c. Defrosting finish conditions After 11 minutes defrosting run, or when T outdoor coil 17 for 4 minutes, the defrosting cycle will stop. The compressor and the outdoor fan will stop. 30 seconds later, the four-way valve will be on. After another 32 seconds, the compressor and the outdoor fan will start. After the cold air prevention cycle, the indoor fan will run at the preset speed. d. Once a heating cycle starts, cold air protection will be triggered, e.g. at the beginning of heating run, or at the end of defrosting. Note: The cold air prevention protection will start 60 seconds (in stead of 30 seconds) after the defrosting run (see Cold Air Prevention Protection ). 13
7.CONTROL MODE 5. Fan The temperature adjustment key is not usable in this mode. The swinging grille can be set using the Mode key. 1) The outdoor fan stops but the indoor fan runs at either auto, high, mid or low speed (auto is taken as high speed).. 2) Sleep run function is ineffective in this mode, but timing ON/OFF can be selected. PROTECTIONS 1. Protection for all running modes 1) Overcurrent pr otection Five seconds after the compressor starts, the compressor will stop running if the current exceeds 30A. If such phenomenon occurs twice or more, the entire system will refuse working and an error will be displayed. 2) Compressor pr otection Once the compressor stops, it cannot be restarted until 3 minutes later. This protection is not for the first power-on. High pressure protection Once high pressure protection occurs, the controller will switch off the compressor immediately. If such phenomenon appears for more than four times within 30 minutes, a n error code will appear. It ca n be restarted through the remote controller or the power button. 2. Protection for cooling and dehumidifying run 1) Anti-freezing protection a. When the compressor runs for 10 minutes or longer, the compr essor and the outdoor fa n will stop if T indoor coil -1. b. If the compressor and the outdoor fan stop running for 6 minutes or T indoor coi l 8, the compressor and the outdoor fan will start. The running mode is the same as cooling. 2) Outdoor coil high temperature protection in cooling mode a. When the outdoor coil temperature exceeds 68 (including 68 ), the indoor fan will run at low speed. b. When the outdoor coil temperature exceeds 73 (including 73 ), it will stop running. c. When the outdoor coil temperature drops to 68 or lower, it will resume the original operation and the indoor fan will run at low speed. d. When the outdoor coil temperature drops to 58 or lower, the indoor fan will run at the preset speed. 3. Sensor protection When the sensor is not correct (open circuit or short circuit), system operation will continue but there will be no temperature protection. Now, an error code will be produced. Room temperature sensor: power light flickers. Indoor heat-exchanger temperature sens or: timer light flickers. Outdoor heat-exchanger temperature sens or: run light flickers. OTHER CONTROLS 1. Sleep mode Working conditions and process es a. During cooling run, the temperature will go up 1 1 hour after the sleep setting. Another 1h later, it will go up another 1. The power will be cut off automatically after running for 6 consecutive hours. b. During heating run, the temperature will go down 2 1 hour after the sleep setting. Another 1h later, it will go up another 2. The power will be cut off automatically after running for 3 consecutive hours. c. If the temperature setting key is pressed a gain during sleep r un, the cycle will restart according the new setting. 14
7.CONTROL MODE 2. Indoor fan speed control Four modes (auto, high, mid, low) can be selected on the remote controller for the indoor fan speed. 1) Auto a. Cooling i. When T indoor T set +4 Ñ, High ii. When T set +2 Ñ T indoor T set +4 Ñ, Mid iii. When T indoor T set +1 Ñ, Low b. Heating i. When T set -T indoor 4 Ñ, High ii. When 2 Ñ T set - T indoor 4 Ñ, Mid iii. When T set - T indoor 2 Ñ, Low Note: The indoor fan speed can be reset 3 minutes after a speed level is set if the ambient temperature changes. There will be no time restriction for remote control. 2) Manual Three speed levels (high, mid, low) are available (except for the dehumidifying mode). 3. Buzzer control When a valid signal from the remote controller or a panel key is received, the buzzer will give off two beeps. During communication between the remote controller and the system unit, the buzzer will not sound when the unit receives signals. 4. Flap control The impeller driven by a step motor can be set using the Flap key. The impeller swinging is available only if the indoor fan runs by preset parameters (the grille will be set to position 6 during cold air prevention run). Press this key, the upper and lower air guides will move, e.g. a) fixed to a position (6 positions in all); b) scan (automatic swinging between the six positions); c) auto: during heating run, swinging between 1~4 positions; during cooling and dehumidifying run, swinging between 3~6 positions. 5. One hour timer control 1) Press this button, the system will be off after running for an hour, irrespective of whether the power is on or off. 2) The 1h time setting can be cancelled through the ON/OFF key during the 1h time run. 3) After pressing the 1h timer key, the time ON/OFF function will lose effect. 6. Time ON/OFF control 1) Set time ON/OFF. 2) Time setting: set the ON/OFF time. It can be set between 1~12 hours, with a 1h step. 3) The timer can be set after the time ON/OFF and the time are selected. 4) Time ON/OFF can be set using the timer Cancel key. Note: the 1h time setting cannot be cancelled using this key. 5) The timer will be automatically cancelled if the remote controller is used for ON/OFF operations. 7. High-power run 15
7.CONTROL MODE Press the High-power key during cooling of heating run to automatically set the fan speed to high. Press it again to cancel, i.e. the fa n will run at the preset speed. If the High-power key is not pressed again after first pressed, high-power run will be automatically halted after running for 15 minutes. CONTROL PANEL INSTRUCTION There are indicators on the display panel to show the working status, as shown below: After connected to the power, the machine can be turned on using the remote controller or emergency switch. When the system is on, the power indicator goes on; when the compressor runs, the run indicator goes on; when the high power function is in use, this indicator goes on; when the timer function is activated, the timer indicator goes on. TROUBLE DISPLAY When the air conditioner works in abnormal state, the lights will automatically display as the following: Room temperature sensor: power light flickers. Indoor heat-exchanger temperature sensor: timer light flickers. Outdoor heat-exchanger temperature sensor: running light flickers. Overcurrent: power light and timer light flicker. Outdoor high voltage: outdoor control panel LED stays on. 16
6.PERFORMANCE 8.SERVICE 5.REFRIGERANT FLOW SYSTEM CURVES CHART DIAGRAM INDOOR UNIT OUTDOOR UNIT 17
6.PERFORMANCE 8.SERVICE 5.REFRIGERANT FLOW SYSTEM CURVES CHART DIAGRAM
6.PERFORMANCE 8.SERVICE 5.REFRIGERANT FLOW SYSTEM CURVES CHART DIAGRAM
9.SENSOR PARAMETER THE PARAMETER OF THE TEMPERATURE SENSOR T( ) Rnom(K ) T( ) Rnom(K ) T( ) Rnom(K ) -30 90, 36 4 13, 42 38 2, 881-29 84, 87 5 12, 77 39 2, 766-28 79, 74 6 12, 15 40 2, 656-27 74, 96 7 11, 56 41 2, 552-26 70, 5 8 11, 01 42 2, 451-25 66, 34 9 10, 48 43 2, 356-24 62, 44 10 9, 987 44 2, 264-23 58, 8 11 9, 518 45 2, 177-22 55, 4 12 9, 074 46 2, 094-21 52, 21 13 8, 653 47 2, 014-20 49, 23 14 8, 253 48 1, 937-19 46, 44 15 7, 875 49 1, 864-18 43, 82 16 7, 516 50 1, 794-17 41, 37 17 7, 175 51 1, 727-16 39, 07 18 6, 862 52 1, 663-15 36, 91 19 6, 545 53 1, 602-14 34, 88 20 6, 253 54 1, 543-13 32, 98 21 5, 977 55 1, 487-12 31, 2 22 5, 714 56 1, 433-11 29, 52 23 5, 404 57 1, 381-10 27, 94 24 5, 226 58 1, 331-9 26, 46 25 5 59 1, 284-8 25, 06 26 4, 785 60 1, 238-7 23, 75 27 4, 581 61 1, 195-6 22, 51 28 4, 386 62 1, 153-5 21, 35 29 4, 201 63 1, 112-4 20, 25 30 4, 024 64 1, 074-3 19, 21 31 3, 856 65 1, 036-2 18, 24 32 3, 696 66 1, 001-1 17, 31 33 3, 544 67 0, 9664 0 16, 44 34 3, 398 68 0, 9335 1 15, 62 35 3, 26 69 0, 9019 2 14, 85 36 3, 127 70 0, 8714 3 14, 11 37 3, 001 20
10. DISASSEMBLY INSTRUCTIONS OPERATION PROCEDURE PHOTOS 1. Remove the grille 1) Open the screw cover of the grille. 2) Take out the scres of the grille. 3) Open the front panel. 4) Take out the screw of the electrical cover and remove the cover. 5) Take out the two middle screws of the grille and remove the grille. Screws Screws Grille Screw Cover Cover 2. Remove the air outlet 1) Remove the display board. 2) Take out the screw of the stepper motor, disconnect the stepper motor and the air outlet. 3) Remove the stepper motor. 4) Take out the screw of the emergency switch and remove the emergency switch. 5) Disconnect the drainage hose and the air outlet. 6) Remove the left fixer of the air outlet. 7) Remove the air outlet. Display board Screws Emergency switch 3. Remove the electrical control box 1) Remov the electrical cover. 2) Take out indoor coil sensor from the sensor bracket. 3) Take out the screw of the connection cable clip and remove the connection cable clip. 4) Take out the screw of the power cable clip and remove the power cable clip. 5) Take out the screws of the terminal board and remove the terminal board. 6) Disconnect and check-up the printed circuit bosrd. 7) Disconnect all the circuitry in the electrical control box. 8) Take out the screws of the electrical control box and remove the electrical control box. Sensor bracket Screw Screw Terminal board Connection cable c Power cable clip Screw 21
10. DISASSEMBLY INSTRUCTIONS 4. Remove the evaporator 1) Disconnect the evaporator and the other parts, take out the screws of the evaporator. 2) Remove the evaporator. Screw Screw 5. Remove the motor cover 1) Take out the screws of the motor cover. 2) Remove the motor cover. Screw Screws Screws Remove the cross-flow fan and the fan motor 1) Take out the screws of the cross-flow fan. 2) Remove the fan motor and the bearing ass'y. 3) Remove the cross-flow fan. Cross-flow fan Screw 22
10. DISASSEMBLY INSTRUCTIONS OPERATING PROCEDURE PHOTOS Rightpanel Toppanel Rightsidepanel Frontpanel Screws Sidepanel Screws 1 2 3 4 5 Remove the Remove the Remove the Remove the Remove the sid Panel. top panel. back guard. right panel. front panel. Screws Screws Scres Backguard Screws 23
10. DISASSEMBLY INSTRUCTIONS OPERATING PROCEDURE 2.Remove the electrical control box 1) Remove all the terminals of the Fan motor wire and the compressor wire. 2 Remove the crankcase heater. 4 Remove all the terminals of the Printed circuit board and remove the electrical Control box. Fan motor wire PHOTO Electrical control box Screws Right side panel 3.Remove the outside fan 1 Take out the nut of the outside Screw Fan. 2 Remove the outside fan. Nut Outside fan Crankcase heater Compressor wire Screws 4.Remov e the fan motor 1 Take out the screws and remove the clip. 2 Remove the fan motor. 5.Remove the right side panel Fan motor Clip 24
10. DISASSEMBLY INSTRUCTIONS OPERATING PROCEDURE PHOTO Terminal cover Nut 6. Remove the compressor 1) Remove the compressor terminal Cover. 2 Remove the compressor wire. 3 Disconnect the liquid tank, suction tube and discharge tube. 4 Remove the liauid tank. 5) Disconnect the compressor, Suction tube and discharge tube. 6 Take out the nut of the compressor. Liquid tank Discharge Tube Suction tube 7 Remove the compressor. Compressor 25
19 20 21 1 2 4 9 6 12 10 11 15 16 18 11. PARTS LIST 3 36 5 32 31 33 35 34 7 8 29 30 28 14 17 13 25 27 26 23 24 22 26
12. PARTS LIST INDOOR UNIT Key No. Part No. Description Q ty 1 RZA-2-1601-015-XX-0 Front Panel 1 2 RZA-2-2305-011-XX-0 Left Air Fiter 1 3 RZA-2-2305-012-XX-0 Right Air Fiter 1 4 RZA-2-1501-023-XX-0 Grill 1 5 RZA-2-2369-035-XX-0 Cover 1 6 RZA-0-4116-078-XX-0 Evaporator Ass y 1 7 RZA-0-2049-048-XX-0 Temperature Sensor 1 8 RZA-0-2049-047-XX-0 Temperature Sensor 1 9 RZA-2-2326-107-XX-0 Water Plate 1 10 RZA-2-2330-024-XX-0 Rebounder 3 11 RZA-0-2509-109-XX-0 Cross-Flow Fan Ass'y 1 12 RZA-0-2510-105-XX-0 Bearing Ass y 1 13 RZA-0-0000-064-XX-0 Fan Motor 1 14 RZA-2-2514-107-XX-0 Motor Guard 1 15 RZA-2-2201-113-XX-0 Base Ass y 1 16 RZA-2-2487-014-XX-0 Mounting Plate 1 17 RZA-2-2487-012-XX-0 Mounting Plate 1 18 RZA-2-2362-021-XX-0 Mounting Plate 1 19 RZA-2-2405-050-XX-0 Base Foam 1 20 RZA-2-2412-399-XX-0 Base Sponginess 1 21 RZA-2-2230-107-XX-0 Installation Plate 1 22 RZA-2-5301-040-XX-0 Electrical Control Box 1 23 RZA-2-2369-036-XX-0 Electrical Control Box cover 1 24 RZA-2-5304-025-XX-0 Power Cable Clip 1 25 RZA-2-5304-024-XX-0 Connection Cable Clip 1 26 RZA-0-5172-265-XX-0 Controll Board 1 27 RZA-0-5172-285-XX-0 PCB 1 28 RZA-0-5306-049-XX-0 Terminal 1 29 RZA-0-0054-036-XX-F Remote Controller 1 30 RZA-0-5250-040-XX-0 Power Cable 1 31 RZA-0-1504-037-XX-0 Air Outlet Frame Ass y 1 32 RZA-2-1523-029-XX-0 Flap 1 33 RZA-0-0000-062-XX-0 Stepper Motor 1 34 RZA-0-5172-266-XX-0 Emergency Switch Board 1 35 RZA-0-1303-105-XX-0 Drainage House Ass y 1 36 RZA-0-5152-036-XX-0 Display Unit Ass y 1 27
12. PARTS LIST 2 4 3 32 36 35 5 34 31 6 25 30 26 33 7 29 8 23 22 28 24 18 21 20 19 17 27 9 11 16 10 12 15 13 14 1 28
12. PARTS LIST OUTDOOR UNIT Key No. Part No. Description Q ty 1 RZA-0-1321-003-XX-0 Fan Guard Ass y 1 2 RZA-2-1112-004-XX-0 Front Panel 1 3 RZA-2-2502-001-XX-0 Outside Fan 1 4 RZA-0-2309-012-XX-0 Top Cover Ass y 1 5 RZA-0-2219-020-XX-0 Left Fixture Brace Ass y 1 6 RZA-0-4102-087-XX-0 Condenser Ass y 1 7 RZA-2-2431-005-XX-0 Rubber Block 1 8 RZA-0-1111-001-XX-0 Back Guard 9 RZA-0-1104-004-XX-0 Right Side Panel Ass y 1 10 RZA-0-5302-007-XX-0 Side Cover Ass y 1 11 RZA-0-2239-036-XX-0 Fan Capacitor 1 12 RZA-0-5306-051-XX-0 Terminal Block 1 13 RZA-0-5304-021-XX-0 Clip Ass y 1 14 RZA-0-5306-018-XX-0 Terminal Block 1 15 RZA-0-5304-015-XX-0 Clip Ass y 1 16 RZA-0-9506-002-XX-0 Contactor 1 17 RZA-0-2239-043-XX-0 Compressor Capacitor 1 18 RZA-0-5172-281-XX-0 Control Block Ass y 1 19 RZA-2-5301-036-XX-0 Capacitory Clip 1 20 RZA-0-5301-014-XX-1 Electrical Box Ass y 1 21 RZA-0-4206-276-XX-0 Capillary Tube 1 22 RZA-0-5259-049-XX-0 Temperature Sensor 1 23 RZA-0-4202-009-XX-0 Capillary Tube 1 24 RZA-0-4525-052-XX-0 4-Way Valve Ass y 1 25 RZA-0-4206-302-XX-0 Capillary Tube Ass y 1 26 RZA-0-4501-050-XX-0 3/8 Valve Ass y 1 27 RZA-0-4501-051-XX-0 5/8 Valve Ass y 1 28 RZA-0-4526-075-XX-0 Compressor Ass y 1 29 RZA-2-2476-050-XX-0 Noise Defending Cover 1 30 RZA-2-2202-028-XX-0 Separator Support Plate 1 31 RZA-0-2506-003-XX-1 Fan Supporter Ass y 1 32 RZA-0-0000-070-XX-0 Fan Motor 1 33 RZA-0-2202-059-XX-0 Base Ass y 1 34 RZA-2-2228-002-XX-0 Drainage Elbow 1 35 852-2-2350-111-00-2 Rubber Tuck 1 36 RZA-0-1112-007-XX-0 Right Panel Ass y 1 29