Movincool CLIMATE PRO 12 Service Manual

SERVICE MANUAL

DocID: 00G00095E

CLIMATE PRO 18

Unit Serial Number Range: 0914XXXXH18 to Present

(From September 2014 to Present)

SERIAL NUMBER LOCATION AND IDENTIFICATION

Nameplate Label Position

Nameplate Label

COOLING AMPS. WITH PUMP

COMPR. OUTPUT

REFRIGERANT/TOTAL CHARGE

DESIGN PRESSURE LO/HI

PART NO./WEIGHT

SERIAL NO.

Month

Model

Sequential
Number

Year

© 2014 DENSO PRODUCTS AND SERVICES AMERICAS, INC.
All rights reserved. This book may not be reproduced or copied, in
whole or in part, without the written permission of the publisher. DENSO
PRODUCTS AND SERVICES AMERICAS, INC. reserves the right to
make changes without prior notice. MovinCool®, Office Pro®,

and SpotCool® are registered trademarks of DENSO Corporation.

Table of Contents

Table of Contents

Operation Section

1. PRECAUTIONS FOR SAFETY

1.1 Foreword. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.2 Definition of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.3 General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2. CONSTRUCTION

2.1 Exterior Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.2 Exterior Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.3 Internal Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.4 Basic Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.5 Air Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.6 Compressor and Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.7 Drain Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3. SPECIFICATIONS

3.1 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.2 Characteristics in Cool Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.3 Characteristics in Heat Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

4. REFRIGERATION SYSTEM

4.1 Refrigeration System Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4.2 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

4.3 Outdoor Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

4.4 Indoor Heat Exchanger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

4.5 High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

4.6 Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

4.7 Electronic Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

4.8 4-Way Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

4.9 Drain Pan for Outdoor Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

5. ELECTRICAL SYSTEM

5.1 Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

5.2 Basic Operation of Electrical Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

5.3 Service Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

5.4 Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

5.5 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Table of Contents

5.6 Power Cord with LCDI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

5.7 Drain Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

5.8 Condensate Pump Kit (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

5.9 Automatic Restart after Power Interruption (Automatic Recovery Feature) . . . . . . . . . . . . . . . . . . . 41

5.10 Compressor Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

5.11 Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

6. EXTERNAL DEVICE CONNECTION

6.1 Millivolt Thermostat Connection (Optional Accessory) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

6.2 24VAC Thermostat Connection (Field Supplied) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

6.3 Warning Device Connection (Field Supplied) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

6.4 Alarm Device Connection (Field Supplied) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

7. CONTROL PANEL

7.1 Control Panel and LCD Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

7.2 Operational Status Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

7.3 Record Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Table of Contents

Repair Section

8. TROUBLESHOOTING

8.1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

8.2 Self-Diagnostic Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

8.3 Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

8.4 Basic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

9. DISASSEMBLY

9.1 Unit Parts Construction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

9.2 Removal of Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

9.3 Removal of Electrical Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

9.4 Removal of Blower Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

9.5 Inspection of Capacitor (for Fan Motor and Compressor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

9.6 Inspection of Drain Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

9.7 Inspection of Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

9.8 Inspection of Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

9.9 Inspection of Transformer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

9.10 Inspection of Electronic Expansion Valve Control Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

9.11 Inspection of 4-Way Valve Controller Coil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

9.12 Inspection of Thermistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

9.13 Inspection of Wiring Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

9.14 Inspection of Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

10. REFRIGERATION SYSTEM REPAIR

10.1 Repair of Refrigeration System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

10.2 Removal of Refrigeration Cycle Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

10.3 Charging the System with R-410A Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90

10.4 Refrigerant Charging Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

11. REASSEMBLY

11.1 Removal of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

11.2 Compressor Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

11.3 Blower Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

11.4 Wiring Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

11.5 Perform the Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

11.6 Caster Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

6

Operation Section

1. PRECAUTIONS FOR SAFETY

1.1 Foreword

• This manual has been published to service the MovinCool Climate Pro 18. Please use this

service manual only when servicing the Climate Pro 18.

1.2 Definition of Terms

WARNING

CAUTION

NOTE Provides additional information that facilitates installation or unit operation.

Describes precautions that should be observed in order to prevent injury to

the user during installation or unit operation.

Describes precautions that should be observed in order to prevent damage to

the unit or its components, which may occur during installation or unit

operation if sufficient care is not taken.

1.3 General Precautions

WARNING

• All electrical work should only be performed by qualified electrical technician. Repair to

electrical components by non-certified technicians may result in personal injury and/or

damage to the unit. All electrical components replaced must be genuine MovinCool parts,

purchased from an authorized dealer.

• Disconnect power supply from the unit before performing any service.

• Before replacing any refrigeration components, recover the refrigerant using standard

recovery procedures and equipment.

• When handling refrigerant, always wear proper eye protection and do not allow the

refrigerant to come in contact with your skin.

• Do not expose refrigerant to an open flame.

• The power supply for this unit should be a dedicated single outlet circuit with a UL

recognized short-circuit and ground-fault protective breaker to prevent electrical shock

from the unit.

• When brazing any tubing, always wear eye protection, and work only in a well ventilated

area.

• Be careful of any sharp edges when working on unit.

2. CONSTRUCTION

ILL00849-00

Unit: Inch (mm)

19.4 (492)

3.0 (76)

3.0 (76)

1.4 (35)1.4 (35)

20.8 (527)

27.5 (698)

4.5

(116)

2.2 (55)

DIA. 11.6 (294)

13.2 (336)11.8 (300) 18.5 (469)

21.4 (544)

2.4 (60)43.5 (1105)

3.7 (93)

49.6 (1258)

2.1 Exterior Dimensions

Operation Section

7

8

ILL00850-00

Service Panel

Indoor Heat Exchanger

Air Inlet Grill

Outdoor Heat Exchanger

Air Inlet Panel

Outdoor Heat Exchanger

Air Outlet Duct

Power Cord

Caster

Drain Tank Cover

Control Panel

Cool/Hot Air Outlet Grill

Operation Section

2.2 Exterior Components

2.3 Internal Structure

ILL00851-00

Outdoor Fan Motor

Indoor Fan

Outdoor Fan

Compressor

Service Box

Connector for Optional
Condensate Pump

Electronic
Expansion Valve

Drain Tank

Indoor Fan Motor

Indoor
Heat Exchanger

Drain Pan

Outdoor
Heat Exchanger

4-Way Valve

Drain Switch

Accumulator

High Pressure
Switch

Operation Section

9

10

ILL00852-00

Exhaust Hot
Air Outlet

Cool Air
Outlet

Indoor Air
Inlet

Outdoor
Air Inlet

Exhaust Cool
Air Outlet

Hot Air
Outlet

Indoor Air
Inlet

Outdoor
Air Inlet

Cool Mode

Heat Mode

Operation Section

2.4 Basic Construction

• The Climate Pro 18 is compact in construction because the indoor and the outdoor heat

exchangers are enclosed in one unit. The interior is divided into three sections. The upper front

face is equipped with the indoor heat exchanger, and the lower front face contains the drain tank

and condensate pump (optional accessory). The rear section contains the outdoor heat

exchanger, the compressor and the control box.

2.5 Air Flow

• In Cool Mode, air drawn from the outdoor air inlet passes through the heat rejection coil

(condenser) and discharges hot air through the exhaust hot air outlet. Air take in from the indoor

air inlet passes through the heat absorption coil (evaporator) and discharges the cool air through

the cool air outlet.

• In Heat Mode, the refrigeration in the unit operates in reverse cycle and the heat rejection coil

(condenser) becomes the heat absorption coil (evaporator). Air drawn from the outdoor air inlet

passes through this heat absorption coil and discharges cool air through the exhaust cool air

outlet. Air taken in from the indoor air inlet passes through the heat rejection coil and discharges

hot air through the hot air outlet.

Operation Section

2.6 Compressor and Fans

• The compressor is hermetically sealed. The indoor fan is a centrifugal type and operated by a

3-speed motor to draw air through the indoor air inlet. The outdoor fan is also a centrifugal type

and operated by a 1-speed motor to draw air through the outdoor air inlet.

2.7 Drain Tank

• A 5.0 gal (19 L) drain tank is supplied with the Climate Pro 18. The condensate (water) is

collected into the tank.

The drain switch activates and stops the operation when tank reaches the level of approximately

4.0 gal (15 L).

11

12

< NOTE >

Operation Section

3. SPECIFICATIONS

3.1 Technical Specifications

Technical Specifications - Table 1

ITEM SPECIFICATIONS

Electronic Features Operation Digital Programmable

Electrical Characteristics Voltage Requirement 1 Phase, 115 V, 60 Hz

Operating Voltage Range Max. 127 V

Min. 104 V

Starting Current 65 A

Recommended Fuse Size 20 A

FLA 15.6 A

LRA 65 A

Cooling Performance

Rating Condition

(AHAM PAC-1-2009)

Indoor Heat Exchanger:

80 °F

(26.7 °C), 50 %RH

Outdoor Heat Exchanger:

80 °F (26.7 °C), 50 %RH

Heating Performance

Rating Condition

(AHAM RAC-1-2008)

Indoor Heat Exchanger:

70 °F (21.1 °C), 57 %RH

Outdoor Heat Exchanger:

47 °F (8.3 °C), 75 %RH

Compressor Type Hermetic Rotary

Ventilation Equipment for

Outdoor Coil

Total Cooling Capacity*

Sensible Cooling Capacity*

Power Consumption*

Current Consumption*

SD-EER 9.5

Power Factor

Total Heating Capacity 13,700 Btu/h (4,010 W)

Power Consumption 1.61 kW

Current Consumption 14.7 A

COP 2.49

Power Factor

Output 1.16 kW

Type of Outdoor Coil (Heat Exchanger) Plate Fin

Type of Fan Centrifugal Fan

1

1

1

1

14,600 Btu/h (4,270 W)

9,900 Btu/h (2,900 W)

1.54 kW

14.1 A

95 %

95 %

Air Flow 700 CFM (1,190 m3/h)

Max. External Static Pressure 0.23 IWG (57 Pa)

Motor Output 0.135 kW

*1 : With outdoor heat exchanger air outlet duct 10 feet (3.0 m) vertical head lift from the ground to the ceiling.

Technical Specifications - Table 2

ITEM SPECIFICATIONS

Operation Section

13

Ventilation Equipment for

Indoor Coil

Power Cord NEMA Plug Configuration 5-20

Refrigerant Refrigerant Control Electronic Expansion Valve

Signal Connection Fire Alarm Input 1 (FA-1, FA-2) • No-voltage contact input

Type of Indoor Coil (Heat Exchanger) Plate Fin

Type of Fan Centrifugal Fan

Air Flow High 540 CFM (918 m3/h)

Medium 440 CFM (748 m3/h)

Low 350 CFM (595 m3/h)

Max. External Static Pressure 0.31 IWG (77 Pa)

Motor Output High 0.12 kW

Medium 0.045 kW

Low 0.017 kW

Gage x Length 12 AWG (3-core) x 10 ft (3.0 m)

Type R-410A

Amount 1.94 lb (0.88 kg)

Fire Alarm Input 2 (Al-1, Al-2)

Warning Signal Output (OS-1, OS-2) 2 A at 30 V (DC/AC) max. with resis-

• Contact resistance less than 100

ohm

tive load

External Wall Thermostat Millivolt Type With terminals RC, O/B, G, Y

24VAC Type With terminals C, O/B, G, Y,

24VAC RC/RH

Dimension W x D x H 21 x 27 x 50 in

(533 x 686 x 1,270 mm)

Weight Net 214 lb (97 kg)

Shipping 250 lb (113 kg)

Drain Tank Capacity 5.0 gal (19 L)

Cooling Operating Condition

Range

Heating Operating Condition

Range

Inlet Air Temperature Max. 95 °F (35 °C), 60 %RH

Min. 65 °F (18 °C), 50 %RH

Without Outdoor Heat

Exchanger Duct

With Outdoor Heat

Exchanger Duct

Max. 80 °F (26.7 °C), 50 %RH

Min. 40 °F (4.4 °C), 50 %RH

Max. 80 °F (26.7 °C), 50 %RH

Min. Indoor Heat Exchanger:

40 °F (4.4 °C), 50 %RH

Outdoor Heat Exchanger:

24 °F (-4.4 °C), 50 %RH

14

< NOTE >

Operation Section

Technical Specifications - Table 3

ITEM SPECIFICATIONS

Maximum Equivalent Duct

Length

Sound Level*

Safety Devices Compressor Overload Protector Included

2

Indoor Heat Exchanger Duct 25 ft (7.6 m)

Outdoor Heat Exchanger Duct 100 ft (30.5 m)

With Outdoor Heat

Exchanger Duct

Without Outdoor Heat

Exchanger Duct

Fan Motor Overload Protector (Indoor/Outdoor) Included

Freeze Protection Thermistor Included

Drain Switch Included

Automatic Restart (Power Interruption) Included

Compressor Time Delay Included

High Pressure Interruption Included

Signal Input/Output Included

Current Fuse for Relay Board Included

High 61 dB (A)

Medium 60 dB (A)

Low 59 dB (A)

High 62 dB (A)

Medium 61 dB (A)

Low 60 dB (A)

Current Fuse for Drain Pan Heater and 4-Way

Val ve

Cutoff Fuse for Drain Pan Heater Included

Control Devices Defrost Heating Included

Drain Pan Heater Heating Included

Delay Timer for Indoor

Fan

Temperature Control Included

Programmable Timer Included

3-Speed Fan Included

Loss of Cooling or Heating Included

On-Screen Self-Diagnostic Codes Included

Cooling Not included

Heating Included

Included

• Specifications are subject to change without notice.

*2 : Measured at 3 feet (1.0 m) from surface of the unit.

3.2 Characteristics in Cool Mode

ILL00853-00

Cooling Capacity (kBtu/h)Relative Humidity (%)

Wet Bulb Temp. ºF (ºC)

11

17

16

15

14

40

50

60

70

80

90

100

13

12

50

(10)55 (13) 60(16)

65

(18)

70

(21)

75

(24)

80

(27)

85

(29)

90

(32)

95

(35)

Dry Bulb Temp. ºF (ºC)

50

(10)55 (13) 60(16)

65

(18)

70

(21)

75

(24)

80

(27)

85

(29)

90

(32)

95

(35)

Hi

Mid

Lo

• All characteristic values are within ±10% tolerance.

(1) Cooling capacity curve

Operation Section

15

16

ILL00854-00

Cooling Capacity (kBtu/h)

11

17

16

15

14

13

12

50

(10)55 (13) 60(16)

65

(18)

70

(21)

75

(24)

80

(27)

85

(29)

90

(32)

95

(35)

Example: Dry bulb: 80 ºF (27 ºC), 50 %RH, High fan speed



Cooling capacity:14.6 kBtu/h

Relative Humidity (%)

Wet Bulb Temp. ºF (ºC)

40

50

60

70

80

90

100

Dry Bulb Temp. ºF (ºC)

50

(10)55 (13) 60(16)

65

(18)

70

(21)

75

(24)

80

(27)

85

(29)

90

(32)

95

(35)

Hi

Mid

Lo

Operation Section

How to read the cooling capacity curve

(2) Power consumption curve

Power Consumption (W)Relative Humidity (%)

Wet Bulb Temp. ºF (ºC)

1.1

40

60

80

100

50

(10)55 (13) 60(16)

65

(18)

70

(21)

75

(24)

80

(27)

85

(29)

90

(32)

95

(35)

Dry Bulb Temp. ºF (ºC)

50

(10)55 (13) 60(16)

65

(18)

70

(21)

75

(24)

80

(27)

85

(29)

90

(32)

95

(35)

1.9

1.8

1.7

1.6

1.5

1.4

1.3

1.2

Hi
Mid
Lo

ILL00855-00

Power Consumption (W)Relative Humidity (%)

Wet Bulb Temp. ºF (ºC)

1.1

40
50
60

80

100

50

(10)55 (13) 60(16)

65

(18)

70

(21)

75

(24)

80

(27)

85

(29)

90

(32)

95

(35)

Dry Bulb Temp. ºF (ºC)

50

(10)55 (13) 60(16)

65

(18)

70

(21)

75

(24)

80

(27)

85

(29)

90

(32)

95

(35)

1.9

1.8

1.7

1.6

1.5

1.4

1.3

1.2

Example: Dry bulb: 80 ºF (27 ºC), 50 %RH, High fan speed



Power consumption : 1.54 kW

Hi
Mid
Lo

ILL00856-00

Operation Section

17

How to read the power consumption curve

18

ILL00857-00

Current Consumption (A)Relative Humidity (%)

Wet Bulb Temp. ºF (ºC)

10

40

60

80

100

50

(10)55 (13) 60(16)

65

(18)

70

(21)

75

(24)

80

(27)

85

(29)

90

(32)

95

(35)

Dry Bulb Temp. ºF (ºC)

50

(10)55 (13) 60(16)

65

(18)

70

(21)

75

(24)

80

(27)

85

(29)

90

(32)

95

(35)

18

17

16

15

14

13

12

11

Hi

Mid

Lo

Current Consumption (A)Relative Humidity (%)

Wet Bulb Temp. ºF (ºC)

10

40
50
60

80

100

50

(10)55 (13) 60(16)

65

(18)

70

(21)

75

(24)

80

(27)

85

(29)

90

(32)

95

(35)

Dry Bulb Temp. ºF (ºC)

50

(10)55 (13) 60(16)

65

(18)

70

(21)

75

(24)

80

(27)

85

(29)

90

(32)

95

(35)

Example: Dry bulb: 80 ºF (27 ºC), 50 %RH, High fan speed
 Current consumption : 14.2 A

18

17

16

15

14

13

12

11

Hi

Mid

Lo

ILL00858-00

Operation Section

(3) Current consumption curve

How to read the current consumption curve

(4) Cool air temperature difference curve

ILL00859-00

Relative Humidity (%)

15 (8.3)

20 (11.1)

25 (13.9)

30 (16.7)

30 40 50 60 70 80

10 (5.6)

Delta-T ºF(ºC)

Hi

Mid

Lo

Operation Section

19

20

ILL00881-00

35
(2)

40
(4)

45
(7)50(10) 55 (13) 60 (16) 65(18)70(21) 75(24) 80(27)85(29)

Heating capacity (kBtu/h)

Dry Bulb Temp. ºF (ºC)

10

12

14

16

18

20

Hi

Lo

Mid

Operation Section

3.3 Characteristics in Heat Mode

• All characteristic values are within ±10% tolerance.

(1) Heating capacity curve

How to read the heating capacity curve

ILL00882-00

35
(2)

40
(4)

45
(7)50(10) 55 (13) 60 (16) 65(18)70(21) 75(24) 80(27)85(29)

Heating capacity (kBtu/h)

Dry Bulb Temp. ºF (ºC)

Example: Dry bulb: 60 ºF (15.6 ºC), 50 %RH, High fan speed



Heating capacity:16 kBtu/h

10

12

14

16

18

20

Hi

Lo

Mid

Operation Section

21

22

ILL00883-00

35
(2)40(4)45(7)50(10) 55 (13) 60 (16) 65(18)70(21) 75(24) 80(27)85(29)

Power Consumption (kW)

Dry Bulb Temp. ºF (ºC)

1.1

1.2

1.4

1.3

1.5

1.6

1.9

1.8

1.7

Hi

Lo

Mid

Example: Dry bulb: 60 ºF (15.6 ºC), 50 %RH, High fan speed
 Power consumption: 1.54 kW

35
(2)40(4)45(7)50(10) 55 (13) 60 (16) 65(18)70(21) 75(24) 80(27)85(29)

Power Consumption (kW)

Dry Bulb Temp. ºF (ºC)

1.1

1.2

1.4

1.3

1.5

1.6

1.9

1.8

1.7

Hi

Lo

Mid

ILL00884-00

Operation Section

(2) Power consumption curve

How to read the power consumption curve

(3) Current consumption curve

ILL00885-00

35
(2)40(4)45(7)50(10) 55 (13) 60 (16) 65(18)70(21) 75(24) 80(27)85(29)

Current Consumption (A)

Dry Bulb Temp. ºF (ºC)

11

12

14

13

15

16

18

17

Hi

Lo

Mid

Example: Dry bulb: 60 ºF (15.6 ºC), 50 %RH, High fan speed
 Current consumption: 14 A

35
(2)40(4)45(7)50(10) 55 (13) 60 (16) 65(18)70(21) 75(24) 80(27)85(29)

Current Consumption (A)

Dry Bulb Temp. ºF (ºC)

11

12

14

13

15

16

18

17

Hi

Lo

Mid

ILL00886-00

Operation Section

23

How to read the current consumption curve

24

ILL00887-00

35
(2)40(4)45(7)50(10) 55 (13) 60 (16) 65(18)70(21) 75(24) 80(27)85(29)

Delta-T ºF (ºC)

Dry Bulb Temp. ºF (ºC)

15(8.3)

20 (11.1)

30 (16.7)

25 (13.9)

35 (19.4)

40 (22.2)

50 (27.8)

45 (25)

Hi

Lo

Mid

Operation Section

(4) Hot air temperature difference curve

Operation Section

ILL00860-00

High Pressure Switch

Indoor Heat
Exchanger

Accumulator

Electronic Expansion
Valve

Electronic Expansion
Valve Controller

Outdoor Heat Exchanger

4-Way Valve Controller

Compressor

4-Way Valve

4. REFRIGERATION SYSTEM

4.1 Refrigeration System Construction

The component parts of the refrigeration system include the following:

• Compressor, Accumulator, Indoor and Outdoor heat exchangers, High pressure switch,

Electronic expansion valve with controller, 4-Way valve with controller

These parts are all connected by copper tubing. All the connections have been brazed.

25

26

ILL00889-00

MF1
(Indoor
Fan Motor)

Outdoor Heat
Exchanger

MF2
(Outdoor
Fan Motor)

EXV (Electronic Expansion Valve)

Compressor

HPRS

(High Pressure Switch)

CTS1
(Indoor Pipe Thermistor)

ODS
(Outdoor Air Inlet Thermistor)

Indoor Heat
Exchanger

Air InAir In

EMV

Accumulator

OLC (Compressor Overload Relay)

CTS2
(Compressor Pipe
Thermistor)

4-Way Valve

RTS
(Indoor Air
Inlet Thermistor)

CTS3 (Outdoor Pipe Thermistor)

Flow of Refrigerant:

Cool Mode

Heat Mode

Operation Section

Operation Section

ILL00861-00

Discharge Gas (High Pressure)

Accumulator

Strainer

Suction Gas (Low Pressure)

Blade

Discharge Valve

Oil

Lubricator

Roller

Cylinder

Rotor

Stator

Terminal

4.2 Compressor

• The compressor used for the unit is hermetically sealed. The compressor and the compressor

motor are in one casing.

(1) Compressor construction

•The construction of a rotary type compressor is divided into two mechanisms; the drive

mechanism (compressor motor), and the compression mechanism (compressor). When the

rotor shaft of the motor (drive mechanism) turns, the roller (compression mechanism) rotates to

compress the refrigerant.

27

28

I000510

Discharge

Hole

Cylinder

Blade

Spring

Suction
Hole

Discharge

Val ve

Shaft

Roller

Operation Section

(2) Basic compressor operation

•The roller (compression mechanism) is set

eccentrically with a certain distance given from

the axis of the center of the cylinder. A spring

loaded blade is mounted on the cylinder. The

roller turns to compress the refrigerant in the

space between the cylinder and eccentrically

mounted roller. The blade is in contact with the

roller by means of spring force. The blade

partitions the space between the suction side

and the discharge side to keep compressed refrigerant from returning to the suction side. There

is no suction valve. The discharge valve is designed not to open until the pressure of the

refrigerant within the cylinder reaches or exceeds discharge side pressure. As a result, the

discharge valve prevents the backward flow of refrigerant gas.

(3) Operation

I001676

Blade

Discharge

Val ve

Roller

I001677

Blade

Discharge

Val ve

Roller

I001678

Blade

Discharge

Val ve

Roller

I001679

Blade

Discharge

Val ve

Roller

Operation Section

29

1) Start of compression

1) The cylinder is filled with low pressure gas.

2) Since pressure in the discharge chamber is

higher than in the cylinder, the discharge

valve is kept closed.

2) Suction and compression

1) The pressure in the cylinder increases

gradually.

2) Refrigerant suction begins on the suction

side of the cylinder.

3) The discharge valve remains closed.

3) Discharge

1) The pressure in the cylinder exceeds that in

the discharge chamber, and the discharge

valve opens.

2) On the suction side, refrigerant suction

continues.

4) Completion of compression

1) When compression is completed, all of the

refrigerant has been drawn from the suction

chamber.

2) Operation then returns to step 1) (Start of

compression) and the above process of

suction and compression continues

repeatedly in succession.

30

I001680

Oil Feed Groove

Oil Hole

Oil Scrapper

Roller

Rotor

Cylinder

Hollow Shaft

Eccentric Shaft

Operation Section

(4) Compressor lubrication

•The lubrication system is comprised of a hollow

shaft, an oil scraper mounted at the end face,

hollow shaft, a shaft journal (shaft bearing),

and the lubrication groove for the shaft journal.

The lubrication groove is wider than the oil

hole. When the shaft turns, oil is scraped

upward by the oil scraper along the inside

diameter of the hollow shaft. The oil is fed

through the oil hole by centrifugal force, then

supplied to the lubrication groove for each

shaft journal, lubricating the bearing. In this

lubrication system, oil enters into each bearing

separately and returns to the oil reservoir. This

system effectively prevents bearing

temperature increases, and offers high

reliability. In addition, the specially treated

shaft journal keeps the bearing from being damaged during high temperature operation.

4.3 Outdoor Heat Exchanger

• The outdoor heat exchanger coil uses copper tubes that are covered with the thin aluminum

protections called plate fins. In cool mode, heat is given off and absorbed by air being pulled

across these fins by the centrifugal fan, and then expelled through the exhaust hot air outlet. In

heat mode, this heat exchanger coil becomes heat absorption coil, and then cool air is expelled

through the exhaust cool air outlet.

4.4 Indoor Heat Exchanger

• The indoor heat exchanger coil is covered with plate fins. In cool mode, heat is removed from

the air being pulled across the indoor heat exchanger by the centrifugal fan and the resulting

cool air is expelled through the cool air outlet grill. In heat mode, this heat exchanger becomes

heat rejection coil, and then hot air is expelled through the hot air outlet grill.

Operation Section

I001768

Pressure of Refrigerant

Movable Point

Snap Disk

Pin

Terminal

Lead Wires

Stationary Point

Molding by Resin

Case

ILL00878-00

Suction Gas (Low Pressure)

To Compressor

4.5 High Pressure Switch

• The high pressure switch prevents the outdoor

heat exchanger and compressor from being

damaged by excessive high pressure in the

high pressure line of the refrigeration cycle.

The switch is normally closed. The snap disk

responds to the variations in pressure and, if

pressure is abnormally high, the snap disk

moves down to push the pin down, causing the

internal contacts to open. This interrupts the

ground signal at the control board (CN18 connector) which turns the compressor off.

• Possible causes of this trouble include:

- The air filter for the outdoor heat exchanger is dirty, restricting air flow.

- The blower for the outdoor heat exchanger is defective.

31

4.6 Accumulator

•The accumulator is mounted on the suction gas

piping between the 4-way valve and the

compressor. The accumulator separates the

liquid refrigerant from the gas refrigerant,

allowing only the gas refrigerant to enter the

compressor. In the accumulator, suction gas is

led into a cylindrical vessel where the speed of

the gas is decreased. This process separates

the refrigerant contained in the gas by the force

of gravity, causing the refrigerant to accumulate at the bottom of the vessel. As a result, the

compressor is protected from possible damage caused by liquid refrigerant intake.

32

I003162

Refrigerant

Flow

Valve Spring Spring

Valve Holder

Val ve

Control Coil

Magnet

Stopper

Delivery Screw

Val ve

ILL00862-00

Operation Section

4.7 Electronic Expansion Valve

• In cool mode, the electronic expansion valve

causes rapid refrigerant expansion by injecting

"high temperature, high pressure liquid

refrigerant" from the outdoor heat exchanger

through a small orifice. The resultant "low

temperature, low pressure mist refrigerant" is

then sent to the indoor heat exchanger. A

solenoid valve adjusts the refrigerant quantity

according to the indoor heat exchanger air inlet

and outlet temperatures so that the mist

refrigerant can undergo heat exchange in the

indoor heat exchanger under optimal

conditions.

• In heat mode, the electronic expansion valve

operates reversal of cool mode.

4.8 4-Way Valve

• The 4-way valve allows a reversal of the

refrigeration cycle, changing from cool to heat

mode. The 4-way valve is powered on during

heat mode. The cycle reversal is initiated by a

small pilot solenoid valve that moves a slider,

thereby changing the direction of the

refrigerant.

• The 4-way valve coil ensures reliable

changeover from cool to heat mode. The valve

is connected to the discharge and suction pipes. This valve coil comes with two lead wires that

are connected to the relay board circuit. The 4-way valve coil is encapsulated in epoxy resin to

protect the winding from liquids.

4.9 Drain Pan for Outdoor Heat Exchanger

• The drain pan for the outdoor heat exchanger comes with a built-in sheet heater to prevent the

drain pan from freezing up. The sheet heater is the product that wires the cord-type heater with

silicon rubber or vinyl chloride resin insulation on aluminum foil.

ILL00871-00

F23

1
1

4

1

4 13

3 4 3 5

4 3 54335

5

1 2

1 3 1 2 2 3

121 41 7

CC

OLC

CF2 CF1

CN

CN CN

DS HPRS

CN

EXV

CN HTR

TF3

G

G

G

GG

G

T1 TRR1

F1

1

2

1

2

S

R

C

H

M

L

1

2

1

2

1

Attachment Plug
Transformer
Compressor Motor
Evaporator Fan Motor (Indoor Fan Motor)

Condenser Fan Motor (Outdoor Fan Motor)
Capacitor for MC
Capacitor for MF1
Capacitor for MF2
Heater
Four-Way Valve
Electronic Expansion Valve
Relay Board
Control Board
Overload Relay for MC
Inner Overload Relay for MF1
Inner Overload Relay for MF2
Drain Switch

AC115V, 1PH, 60Hz, 20A

TB1

MC

EMV

MF2

IOLF2

MF1

IOLF1

TF1 TF2

AC115V

CN01

CN02

CN03

CN30

CB

CN37 CN11 CN12

RB

RTS CTS1CTS2CTS3 ODS

1 6

CN14

1

1

5

6

CN18

TB2

JUMPER
LINE

TB3

CN34

1

4

CN31

RL07RL04RL03 RL08RL06

CN27 CN26CN25

RL01RL09

RL02

CN17

1

3

1

6

CN19

AC20V

TNS

AP
TNS

MC
MF1
MF2

CC
CF1
CF2
H T R

E MV
EXV

R B
C B
OLC

IOLF1
IOLF2
D S

H P R S
R TS

C TS1

C TS2

C TS3

O D S

TB1
TB2

TB3

F1
F2

T F1
T F2
T F3

High Pressure Switch
Room Thermistor (Indoor Air Inlet Thermistor)

Evaporator Pipe Thermistor
(Indoor P

ipe Thermistor)

Compressor Pipe Thermistor
Condenser Pipe Thermistor

(Outdoor Pipe Thermistor)

Outdoor Thermistor
(Outdoor Air Inlet Thermistor)

Terminal Block
Terminal Block
Terminal Block

Fuse
Fuse
Fuse for TNS
Fuse for TNS

Fuse for HTR

GND

RX

TX

+5V

AL-2

AL-1

FA-2

FA-1

OS-2

OS-1

Millivolt RC

(Jumper)

24VAC C

O/B

G

Y

24VAC RC/RH

24VAC Hot

24VAC Neutrol

5. ELECTRICAL SYSTEM

5.1 Wiring Diagram

Operation Section

33

34

Operation Section

5.2 Basic Operation of Electrical Circuit

• There are two basic components used to control the operation of electrical system:

- Control panel assembly

- Service box

• The control panel assembly contains the display panel and keypad. The service box contains all

input and output devices such as temperature devices, sensors, relays, switches and

microprocessor.

(1) Fan Only mode

• Fan Only mode can be selected by pressing the MODE button on the control panel and

confirming to start the operation of Fan Only mode. In this mode, the fan relay RL02 is closed

and the fan speed relays are either closed or opened depending on fan speed setting. When fan

Hi speed is set, the relay RL03 terminal 4 and the relay RL04 terminal 4 are closed. When fan

Mid speed is set, the relay RL03 terminal 3 and the relay RL04 terminal 4 are closed. When fan

Lo speed is set, the relay RL04 terminal 3 is closed.

(2) Cool mode

• Cool mode can be selected by pressing the MODE button on the control panel and confirming

to start the operation of Cool mode. In this mode, the indoor fan relays RL02, RL03, and RL04

are operated based on fan speed setting, and the outdoor fan relay RL09 and the compressor

relay RL01 are operated after the 120 seconds time delay has been expired.

(3) Heat mode

• Heat mode can be selected by pressing the MODE button on the control panel and confirming

to start the operation of Heat mode. In this mode, the 4-way valve relay RL06 and the indoor fan

relays RL02, RL03, and RL04 are operated based on fan speed setting. The outdoor fan relay

RL09 and the compressor relay RL01 are operated after the 120 seconds time delay has been

expired. During Heat mode, the heater relay RL08 is closed when the ODS (outdoor air inlet

thermistor) detects below 24 °F (-4 °C) to prevent the drain pan from freezing and opened when

the ODS detects above 43 °F (6 °C).

Operation Section

ILL00863-00

Terminal Block 1 (For Power)

Relay Board

Relay Board Fuse (F2)

(1 A, 250 V)

Terminal Block 2
(For Input/Output Signal)

Terminal Block 3
(For External Thermostat)

Fuse (F1)
(1.5 A, 250 V for
4-Way Valve,
Drain Pan Heater of
Outdoor Heat Exchanger)

Compressor Motor
Capacitor

Transformer (For Relay Board)

Fan Motor Capacitor

<Service Box>

5.3 Service Box

(1) Capacitors

• The capacitors are used to temporarily boost the power output available to the fan motors and

the compressor at start-up.

• The specifications of each capacitor are listed below:

Capacitor Application Volta ge Rating Capacitance

Fan Motors 370 VAC 7.5 μF

Compressor Motor 370 VAC 60 μF

35

(2) Terminal blocks

• There are three terminal blocks in the service box, a power terminal block used for the power

line connection, and two low signal terminal blocks used for external thermostat and signal

connections.

36

< NOTE >

ILL00865-00

Fuse

DIP Switch

LEDs

(3) Relay board

• The relay board is powered by 20 VAC from the secondary side of the step down transformer.

This voltage is then converted from 20 VAC to 12 VDC and supplied to the relay driver circuits

on the board. The 12 VDC is then converted again into 5 VDC and supplied to the

microprocessor, sensors, and switches on the relay board.

• The relay board contains surge protection circuit, AC power interruption and monitoring circuit,

fuse, and DIP switches (no function and are defaulted to the OFF positions). There are also 5

LEDs on the relay board that provides a visual tool to quickly diagnose problems on the relay

board. These LED's functional descriptions and status are listed in the table below.

LED Number Function and Description Normal Status

Operation Section

LED01 Indicates that the +5 VDC line is normal. Green LED is on.

LED02 Not in use. Not in use.

LED03 Indicates that the +12 VDC line is normal. Green LED is on.

LED04 Indicates that serial connection between the relay

board and the controller board is normal.

LED05 Indicates that serial connection between the relay

board and the controller board is normal.

Yellow LED is blinking.

Yellow LED is blinking.

The relay board must be serviced as a complete assembly. It has only one serviceable

component, the fuse. (see below)

• The relay board fuse provides protection

against damage to the step-down transformer.

It must be replaced with the exact type of fuse

or an equivalent.

Specifications:

- 1 A, 250 V

CAUTION

Failure to use the exact type of fuse could result in damage to the unit and/or to components. It

could also void the warranty of the unit.

(4) Transformer for relay board

ILL00879-00

Secondary

20 V

<Wiring Diagram>

40 VA, 60 Hz

1

5

10

6

4

2

Primary

115 V

ILL00905-00

Secondary

Primary

Connected to
Signal Terminals
(24VAC Neutral,
24VAC Hot)

40 VA, 60 Hz

Connected to
Terminals
(R1, T1)

3

10

6

120 V24 V

3

5

10

6

<Wiring Diagram>

• A dry-type transformer rated 40 VA is equipped

within the unit to provide step down voltage

from 115 V to 20 V.

• Terminals 1 and 5 are connected to 115 V

power source to supply power to secondary

side.

• Terminals 6 and 10 of the secondary side are

connected to the relay board to provide 20 V

output.

Specifications:

- Type: Dry type

- Rated VA: 40 VA

- Power Requirement: 1 Phase, 60 Hz

Operation Section

37

- Primary Voltage: 115 V

- Secondary Voltage: 20 V

(5) Optional transformer for 24VAC thermostat (field supplied)

• A dry-type transformer rated 40 VA is equipped

within the unit to provide step down voltage

from 115 V to 24 V.

• Terminals 3 and 5 are connected to 115 V

power source to supply power to secondary

side.

• Terminals 6 and 10 of the secondary side are

connected to the signal terminals to provide 24

V output.

Specifications:

- Type: Class 2 transformer

- Rated VA: 40 VA

- Power Requirement: 1 Phase, 60 Hz

- Primary Voltage: 115 V

- Secondary Voltage: 24 V

38

< NOTE >

ILL00866-00

CF1-1 (White)

CF1-2 (White/Brown)

RL03-NC (H) (Black)

RL03-NO (M) (Red)

RL04-NO (L) (Blue)

Ground

(Green/Yellow)

ILL00867-00

CF2-1 (White)

CF2-2 (White/Brown)

Ground

(Green/Yellow)

RL09-NO (Black)

Operation Section

5.4 Fan Motor

(1) Indoor fan motor

• The indoor fan motor is a 1 phase, induction

type 3 speed motor.

Specifications:

- Rated Voltage: 115 V, 60 Hz

- Rated Output: Hi - 115 W, Mid - 44.4 W, Lo -

15.4 W

(2) Outdoor fan motor

• The outdoor fan motor is a 1 phase, induction

type 1 speed motor.

Specifications:

- Rated Voltage: 115 V, 60 Hz

- Rated Output: 127 W

An internal overload relay is used to protect the fan motor. This relay is built into the fan motor and

interrupts the flow of current when there is an over current situation, or if abnormally high

temperature builds up in the fan motor.

Operation Section

I001691

Bimetal

Terminal

Points

ILL00872-00

Reset Button

Test Button

5.5 Compressor

(1) Compressor motor

• The compressor motor is a 1 phase, induction type motor and is contained within the same

housing as the compressor.

Specifications:

- Rated Voltage: 115 V, 60 Hz

- Rated Output : 1160 W

(2) Compressor overload relay

• An external compressor overload relay is used

to protect the compressor motor. This relay is

mounted within the connector housing that

attaches to the top of the compressor. The

39

relay interrupts the flow of current when there is

an overload condition and, high temperature

builds up in the compressor.

Operating Temperature

OFF (Open Contacts) ON (Closed Contacts)

302 °F (150 °C)

156 °F (69 °C) 19.0 MRA4720-12027

Non-Operating Limit at 176 °F

(100 °C) (A)

Marking

5.6 Power Cord with LCDI

• The Climate Pro 18 is equipped with UL recognized LCDI power cord and NEMA plug

configuration (5-20). The appropriate outlet must be used for this plug type. LCDI is used for

monitoring leakage current. Once leakage current is detected, LCDI de-energizes the unit.

40

ILL00873-00

2

NC

C

1

DS2

DS1

Indoor Heat Exchanger

Drain Pan

Drain Tube

Drain Tank

Fulcrum

Drain Water

Base Plate Top

Base Plate

Base Plate Bottom

Drain Switch

Spring

To CN18

Operation Section

5.7 Drain Switch

• The Climate Pro 18 is equipped with a drain switch. When the drain tank accumulates

approximately 4.0 gal (15 L) of condensate (water) in the drain tank, the drain switch sends a

signal to the microprocessor. The microprocessor stops all operation of the unit, displays the

"FL" on the LCD and closes the contact of output signal.

• This system utilizes a 0.1 A, 125/250 VAC micro-switch for this function. When drain water

accumulates approximately 4.0 gal (15 L) in the drain tank, the drain tank base plate, which is

supported at its fulcrum, is pushed down in the arrow direction as shown in the figure below.

• When the drain tank base plate is forced down, the top of the drain tank base plate turns off the

contacts #1-#2 of the micro switch. This causes the ground signal at the CN18 connector of the

relay board to go open. When the microprocessor detects this event, it shuts the unit off, displays

the "FL" on the LCD and closes the contact of output signal.

• When the drain tank is removed (or the drain tank is emptied), the top of the drain tank base

plate returns to its original position from the tension of the coil spring. Then contacts #1-#2 of

the drain switch close. This provides a ground to the microprocessor through the CN18

connector.

Operation Section

41

(1) How to re-start the unit

•

Press the START/STOP button on the control panel. The unit returns to the previous operation mode

.

5.8 Condensate Pump Kit (Optional)

• The Climate Pro 18 model comes standard with a drain tank, which collects the water that forms

on the heat exchangers during normal operation. If the unit is required to operate continuously

without periodically emptying this tank, a condensate pump may be needed. A condensate

pump kit is available for this model.

5.9 Automatic Restart after Power Interruption (Automatic Recovery Feature)

• The program within the microprocessor of the Climate Pro 18 contains a feature that

automatically restarts the unit after power is lost and regained. The unit returns to the same

operation mode as it was prior to the loss of power. Any preset program is retained in the

memory in the event power loss occurs.

5.10 Compressor Protection

• There is a time delay program within the microprocessor. This prevents a heavy load from being

applied on the compressor motor when restarting the unit cool or heat mode after a very short

period of time. This delay is in effect any time when the compressor is turned on by selection of

the cool or heat mode operation. temperature set point (thermostatic control), power interruption

restart or condensate pump (optional) operation.

Specifications:

Time delay

- 120 ± 20 sec.

5.11 Temperature Control

• The compressor operation during cool or heat mode operation is controlled by the

microprocessor which receives input signals from the RTS (indoor air inlet thermistor) and the

setting of the temperature set point. The temperature set point (desired room temperature) can

be adjusted by pressing the TEMP+ or -TEMP button on the control panel. The adjustment

range of the temperature set point is:

For cool mode:

- 65 °F ~ 90 °F (18 °C ~ 32 °C)

For heat mode:

- 55 °F ~ 80 °F (13 °C ~ 27 °C)

42

Operation Section

6. EXTERNAL DEVICE CONNECTION

6.1 Millivolt Thermostat Connection (Optional Accessory)

WARNING

Disconnect power before installation. Beware that some residual voltage may remain in

the unit immediately after the power is disconnected.

1) Select the proper location where the millivolt thermostat can be conveniently accessed and

install it at the selected location.

CAUTION

Do not install the millivolt thermostat where artificial heating condition may occur (i.e. hot stove,

hot pipe, and fireplace or under direct sunlight).

2) Set the millivolt thermostat to cool or heat mode without power connection on the unit. Prepare

the millivolt thermostat wires.

Recommended wire size:

- 18 ~ 20 AWG

3) Turn the unit off and unplug the power cord.

Take out seven (7) screws and remove the

service panel from rear of the unit.

Cap

Screws (7)

ILL00806-00

4) Squeeze the inner latches and push out the

black cap from inside the panel. Insert the

millivolt thermostat wires through the hole in

the rear panel.

Cap

Latch

ILL00046-01

Operation Section

< NOTE >

Neutral

Hot

43

5) Connect the millivolt thermostat wires to the terminal block according to the connection table

shown below. Reinstall the service panel to the unit.

Service Box

Connection Table

Neutral

Hot

Millivolt

Thermostat

Wire No.

RC

O/B

Y

Unit

Terminal Block 3

Terminal No.

Millivolts RC

O/B

GG

Y

TB3

6) Plug in the power cord.

7) Press MENU/ESC button to go to MENU.

Use TEMP+ or -TEMP button to select

EXTERNAL THERMOSTAT and press ENTER

button to confirm. LCD displays a notification

screen.

Millivolt Thermostat

ILL00776-01

ILL00813-00

If no button is pressed for 1 minute, LCD displays the previous mode.

44

Operation Section

8) Use TEMP+ or -TEMP button to select YES

and press ENTER button to confirm. LCD

displays

"EXTERNAL THERMOSTAT

ACTIVATED" and "KEY LOCKED" with the

room temperature. LED color changes from

orange to green.

9) To deactivate thermostat connection, press

and hold MENU button for 5 seconds. Other

buttons are unlocked and the unit enters

standby mode. LED color changes from green

to orange.

ILL00814-00

ILL00815-00

Operation Section

24VAC Thermostat Connection Table

24VAC Transformer Connection Table

24VAC RC/RH

24VAC C

24VAC

Thermostat

Wire No.

Unit

Terminal Block 3

Terminal No.

O/B

G

Y

C

O/B

RC/RH

G

Y

R1

24VAC

Trasformer Wire

No.(Primary Side)

Unit

Terminal Block 1

Terminal No.

T1

R1

T1

24VAC Hot

24VAC

Trasformer Wire

No.(Secondary Side)

Unit

Terminal Block 3

Terminal No.

24VAC Neutral

Hot

Neutral

Jumper Plug

24VAC Thermostat

24VAC Transformer

Primary

Secondary

TB3

TB1

Service Box

NeutralNeutral

HotHot

ILL00880-00

6.2 24VAC Thermostat Connection (Field Supplied)

• An optional 24VAC transformer is required with a field supplied 24VAC thermostat.

WARNING

Disconnect power before installation. Beware that some residual voltage may remain in

the unit immediately after the power is disconnected.

45

1) Turn the unit off and unplug the power cord. Refer to the previous section to remove the service

panel and insert the thermostat wires through the hole in the rear panel. Connect the 24VAC

thermostat wires to the terminal block according to the 24VAC thermostat connection table

shown above.

2) Install the 24VAC secondary class 2 transformer to the service box. Insert the secondary side

wires through the upper grommet hole in the service box. Connect the wires to the terminal

blocks according to the 24VAC transformer connection table shown above. All wiring must

comply with applicable local codes, ordinances, and regulations.

Specifications:

- Transformer: Primary 115 V, Secondary 24 V

- Recommended wire size: 18 AWG or 20 AWG

46

< NOTE >

< NOTE >

Operation Section

3) Remove the jumper plug from the terminal block. Reinstall the service panel to the unit.

Keep this jumper plug in a safe place to reuse when the 24VAC thermostat is removed from the

unit.

4) Plug in the power cord.

5) Press MENU/ESC button to go to MENU.

Use TEMP+ or -TEMP button to select

EXTERNAL THERMOSTAT and press ENTER

button to confirm. LCD displays a notification

screen.

ILL00813-00

If no button is pressed for 1 minute, LCD displays the previous mode.

6) Use TEMP+ or -TEMP button to select YES

and press ENTER button to confirm. LCD

displays "EXTERNAL THERMOSTAT

ACTIVATED" and "KEY LOCKED" with the

room temperature. LED color changes from

orange to green.

7) To deactivate thermostat connection, press

and hold MENU button for 5 seconds. Other

buttons are unlocked and the unit enters

standby mode. LED color changes from green

to orange.

ILL00814-00

ILL00815-00

Operation Section

6.3 Warning Device Connection (Field Supplied)

• The controller of this unit is equipped with a warning signal output relay which can be used to

monitor failure condition of the unit and is compatible with various external warning devices such

as alarm speaker, light indicators, etc.

Specifications:

- Relay type: Form C, normal open dry contact

- Relay output contactor rating: 2 A at 30 V (DC/AC) maximum with resistive load

WARNING

Disconnect power before installation. Beware that some residual voltage may remain in

the unit immediately after the power is disconnected.

1) Turn the unit off and unplug the power cord.

Take out seven (7) screws and remove the

Cap

47

service panel from rear of the unit.

2) Squeeze the inner latches and push out the

black cap from inside the panel.

Insert the warning signal wires through the hole

in the rear panel.

Recommended wire size:

- 16 AWG ~ 22 AWG

Screws (7)

ILL00806-00

Cap

Latch

ILL00046-01

48

Service Box

Warning Device

ILL00774-01

NeutralNeutral

HotHot

TB2

Operation Section

3) Connect the warning signal wires to the terminals OS-1 and OS-2 as shown in the above figure.

Reinstall the service panel to the unit.

4) Plug in the power cord.

Operation Section

ILL00775-01

Service Box

Alarm Device 1

Alarm Device 2

NeutralNeutral

HotHot

TB2

6.4 Alarm Device Connection (Field Supplied)

• The controller of this unit is equipped with two sets of input signal terminals on the terminal block

which can connect the external alarm devices such as a fire alarm device. The input signal

terminals should only be connected to a close or an open dry contact. When receiving the

signals from the external alarm devices, the unit turns off and does not turn back on until it has

been RESET.

WARNING

Disconnect power before installation. Beware that some residual voltage may remain in

the unit immediately after the power is disconnected.

49

1) Turn the unit off and unplug the power cord.

Refer to the previous section to remove the service

panel and insert the alarm device wires through the hole in the rear panel.

Recommended wire size:

- 16 AWG ~ 22 AWG

2) Connect the alarm signal wires to terminal AI-1 and AI-2 and/or FA-1 and FA-2 as shown in the

above figure. Reinstall the service panel to the unit.

3) Plug in the power cord.

50

lLL00778-00

1

7

2

4

8

5

3

6

Operation Section

7. CONTROL PANEL

7.1 Control Panel and LCD Indicators

• Refer to the OPERATION MANUAL supplied with the unit for daily operation.

(1) Control panel

1 START/STOP button Start or stop the unit operation.

2 LED

3 MODE button

4 MENU/ESC button

Illuminate in Orange color for Self-Diagnostic and Standby mode, in Green color

for normal operation.

Select operation mode (FAN ONLY, COOL, and HEAT).

FAN ONLY : Fan operates continuously.

COOL : Once the room temperature reaches the set point temperature, the

unit operates in FAN ONLY mode. When switched from HEAT to

COOL mode operation, the unit initially operates in FAN ONLY

mode.

HEAT : Once the room temperature reaches the set point temperature, the

unit stops. When switched from COOL to HEAT mode operation,

the unit stops until the compressor operates. When FAN mode is

set to AUTO, the fan operates within 1 minute after the compressor

operates.

Display the menu selection screen or to escape from the menu selection

screen.

< NOTE >

5 ENTER button Select item in Menu mode.

6 FAN+, -FAN buttons Change fan speeds Hi, MID, LO.

7 TEMP+, -TEMP buttons Change set point temperature.

Operation Section

51

8 LCD

Display operation mode, status, notification, confirmation, and self-diagnostic

codes with two backlight colors.

• When the unit is connected to power, the LED illuminates in orange color, and the LCD displays

date, time and the previous mode setting condition with blue backlight that stays on for 60

seconds, then turns off (standby mode). The backlight turns on again if any button is pressed.

• The RTS (indoor air inlet thermistor) monitors the inlet air temperature versus setpoint

temperature and automatically switches ON and OFF during cooling or heating operation.

• The fan mode control determines whether the fan continues to operate or stop when the

compressor stops during COOL or HEAT mode. The unit has been preset at the factory for

continuous fan operation in COOL and for fan AUTO operation in HEAT mode. Fan mode can be

changed on the control panel under Menu.

52

< NOTE >

Operation Section

(2) LCD indicators

2

1

6

10

3

9

7

8

1 Day of the week Indicate day of the week.

2 Time of the day Indicate time of the day.

3 Room Temp

4 Key Locked

Indicate room temperature.

Temperature range: 0 °F ~ 99 °F (0 °C ~ 99 °C)

Indicate keypad is locked.

Disable all buttons on the control panel except MENU/ESC button.

4

5

lLL00779-00

11

lLL00780-00

12

ILL00781-00

Indicate set point temperature. "MIN" or "MAX" indicates minimum or maximum value.

5 Set Temp

6 Fan Only/Cool/Heat Indicate operating mode.

7 Fan Mode Indicate AUTO or ON.

8 Fan Speed Indicate HI, MID or LO.

9 External Indicate external millivolt or 24VAC thermostat is connected.

10 Program Running Indicate Program is running.

11 Defrost

12 Outside Operating Range

Temperature range for COOL mode operation: 65 °F ~ 90 °F (18 °C ~ 32 °C)

Temperature range for HEAT mode operation: 55 °F ~ 80 °F (13 °C ~ 27 °C)

Indicate defrost operation during heating.

When the ambient temperature is low, the unit automatically stops and starts

defrosting operation for maximum 15 minutes ("DEFROST" is displayed).

The unit returns to heating operation after defrosting operation is completed.

Indicate the unit is used outside of the operating condition range.

When the ambient temperature falls outside the operating condition range,

the unit automatically stops and displays this notification.

The unit has been preset at the factory to display the temperature in °F. The temperature scale

can be changed from °F to °C on the control panel under Menu.

Operation Section

< NOTE >

< NOTE >

7.2 Operational Status Display

• The operational status of each functional part can be displayed on the LCD while the unit is
running.

(1) Display method

• Press and hold MENU/ESC and ENTER

buttons for 5 seconds.

• Use FAN+ or -FAN button to select "STATUS",

and press ENTER button to confirm. The

operational status content is displayed.

ILL00874-00

53

ILL00875-00

• If no button is pressed for 1 minute, the LCD automatically displays the previous mode.

• Press Menu/ESC button again to return to the previous screen.

Display Code Display Item Display Unit

EXV Electronic expansion valve opening rps

RTS Indoor air inlet thermistor temperature °F/°C

ODS Outdoor air inlet thermistor temperature °F/°C

CTS1 Indoor pipe thermistor temperature °F/°C

CTS2 Compressor pipe thermistor temperature °F/°C

CTS3 Outdoor pipe thermistor temperature °F/°C

RTS2 Not in use. -

Display unit °F or °C can be changed on the control panel. Press MENU/ESC button, select TEMP.
SCALE by TEMP+ or -TEMP button, and press ENTER button. Select °F or °C, and press ENTER
button to confirm.

(2) Exiting operational status display

• To exit the operational status display, press MENU/ESC button.

54

< NOTE >

Operation Section

7.3 Record Display

• The record of unit power on time, compressor operating time, defrosting time and self-diagnostic

codes can be displayed on the LCD while the unit is running.

• The unit power on time, compressor operating time, and defrosting time can be stored up to

65500 hours (automatically cleared to 0 hour and start counting).

• The self-diagnostic codes can be stored up to 3 different codes.

(1) Display method

• Press and hold MENU/ESC and ENTER

buttons for 5 seconds.

• Use FAN+ or -FAN button to select

"RECORD", and press ENTER button to

confirm. The record content is displayed.

ILL00876-00

ILL00877-00

• If no button is pressed for 1 minute, the LCD automatically displays the previous mode.

• Press Menu/ESC button again to return to the previous screen.

Operation Section

< NOTE >

Display Item Description Display Unit

TOTAL TIME Total unit power on time hr

COOL TIME Compressor operating time during cool mode hr

HEAT TIME Compressor operating time during heat mode hr

DEF. TIME Defrosting time during heat mode hr

DIAGNOSTIC CODE 1 Self-diagnostic code 1: Latest code AL1

(Example)

55

DIAGNOSTIC CODE 2 Self-diagnostic code 2: Previous code before the DIAGNOSTIC

CODE 1

DIAGNOSTIC CODE 3 Self-diagnostic code 3: Previous code before the DIAGNOSTIC

CODE 1 and 2.

If there is no recorded self-diagnostic code, "--" is displayed.

(2) Exiting record display

• To exit the record display, press MENU/ESC button.

AS

(Example)

HP

(Example)

56

Repair Section

8. TROUBLESHOOTING

8.1 Troubleshooting

• Before troubleshooting the system, the following inspection should be performed.

WARNING

• Disconnect power supply from the unit before performing any service. Beware that some

residual voltage may remain in the unit immediately after the power is disconnected.

(1) Inspection of power source voltage

• Check the voltage of the power source.

- 1 Phase 115 V (60 Hz)

• Check the operation and condition of the fuse or circuit breaker in the power source.

(2) Inspection of power cord

• Check the power cord. If dirty, wipe off with a clean dry cloth. If damage or excess play is found,

replace it.

(3) Inspection of air filters

• Check the air filters. If dirty, clean the air filters as described in the OPERATION MANUAL

supplied with the unit. If damage is found, replace it.

(4) Inspection of drain tank

• Check the drain tank and empty the water. If damage is found, replace it.

The following pages (page 57 to 68) are self-diagnostic codes and troubleshooting information.

Repair Section

ILL00829-00

ILL00830-00

ILL00831-00

ILL00832-00

ILL00833-00

8.2 Self-Diagnostic Codes

• Self-diagnostic codes are displayed on the control panel LCD with backlight in orange color

under the following conditions. Refer to the troubleshooting chart on page 62 to 66 for the

remedies.

Self-Diagnostic Codes - Table 1

Code Condition LCD Display and Description

Alarm device connected to FA-1 and FA-2 of the terminal block 1 is

activated. The unit stops, LCD displays “AL1”, relay contact RL07 for

terminal OS-1 and OS-2 closes, and buzzer sounds.

AL1

Alarm device connected to AI-1 and AI-2 of the terminal block 1 is

activated. The unit stops, LCD displays “AL2”, relay contact RL07 for

terminal OS-1 and OS-2 closes, and buzzer sounds.

AL2

57

FL

HP

AS

Drain tank is full of water.

The unit stops, LCD displays “FL”, and relay contact RL07 for terminal

OS-1 and OS-2 closes.

High pressure protection is activated.

When the high pressure switch is activated up to 8 times in 24 hours,

LCD displays “HP”, the unit stops, and relay contact RL07 for terminal

OS-1 and OS-2 closes.

Optional condensate pump safety switch is activated.

When the optional condensate pump safety switch is activated due to any

kink and/or blockage in the drain line or due to improper routing of the

drain line, or missing short jumper connector for the optional condensate

pump, the unit stops, LCD displays “AS”, and relay contact RL07 for

terminal OS-1 and OS-2 closes.

58

< NOTE >

ILL00834-00

ILL00835-00

ILL00836-00

ILL00837-00

ILL00838-00

ILL00839-00

Repair Section

Self-Diagnostic Codes - Table 2

Code Condition LCD Display and Description

Cooling or heating function failure

When loss of cooling or heating occurs 3 times and the following

condition continues for 15 minutes, the unit stops, LCD displays “CF”,

CF

E1

E2

and relay contact RL07 for terminal OS-1 and OS-2 closes.

During Cooling operation when RTS - CTS2 < 9 °F (5 °C), and during

Heating operation (except defrost operation) when ODS - CTS3 < 2 °F (1

°C) and ODS > 50 °F (10 °C).

RTS thermistor failure

When the indoor air inlet thermistor becomes short or open, the unit

stops, LCD displays “E1”, and relay contact RL07 for terminal OS-1 and

OS-2 closes.

ODS thermistor failure

When the outdoor air inlet thermistor becomes short or open, the unit

stops, LCD displays “E2”, and relay contact RL07 for terminal OS-1 and

OS-2 closes.

E3

E4

E5

CTS1 thermistor failure

When the indoor pipe thermistor becomes short or open, the unit stops,

LCD displays “E3”, and relay contact RL07 for terminal OS-1 and OS-2

closes.

CTS2 thermistor failure

When the compressor pipe thermistor becomes short or open, the unit

stops, LCD displays “E4”, and relay contact RL07 for terminal OS-1 and

OS-2 closes.

CTS3 thermistor failure

When the outdoor pipe thermistor becomes short or open, the unit stops,

LCD displays “E5”, and relay contact RL07 for terminal OS-1 and OS-2

closes.

Use TEMP+ or -TEMP button to scroll down the LCD screen with "T" mark.

Repair Section

< NOTE >

8.3 Troubleshooting Chart

• To accurately troubleshoot the problem, it is important to carefully confirm the nature of the

problem. Common problems are:

- Insufficient cooling or heating.

- Unit does not operate.

- Overflow of drain water.

- Abnormal noise or vibrations.

(1) Insufficient cooling or heating

• Cooling or heating system problem generally results from electrical or mechanical components

such as fan motor, compressor, control switch.

• There is a possibility of insufficient cooling or heating due to clogging of the air filters. So make

sure to first check if the air filters are clogged or not.

59

• Check the power supply because of the possibility of power source failure.

• Check the installation site for operating temperature and installation space (unobstructed airflow).

60

Repair Section

Troubleshooting of Insufficient Cooling or Heating - Table 1

Condition

Insufficient Cooling

or Heating

Usage conditions

(high/low temperature)

Check Area Possible Cause Remedy

Operates near minimum or

maximum of operation

range.

Review the installation

place.

Air volume

normal

Compressor

operates.

Compressor

does not

operate.

No air

Dirt in the indoor or outdoor

heat exchanger

Frost in the refrigeration

system

No temperature difference

between indoor and outdoor

heat exchangers

Voltag e Low voltage Repair the power supply.

Compressor relay on the

relay board

Capacitor for compressor

motor

Compressor coil resistance

(0 ohm or ∞ ohm)

Fan on-off relay on the relay

board

Coil resistance of indoor or

outdoor fan motor

(0 ohm or ∞ ohm)

Insufficient heat exchange Clean the heat

exchangers.

Clogging at the frost section Service the refrigeration

system.

Insufficient refrigerant Check the leaking part,

then repair and charge

the correct amount of

refrigerant.

Open circuit or insufficient

contact surface area

Capacitor malfunction Replace the capacitor.

Short or open circuit Replace the compressor.

Open circuit or insufficient

contact surface area

Short or open circuit Replace the fan motor.

Replace the relay board.

(In case of short, check

the compressor relay.)

Replace the relay board.

Air filter Clogged air filter Clean the air filter.

Indoor or outdoor heat

Abnormal

air volume

Insufficient

air volume

exchanger

Duct connection state Improper connection Repair duct connection.

Indoor or outdoor fan motor Abnormal rotation Replace the fan motor.

Fan speed change relay on the

relay board

Clogged indoor or outdoor

heat exchanger

Crushed fins Repair or replace the

Open circuit or insufficient

contact surface area

Clean the indoor or

outdoor heat exchanger.

heat exchanger.

Replace the relay board.

Repair Section

< NOTE >

Troubleshooting of Insufficient Cooling or Heating - Table 2

Condition

Insufficient Cooling

or Heating

No hot air

during

HEAT

mode

operation

LCD display

shows

HEAT

mode, but

operates in

COOL

mode.

F1 fuse (1.5 A) F1 fuse (1.5 A) is blown. Replace the F1 fuse

4-way valve 4-way valve failure Replace the coil on the 4-

Check Area Possible Cause Remedy

(1.5 A).

way valve.

Under heating mode operation, when the room temperature is higher than 68 °F (20 °C), the low

fan speed option is deactivated and switched to medium fan speed to prevent high pressure

protection activation.

61

62

Repair Section

(2) Unit does not operate

• In this case, there is a possibility of safety device activating due to the clogged air filter. So make

sure to first clean the air filter and then start up again to confirm if the problem lies with the air

filter.

• Check the installation site for operating temperature and installation space (unobstructed

airflow).

Troubleshooting of Unit does not operate - Table 1

Condition Check Area/Diagnostic

Unit does

not operate.

No display

on LCD

screen

LCD

displays

self-

diagnostic

codes.

Possible Cause Remedy

Code

Voltag e Power failure Check and fix power supply

and connection.

Ground fault protective

breaker

LCDI power cord Power cord is tripped. Reset the power cord.

F2 fuse (1.0 A) on the relay

board

AL1 Alarm device connected to

AL2 Alarm device connected to

Ground fault protective

breaker is tripped.

Defective ground fault

protective breaker

Power cord is damaged. Replace the power cord.

F2 fuse (1.0 A) is blown. Check the F2 fuse (1.0 A) on

FA-1 and FA-2 of the

terminal block 1 is activated.

AI-1 and AI-2 of the terminal

block 1 is activated.

Reset the ground fault

protective breaker.

Repair the ground fault

section.

the relay board. If the fuse is

blown, check power supply

for short, repair the shorting

section, then replace the

fuse.

1. Check FA-1, FA-2

connection.

2. Identify and correct

condition causing the

alarm.

3. Press and hold FAN+ and -

FAN buttons for 5 seconds

to reset.

1. Check Al-1, Al-2

connection.

2. Identify and correct

condition causing the

alarm.

3. Press and hold FAN+ and -

FAN buttons for 5 seconds

to reset.

Troubleshooting of Unit does not operate - Table 2

Repair Section

63

Condition Check Area/Diagnostic

Unit does

not operate.

LCD

displays

self-

diagnostic

codes.

Possible Cause Remedy

Code

FL Drain tank is full of water. 1. Drain the water from the

tank.

2. Place the tank back in the

unit.

3. Press START/STOP

button to start.

Loose drain switch

connection.

Defective drain switch. 1. Replace the drain switch.

1. Reconnect the drain switch

and check connection.

2. Press START/STOP

button to start.

2. Press START/STOP

button to start.

64

Repair Section

Troubleshooting of Unit does not operate - Table 3

Condition Check Area/Diagnostic

Unit does

not operate.

LCD

displays

self-

diagnostic

codes.

Possible Cause Remedy

Code

HP Operating outside of the

operating temperature

range.

Air flow is blocked or

restricted.

Loose high pressure switch

connection

1. Check operating

temperature and humidity

condition. Do not use the

unit outside the operating

condition range. (See page

13.)

2. Press and hold FAN+ and -

FAN buttons for 5 seconds

to reset.

1. Clean the air filters.

2. Ensure 24 inch (610 mm)

clearance in front of the

unit air inlets and air flow is

not blocked or restricted.

3. Press and hold FAN+ and -

FAN buttons for 5 seconds

to reset.

1. Reconnect the high

pressure switch and check

connection.

2. Press and hold FAN+ and

-FAN buttons for 5

seconds to reset.

Defective electronic

expansion valve

Defective high pressure

switch (short or open)

Refrigerant is over charged. 1. Charge correct amount of

1. Replace the electronic

expansion valve.

2. Press and hold FAN+ and

-FAN buttons for 5

seconds to reset.

1. Replace the high pressure

switch.

2. Press and hold FAN+ and

-FAN buttons for 5

seconds to reset.

refrigerant. (See page 95.)

2. Press and hold FAN+ and

-FAN buttons for 5

seconds to reset.

Troubleshooting of Unit does not operate - Table 4

Repair Section

65

Condition Check Area/Diagnostic

Unit does

not operate.

LCD

displays

self-

diagnostic

codes.

Possible Cause Remedy

Code

AS Optional condensate pump

stops pumping water due to

any kinks and/or blockage in

the drain line or due to

improper routing of the drain

line.

Defective condensate pump 1. Repair or replace the

Missing or loose jumper

connector on the unit

without the condensate

pump

CF Defective compressor 1. Replace the compressor.

1. Remove any blockage or

kinks from the drain line or

improve hose installation.

2. Press and hold FAN+ and -

FAN buttons for 5 seconds

to reset.

condensate pump.

2. Press and hold FAN+ and -

FAN buttons for 5 seconds

to reset.

1. If the jumper connector is

in place, check connection.

If the jumper connector is

missing, insert the jumper

connector and check

connection.

2. Press and hold FAN+ and -

FAN buttons for 5 seconds

to reset.

2. Press and hold FAN+ and -

FAN buttons for 5 seconds

to reset.

E1 Loose RTS thermistor

connection

Defective RTS thermistor

(short or open)

E2 Loose ODS thermistor

connection

Defective ODS thermistor

(short or open)

E3 Loose CTS1 thermistor

connection

Defective CTS1 thermistor

(short or open)

Reconnect the RTS

thermistor and check

connection.

Replace the RTS thermistor.

Reconnect the ODS

thermistor and check

connection.

Replace the ODS thermistor.

Reconnect the CTS1

thermistor and check

connection.

Replace the CTS1

thermistor.

66

Repair Section

Troubleshooting of Unit does not operate - Table 5

Condition Check Area/Diagnostic

Unit does

not operate.

LCD

displays

self-

diagnostic

codes.

LCD

displays

notification.

LCD shows

normal, but

the unit does

not start.

Possible Cause Remedy

Code

E4 Loose CTS2 thermistor

connection

Defective CTS2 thermistor

(short or open)

E5 Loose CTS3 thermistor

connection

Defective CTS3 thermistor

(short or open)

OUTSIDE OPERATING

RANGE

DEFROST Unit is under defrost control. Wait until defrost control is

KEY LOCKED Buttons on the control panel

EXTERNAL THERMOSTAT

ACTIVATED

Set point temperature Room temperature

Unit is operating outside

operating range.

are locked.

Status is changed to control

by an external thermostat.

reached the set point

temperature and the unit

operation stopped.

Reconnect the CTS2

thermistor and check

connection.

Replace the CTS2

thermistor.

Reconnect the CTS3

thermistor and check

connection.

Replace the CTS3

thermistor.

Check product specification

for temperature operating

range.

Press any key to exit.

completed.

Press and hold MENU/ESC

button for 5 seconds to

unlock.

Operate the unit by an

external thermostat.

Adjust the set point

temperature.

Fan on-off relay on the relay

board

Fan speed change relay on

Unit stops

immediately

after

starting.

LCD

displays

normally.

the relay board

Fan motor insulation

resistance

Compressor relay on the

relay board

Compressor insulation

resistance

Open circuit or insufficient

contact surface area

Open circuit or insufficient

contact surface area

Insulation failure on the fan

motor

Open circuit or insufficient

contact surface area

Insulation failure on

the compressor

Replace the relay board.

Replace the relay board.

Replace the fan motor.

Replace the relay board.

Replace the compressor.

Troubleshooting of Unit does not operate - Table 6

Condition Check Area Possible Cause Remedy

Temperature of fan motor

(abnormally high)

Temperature of

compressor (abnormally

high)

Unit stops

after

running for

a while.

LCD

displays

normally.

Refrigerant leakage Insufficient refrigerant or gas

Activation of the internal

overload relay (IOLF) due to

fan motor malfunction

Activation of the overload

relay (IOLC) due to the

defective overload relay

Activation of the overload

relay (IOLC) due to the

defective compressor

leakage

Repair Section

67

Replace the fan motor.

Inspect the overload relay. If

defective, replace it.

Inspect the compressor. If

defective, replace it.

Repair and charge

refrigerant.

Dirt on indoor or outdoor

heat exchanger

Duct connection state Improper connection Repair duct connection.

(3) Overflow of drain water

Condition Check Area Possible Cause Remedy

Indoor or outdoor drain pan Cracks in the drain pan Check and replace the

Drain hole of the indoor or

Overflow of water from the

unit

outdoor drain pan

Clogged air filter Reversed air flow from the

Insufficient cooling or

heating of the heat

exchanger

Clogged drain hose Check and repair the

drain hole due to excessive

negative pressure inside of

the unit

Clean the heat exchanger.

drain pan.

drain hose.

Clean the air filter.

68

Repair Section

(4) Abnormal noise or vibration

• To prevent abnormal noise or vibration, carefully determine the source of the problem and come

up with proper countermeasures to solve the problem so that it does not occur again.

Condition Check Area Possible Cause Remedy

Indoor or outdoor fan Fan interference Repair the interfering

Abnormal noise or

vibration

Compressor nuts Loose nuts Tighten the nuts.

Piping Pipe interference Repair the interfering

Panel fixing screws Loose screws Tighten the screws.

8.4 Basic Inspection

• Perform the following inspection before disassembly.

section.

Fan deformation Replace the fan.

section.

(1) Inspection of plate fins

• To inspect the plate fins of either the indoor or

outdoor heat exchanger, the air filter must be

removed. After removal of the air filters, inspect

the plate fins for any dirt, dust, lint, or debris

that may have caused insufficient cooling or

heating performance of the unit. If cleaning of

the fins is necessary, it is recommended that

this service be performed by a qualified service

technician.

(2) Examination of operating environment

• Operating environments can vary depending on location, climate and surrounding conditions.

Installation location also can cause operational problems. Consult your dealer concerning

operational environment requirements.

I001780

Repair Section

ILL00890-00

Thermometer

Thermometer

Cool/Hot Air Out

Indoor Air In

(3) Inspection of cooling or heating performance

• Measure the difference in temperature between the inlet of the indoor heat exchanger and the

cool/heat air vent. If the difference is out of the range given in the graphs on page 19 and 24,

proceed with the remedy suggested in the troubleshooting chart on page 59 to 61.

69

70

ILL00891-00

Left Panel

Front Cater

Rear Caster

Power Cord

Indoor Drain Pan

Outdoor Drain Pan

Drain Tank Cover

Divider Panel for
Outdoor Heat
Exchanger

Drain Tank

Air Outlet Grill

Right Filter Panel

Wire Frame

Top Panel

Right Handle

Upper Front Panel

Control Panel

Drain Tank Base Plate

Service Panel

Drain Switch Wire

Right Panel

Front Filter Panel

Air Filter

Rear Panel

Left Handle

Wire Frame

Blower Assembly
(Indoor Heat Exchanger)

Air Filter

Blower Assembly
(Outdoor Heat Exchanger)

Repair Section

9. DISASSEMBLY

WARNING

• Disconnect power supply from the unit before performing any service. Beware that some

residual voltage may remain in the unit immediately after the power is disconnected.

9.1 Unit Parts Construction

9.2 Removal of Panels

ILL00892-00

Screw (1)

Screw (1)

Screws (2)

ILL00893-00

I002206

Tabs

Pivots

Repair Section

71

1) Remove the drain tank.

I002203

2) Remove four (4) screws from the upper front

panel.

3) Slide the upper front panel forward and remove.

4) Louver can be removed from the upper front

panel by unsnapping the lock tap and removing

the louver from its pivots.

72

ILL00894-00

Screws (7)

ILL00895-00

Screws (7)

Screws (2)

ILL00896-00

Screws (2)

Screws (3)

Screws (2)

Screws (3)

ILL00897-00

Screws (4)

Screws (2)

Screws (2)

Repair Section

5) Remove seven (7) screws from the service

panel.

6) Remove nine (9) screws from the rear panel.

7) Remove eight (8) screws from the rear panel and

two (2) screws from the outdoor fan casing.

8) Remove eight (8) screws from the left panel.

Repair Section

ILL00898-00

Screws (3)

Screws (4)

Screws (3)

9) Remove ten (10) screws from right panel.

73

74

ILL00863-00

Terminal Block 1 (For Power)

Relay Board

Relay Board Fuse (F2)
(1 A, 250 V)

Terminal Block 2
(For Input/Output Signal)

Terminal Block 3
(For External Thermostat)

Fuse (F1)
(1.5 A, 250 V for
4-Way Valve,
Drain Pan Heater of
Outdoor Heat Exchanger)

Compressor Motor
Capacitor

Transformer (For Relay Board)

Fan Motor Capacitor

<Service Box>

Repair Section

9.3 Removal of Electrical Parts

WARNING

• Disconnect power supply from the unit before performing any service. Beware that some

residual voltage may remain in the unit immediately after the power is disconnected.

(1) Service box

1) Remove seven (7) screws from the service panel. (See page 72.)

2) Remove the electrical parts.

- Fuse 1: Remove one (1) screw from the control box.

- Fan motor capacitors: Remove two (2) screws from the control box.

- Compressor motor capacitor: Remove two (2) screws from the control box.

- Terminal block 1: Remove two (2) from the control box.

- Terminal block 2: Remove two (2) from the control box.

- Terminal block 3: Remove two (2) from the control box.

- Transformer: Remove two (2) from the control box.

(2) Relay board

ILL00899-00

CN17: To Optional Condensate Pump

CN37: To Electronic Expansion Valve

CN30: Control Panel Board

CN03: To Transformer

CN02: To Transformer

CN01: To Terminal Block 1
(#R, T for Power)

RL09-COM

CN18: To Drain Switch,
High Pressure Switch

CN14: To ODS, CTS2, CTS3 Thermistors

CN12: To RTS, CTS Thermistors

CN31: To Terminal Block 2
(#GND, Rx, Tx, +5V for Serial Communication Port)

CN34: To Terminal Block 3 for Millivolt,
24VAC thermostat

RL01A-4

RL01A-3

RL04-NO

RL04-NC

RL04-COM

RL03-NO

RL03-NC

RL03-COM

RL02-NO

RL02-COM

CN27: To Outdoor Drain Pan Heater

CN25: To 4-Way Valve

CN26: To Terminal Block 2
(#OS-1, OS-2 for Warning Device)

RL09-NO

1) Remove nine (9) supports from the service panel. (See page 72.)

2) Disconnect twenty six (26) connectors from the relay board.

Repair Section

75

76

ILL00912-00

Screws (2)

Screws (2)

ILL00900-00

CN2 Connector

Repair Section

(3) Control panel

1) Remove four (4) screws from the control panel

stay.

2) Disconnect the CN2 connector from the control

board.

Repair Section

ILL00902-00

Old Battery

Holder

<Control Board>

ILL00903-00

Holder

<Control Board>

New Battery

(4) Battery replacement of control board

• If the clock is reset to initial setting "SUN 12:00AM" when the unit is powered on, it is time to

replace the battery on the control board.

1) Remove the old battery from the holder.

2) Insert new battery securely in the direction shown

in the diagram.

77

Specifications:

- Type: 3 V CR2032

CAUTION

When inserting the battery, make sure the

direction of polarity (plus/minus) is correct as

shown.

78

ILL00901-00

Outdoor Fan Casing

Stay for Control Panel

Indoor Wind
Direction Stay

Indoor Fan Casing

Center Panel

Indoor Fan Motor

Indoor Fan

Stay for Indoor Fan Motor

Outdoor Fan Motor

Stay for Outdoor
Fan Casing

Outdoor Fan

Ring

Repair Section

9.4 Removal of Blower Assembly

(1) Removal of outdoor fan and motor

ILL00907-00

Ring

Outdoor Fan Casing

Screws (3)

Outdoor Fan

Nuts (2)

Nuts (2)

Set Screw

ILL00908-00

Outdoor Fan Motor

Nuts (4)

Repair Section

79

1) Remove three (3) screws and take out the ring.

2) Loosen the set screw using a hex key. Then remove the outdoor fan.

3) Remove four (4) nuts and remove the outdoor fan casing.

4) Remove four (4) nuts and remove the outdoor fan motor.

80

ILL00909-00

Indoor Fan Motor

Indoor Fan

Motor Stay

Nuts (4)

Nuts (4)

Set Screw

Repair Section

(2) Removal of indoor fan and motor

1) Remove four (4) nuts from the motor stay and take out the motor stay together with the indoor

fan and motor.

2) Loosen the set screw using a hex key. Then remove the indoor fan.

3) Remove four (4) nuts from the motor stay and remove the indoor fan motor.

9.5 Inspection of Capacitor (for Fan Motor and Compressor)

(1) Ohmmeter method

• Set the ohm-meter to the 10M range. Place the

two probes against the two terminals of the

capacitor. At first, the ohm-meter should

indicate small value, then the reading should

gradually increase towards infinity. This

indicates that the capacitor is charging. If the

reading indicates infinity right away (open) or

the ohm-meter fails to move from 0. (shorted),

replace the capacitor.

I001808

Repair Section

ILL00904-00

2

NC

C

1

DS2

DS1

To CN18

Drain Switch

Top of Base Plate

ILL00866-00

CF1-1 (White)

CF1-2 (White/Brown)

RL03-NC (H) (Black)

RL03-NO (M) (Red)

RL04-NO (L) (Blue)

Ground

(Green/Yellow)

(2) Capacitance tester method

• Using a capacitance tester and the chart on page 35, test the capacitor for the value indicated.

If the value tested is not within 10 % of indicated capacitance, replace the capacitor.

WARNING

• Properly discharge the capacitor(s) before testing and after testing has been completed.

• Failure to do so could cause damage to test equipment or the unit and/or result in

personal injury (electrical shock) or death.

9.6 Inspection of Drain Switch

• Check for continuity between terminals 1 and 2

when drain switch is pressed. With drain switch

depressed, there is no continuity between

81

terminals 1 and 2. Replace drain switch if

continuity does not satisfy the above condition.

9.7 Inspection of Fan Motor

(1) Indoor fan motor

• Check resistance across the terminals of the

fan motor. (All terminals must be disconnected

from the unit.)

- High resistance between CF1-1 and CF1-2

- Medium resistance between CF1-2 and

RL03-NC (H)

- Low resistance between CF1-1 and RL03-

NC (H)

• If the resistance reading does not meet the

above conditions, replace the fan motor.

82

ILL00867-00

CF2-1 (White)

CF2-2 (White/Brown)

Ground

(Green/Yellow)

RL09-NO (Black)

I002249

C

S

R

I001701

Repair Section

(2) Outdoor fan motor

• Check resistance across the terminals of the

fan motor. (All terminals must be disconnected

from the unit.)

- High resistance between CF2-1 and CF2-2

- Medium resistance between RL09-NO and

CF2-2

- Low resistance between RL09-NO and CF2-

1

• If the resistance reading does not meet the

above conditions, replace the fan motor.

9.8 Inspection of Compressor

(1) Compressor motor

• Check resistance across the terminals of the

compressor motor. (All terminals must be

disconnected from the unit.)

- High resistance between S (Start) and R

(Run)

- Medium resistance between S (Start) and C

(Common)

- Low resistance between R (Run) and C

(Common)

• If the resistance reading does not meet the above conditions, replace the compressor.

(2) Overload relay

• Check for continuity across two terminals of the

overload relay. At normal temperature, there

should be continuity across the terminals.

Operating Temperature

OFF (open contacts) ON (closed contacts)

302 °F (150 °C)

• If there is no continuity across the terminals,

replace the overload relay.

156 °F (69 °C)

9.9 Inspection of Transformer

ILL00879-00

Secondary

20 V

<Wiring Diagram>

40 VA, 60 Hz

1

5

10

6

4

2

Primary

115 V

ILL00905-00

Secondary

Primary

Connected to
Signal Terminals
(24VAC Neutral,
24VAC Hot)

40 VA, 60 Hz

Connected to
Terminals
(R1, T1)

3

10

6

120 V 24 V

3

5

10

6

<Wiring Diagram>

(1) Transformer for relay board

• Check resistance across the terminals of the

transfomer for the relay board. (All terminals

must be disconnected from the unit.) Primary

resistance value should be between 10 to 50

times larger than the secondary resistance

value.

• If the resistance reading does not meet the

above condition, replace the transformer.

(2) Transformer (optional) for 24VAC thermostat (field supplied)

• Check resistance across the terminals of the

Repair Section

83

transformer for the 24VAC thermostat. (All

terminals must be disconnected from the unit.)

Primary resistance value should be between

10 to 50 times larger than the secondary

resistance value.

• If the resistance reading does not meet above

condition, replace the transformer.

84

ILL00906-00

76543

21

Connector Number

Wire Color

1 Red
2 Blue
3 Orange
4 Yellow
5
6

7

White
Not in use
Not in use

ILL00862-00

I003204

Repair Section

9.10 Inspection of Electronic Expansion Valve Control Coil

• Check resistance across the connector pins of

the electronic expansion valve control coil. Coil

resistance should be between 26 to 56 ohm at

room temperature.

- Between Blue and Red

- Between Orange and Red

- Between Yellow and Red

- Between White and Red

• If the resistance reading does not meet the

above condition, replace the electronic

expansion valve control coil.

9.11 Inspection of 4-Way Valve Controller Coil

• Check resistance across the connector pins of

the 4-way valve controller coil. Coil resistance

should be between 350 to 520 ohm at room

temperature.

• If the resistance reading does not meet the

above condition, replace the 4-way valve

controller coil.

9.12 Inspection of Thermistor

• Using an ohmmeter, check the resistance

value across the 2-pin connector.

• Thermistors:

- Indoor air inlet thermistor (RTS)

- Outdoor air inlet thermistor (ODS)

- Indoor pipe thermistor (CTS1)

- Compressor pipe thermistor (CTS2)

- Outdoor pipe thermistor (CTS3)

20

Thermistor Specification

15

10

5

Resistance (k ohm)

0

32

(0)41(5)50(10)59(15)68(20)77(25)86(30)95(35)

Temp.°F (°C)

104
(40)

133
(45)

122
(50)

Repair Section

9.13 Inspection of Wiring Connection

• Refer to the wiring diagram on page 33 and check the connection of each wire.

CAUTION

Secure the wires using clamps to prevent contact with the edges of the structure, etc. Secure the

wires in the same position as prior to removal.

9.14 Inspection of Refrigeration System

• In most cases, the probable cause for insufficient cooling or heating is a clog in the system, a

leakage or an incorrect amount of refrigerant. In such cases, inspect the system according to

the following procedure.

(1) Clogged refrigeration system

85

• Check the component parts of the refrigeration system, including piping, that could be clogged

with refrigerant. If clogged with refrigerant, only the clogged part is partially frosted. If this occurs,

change the part in question.

(2) Refrigerant leak

• Carefully check all connections, and each component for leaks whenever the refrigeration

system is installed or repaired. Use an electronic gas leak tester to inspect the system. (See "10.

REFRIGERATION SYSTEM REPAIR" section.)

(3) Insufficient refrigerant

• When the unit is not producing sufficient cooling or heating, follow the troubleshooting chart on

page 60 to page 61 to confirm the cause of the problem. Then, charge the system with

refrigerant to the specified amount as indicated on page 95.

86

I002225

Clearance

Clearance From The Pipe Fitting and Tubing.

0.001~0.003 in
(0.025~0.075 mm)

a

a

Repair Section

10. REFRIGERATION SYSTEM REPAIR

10.1 Repair of Refrigeration System

• In case there is a leak, obstruction, or problem in the refrigeration system of this unit, replace or

repair the part in question. After replacing any component, all connections must be brazed.

(1) Proper brazing techniques

• It is desirable to use a slightly reduced flame. Oxyacetylene is commonly used since it is easy

to judge and adjust the condition of the flame. Unlike gas welding, a secondary flame is used for

brazing. It is necessary to preheat the base metal properly depending on the shape, size or

thermal conductivity of the brazed fitting.

• The most important point in flame brazing is to bring the whole brazed fitting to a proper brazing

temperature. Care should be taken not to cause overflow of brazing filler metal, oxidization of

brazing filler metal, or deterioration due to the overheating of flux.

(2) Brazed fittings and fitting clearance

• In general, the strength of brazing filler metal is

lower than that of the base metal. So, the

shape and clearance of the brazed fitting are

quite important. As for the shape of the brazed

fitting, it is necessary to maximize its adhesive

area. The clearance of the brazed fitting must

be minimized to facilitate brazing filler metal to

flow into it by capillary action.

(3) Cleaning brazing filler metal and pipe

• When the refrigeration system has been opened up, exposure to heat may have caused brazing

filler metal to stick to the inside and outside of the pipe. Brazing filler metal may also be

compounded with oxygen in the air to form oxide film. Fats and oils may stick to the pipe from

handling. All these factors can reduce effectiveness of brazing. It is necessary to eliminate

excess brazing filler metal using sand paper and by cleaning thoroughly with a solvent such as

trichlene.

CAUTION

Do not use chlorine cleaner.

Repair Section

< NOTE >

I000564

Burner

45°

Tube

Brazing Filler Metal

Vertical Down Joint

I001725

Burner

45°

Tube

Brazing Filler Metal

Vertical Up Joint

(4) Use of dry nitrogen gas

• During brazing, the inside of the pipe undergoes an oxidative reaction due to the brazing flame.

Introduce dry nitrogen gas (0.27 gal/min (1 L/min); adjust with the flow regulator) through the

pinch-off tube of the refrigerant.

Take care not to allow dirt, water, oil, etc. to enter into the pipe.

(5) Vertical Joint

• Heat the whole brazed fitting to a proper

brazing temperature. Bring the brazing filler

metal into contact with the fitting so that the

brazing filler metal starts flowing by itself.

• Stop heating the fitting as soon as the brazing

87

filler metal has flown into the clearance. Since

the brazing filler metal flows easily into the

portion heated to a proper temperature, it is

essential to keep the whole fitting at a proper

brazing temperature.

88

< NOTE >

ILL00910-00

Compressor A, B

A, B, C, D

C, F, G, H

N, O

C, D

E

Indoor Heat Exchanger

Outdoor Heat Exchanger

High Pressure Switch

Electronic Expansion Valve

Distributor

Part to Replace Disconnect At

C

Pipe 1

Pipe 2

E

B

Tube 2

N

Tube 1

O

A

D

F

G

H

Repair Section

10.2 Removal of Refrigeration Cycle Components

WARNING

• Before replacing any refrigeration cycle component, recover the refrigerant using

standard recovery procedures and equipment.

• When recovering the refrigerant, use the pinch-off tubes at the low pressure side (tube 1)

and high pressure side (tube 2) as shown in the figure below.

CAUTION

• To prevent oxidation, dry nitrogen should be conducted (flow rate 0.27 gal/min (1 L/min)) through

the pinch-off tube during any brazing operation.

• During any component replacement involving brazing, shield nearby parts with a steel plate, etc.,

to protect them from the flame.

When replacing the compressor, attach the pipe 1 and the pipe 2 packaged in the compressor

assembly.

Repair Section

ILL00914-00

I, J, K, L

M

(Remove one screw.)

P

(Pull up from the clip.)

Part to Replace Disconnect At

Electronic Expansion
Valve Controller

4-Way Valve

4-Way Valve Controller

Pipe Assembly D, Q, R, S

A, B, D, T

C, U

Pipe Assembly with High
Pressure Switch and
4-Way Valve

Pipe Assembly with
Electronic Expansion Valve

C

B

M

L

I

K

J

T

P

Q

R

S

A

D

U

89

90

ILL00084-00

Step 1

Step 5

Step 6

Step 4

Step 3

Step 2

Connect manifold gauge.

1) Evacuate the system.

• 15 minutes or more.

• 30 inHg (100 kPa) or more of vacuum.

2) Stop evacuating the system.

• Leave for 5 minutes.

3) Check the vacuum.

When leak is found,
repair the connection
or components.

Charge the system with R-410A.

• See “Technical Specifications” for the specified amount.

Remove manifold gauge.

Test the system for leaks.

Connect to refrigerant source.

Repair Section

10.3 Charging the System with R-410A Refrigerant

• Always ensure that the refrigeration system has been properly evacuated before charging with

the specified amount of R-410A.

• Equipments is only for R-410A.

• Liquid charge (no gas charge).

• Make sure not to use more than 90 % of the initial weight of R-410A in the cylinder.

WARNING

• When handling refrigerant (R-410A), the following precautions should always be

observed:

- Always wear proper eye protection while handling refrigerant.

- Maintain the temperature of the refrigerant container below 104 °F (40 °C).

- Perform repairs in a properly ventilated area. (Never in an enclosed environment.)

- Do not expose refrigerant to an open flame.

- Never smoke while performing repairs, especially when handling refrigerant.

- Take caution so that the liquid refrigerant does not come in contact with the skin.

• If liquid refrigerant strikes eye or skin:

- Do not rub the eye or the skin.

- Splash large quantities of cool water on the eye or the skin.

- Apply clean petroleum jelly to the skin.

- Go immediately to a physician or to a hospital for professional treatment.

(1) Connection of gauge manifold

< NOTE >

I002183

Pinch-Off Tube

Seal

Charging Hose
Side

Refrigerant
Cycle Side

I000568

High Pressure Valve
(Closed)

High Pressure
Side Tube

Vacuum Pump
(when stopped)

Low Pressure
Valve (Closed)

Red Hose

Green Hose

Process Tube Fitting

I002227

LO

ClosedHIOpenLOClosedHIClosed

Valve Setting

30 inHg (100 kPa) or larger

High Pressure Valve

High Pressure Gauge

Gauge

High Pressure
Side Tube

Vacuum Pump
(in Operation)

Low Pressure
Val ve

Repair Section

91

1) Properly remove the crushed end of the pinch-off

tube at the high pressure side and the low

pressure side of the refrigerant cycle with a pipe

cutter.

2) Fit the process tube fitting to the pinch-off tube on

both sides.

3) Connect the charging hoses (red-high pressure

side) for the gauge manifold to the process tube

fitting.

(2) Evacuation

Connect the hoses using care not to mistake

the high pressure side for the low pressure side

and vice versa.

4) Connect the charging hose (green) at the center

of the gauge manifold to the vacuum pump.

1) Open the high pressure valve (Hl) of the gauge

manifold.

2) Turn on the vacuum pump to start evacuation.

(Evacuate the system for approximately 15

minutes.)

3) When the low pressure gauge indicates 30 inHg

(100 kPa) or larger, turn off the vacuum pump

and close the high pressure valves of the gauge

manifold.

92

ILL00085-00

Return

Pipe Brazing

LO

ClosedHIClosed

Valve Setting

Pressure Gauge

Repair Section

(3) Checking vacuum

1) Leave the high pressure valve and the low

pressure valve of the gauge manifold closed for 5

minutes or more, and confirm that the gauge

pointer does not return to zero.

2) If the gauge pointer returns gradually to zero

there is a leak somewhere in the system (this

could also include gauge manifold). Perform leak

check according to procedure indicated in the

next step. Once leak has been found and

repaired, evacuate the system once more and

confirm the system holds vacuum.

(4) Checking gas leak

I001901

Open The Valve
of Refrigerant
Cylinder

To Process Tube Fitting

Charging Hose
(Green)

Refrigerant

Cylinder R-410A

Red

LO

ClosedHIClosed

Valve Setting

Air Purging

I002228

LO

ClosedHIOpen

LO

ClosedHIClosed

Refrigerant

Cylinder R-410A

Valve Setting

Gauge Reading

57 psi

(390 kPa)

Open High Pressure
Val ve

High Pressure
Side Tube

Low Pressure
Valve (Closed)

Process Tube Fitting

Refrigerant
Cylinder
Val ve
(Open)

Repair Section

93

1) Remove the charging hose (green) from the

vacuum pump, and connect the hose to the

refrigerant cylinder (R-410A).

2) Loosen the nut on the gauge manifold side of the

charging hose (green).

3) Open the valve of refrigerant cylinder and

perform air purging in the charging hose (green).

Then tighten the nut.

4) Open the high pressure valve of the gauge

manifold. Charge the system with refrigerant until

the low pressure gauge indicates 57 psi

(0.39 kPa). After charging is complete, close the

high pressure valve.

5) Open the valve of refrigerant cylinder and

perform air purging in the charging hose (green).

Then tighten the nut.

6) Check carefully for gas leaks inside the

refrigeration system using the gas leak tester.

7) Repair any leak.

WARNING

Any repair on a charged system should be

performed by a licensed professional only.

WARNING

Before checking for gas leaks, fully confirm

that there is nothing flammable in the area

to cause an explosion or fire. Contact of

refrigerant with an open fire generates

toxic gas.

94

< NOTE >

I002227

LO

ClosedHIOpenLOClosedHIClosed

Valve Setting

30 inHg (100 kPa) or larger

High Pressure Valve

High Pressure Gauge

Gauge

High Pressure
Side Tube

Vacuum Pump
(in Operation)

Low Pressure
Val ve

Repair Section

(5) Evacuation (repeat)

1) Close the valve of the refrigerant cylinder. Then

remove the charging hose (green) from the

refrigerant cylinder, and connect it to the

refrigerant recovery machine.

Keep the high pressure valve and the low

pressure valve of the gauge manifold closed.

2) Using procedure in the “Evacuation”, evacuate

the system until the low pressure gauge indicates

30inHg (100 kPa) or larger. (For 15 minutes or

more.)

3) After evacuation is complete, close the high and

the low pressure valves of the gauge manifold.

CAUTION

Make sure to evacuate the system twice or

more using the repetitive vacuum method.

Evacuate the system an additional time on

rainy or humid days.

10.4 Refrigerant Charging Work

I001901

Open The Valve
of Refrigerant
Cylinder

To Process Tube Fitting

Charging Hose
(Green)

Refrigerant

Cylinder R-410A

Red

LO

ClosedHIClosed

Valve Setting

Air Purging

I001903

LO

ClosedHIOpen

LO

ClosedHIClosed

Refrigerant

Cylinder R-410A

Valve Setting

Specified Amount

of Refrigerant

High Pressure Valve

High Pressure
Side Tube

Process Tube Fitting

Valve of
Refrigerant
Cylinder

Weight

(1) Refrigerant charging

Repair Section

95

1) Remove the charging hose (green) from the

vacuum pump, and connect it to the refrigerant

cylinder

(R-410A).

2) Loosen the nut on the gauge manifold side of the

charging hose (green). Open the valve of the

charging hose (green). Open the valve of the

refrigerant cylinder. After air purging, tighten this

nut and close the valve of the refrigerant cylinder.

3) Securely place the refrigerant cylinder on a scale

with a weighing capacity of 70 lb (30 kg) that is

graduated by 0.2 oz (5 g).

4) Open the high pressure valve of the gauge

manifold and the valve of the refrigerant cylinder.

Charge the system with refrigerant to the

specified amount.

Standard Amount of Refrigerant:

1.94 lb (0.88 kg)

CAUTION

The amount of refrigerant charged has a great

effect on the cooling and heating capacity of

the unit. Charge to the specified amount,

always observing the scale graduations while

charging.

5) Close the high pressure valve of the gauge

manifold and the valve of the refrigerant cylinder.

96

I002185

Pinch-Off Tube

Pinch-Off Tool

Process Tube Fitting

Charging Hose

To Gauge
Manifold Side

To Refrigerant
Cycle Side

Repair Section

(2) Removal of gauge manifold

1) Crimp the pinch-off tube with a pinch-off tool.

2) Remove the gauge manifold and the process

tube fitting. Crush the end of the pinch-off tube.

3) Braze the end of the pinch-off tube.

4) Ensure that a gas leak is not present at the

pinched off portion and the brazed end.

Repair Section

ILL00178-00

Nut

Steel Collar

Cushion

Plate Washer

ILL00913-00

Set Screw

11. REASSEMBLY

11.1 Removal of Unit

• Reassemble the unit in the reverse order of removal. Described below are the parts that require

special care in reassembling the unit. Perform all wiring or rewiring as referenced in the wiring

diagram.

11.2 Compressor Mounting

• Mount the compressor on the frame, using

cushions, steel collars, plate washers and nuts.

97

11.3 Blower Assembly

11.4 Wiring Notice

• Secure the wires using clamps so that they do not come into contact with the edges of the

structure. Secure the wires using clamps in the same position they were before removal.

• Tighten the set screws of indoor and outdoor fans

at the torque shown below.

CAUTION

• Tightening torque:

- 10.84 ± 2.17 ft•lbf (15 ± 2.7 N•m)

98

< NOTE >

Repair Section

11.5 Perform the Inspection

• Perform the inspection of cooling and heating performance and check for abnormal noise or

vibration.

11.6 Caster Maintenance

• Lubricate bearings in caster as needed with standard bearing grease using the zerk fitting.

Casters should roll and swivel freely. Check for dirt or dust build up. Remove dust or dirt build up.

P/N: SV0082-00

First Issue: December 2014