Cooper & Hunter AIR-MASTER Series Service Manual Download Page 54 | Manualshive

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Installation and Maintenance

Service Manual

11.2 Removal Procedure of Outdoor Unit

18K

1. Before disassembly

2. Remove big handle

Remove the connection screw fixing the big

handle and then remove the handle.

3. Remove top cover plate

Remove connection screws connecting the top

panel with the front panel and the right side plate,

and then remove the top panel.

big handle

top panel

Steps

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Summary of Contents for AIR-MASTER Series

Page 1: ... Conditioner AIR MASTER Series MODELS SERVICE MANUAL Designed by Cooper Hunter International Corporation Oregon USA www cooperandhunter com For proper operation please read and keep this manual carefully CH S18RX4 CH S24RX4 EN ...

Page 2: ...Control 14 6 1 Remote Controller Introduction 14 6 2 Brief Description of Modes and Functions 18 Part Ⅱ Installation and Maintenance 23 7 Notes for Installation and Maintenance 23 8 Installation 25 8 1 Installation Dimension Diagram 25 8 2 Installation Parts checking 27 8 3 Selection of Installation Location 27 8 4 Electric Connection Requirement 27 8 5 Installation of Indoor Unit 27 8 6 Installat...

Page 3: ...1 Removal Procedure 46 11 1 Removal Procedure of Indoor Unit 46 11 2 Removal Procedure of Outdoor Unit 51 Appendix 61 Appendix 1 Reference Sheet of Celsius and Fahrenheit 61 Appendix 2 Configuration of Connection Pipe 61 Appendix 3 Pipe Expanding Method 62 Appendix 4 List of Resistance for Temperature Sensor 63 ...

Page 4: ...1 Technical Information Service Manual 1 Summary Part Ⅰ Technical Information Indoor Unit Outdoor Unit 18K 24K Remote ControlIer ...

Page 5: ... HSPF W W Application Area m3 141 Indoor Unit Model of indoor unit Fan Type Cross flow Diameter Length DXL mm Φ98X710 Fan Motor Cooling Speed SH H M L SL r min 1350 1200 1050 900 Fan Motor Heating Speed SH H M L SL r min 1420 1250 1150 1050 Output of Fan Motor W 20 Fan Motor RLA A 0 31 Fan Motor Capacitor μF 1 5 Input of Heater W Evaporator Form Aluminum Fin copper Tube Pipe Diameter mm Φ7 Row fin...

Page 6: ...r Speed rpm 770 Output of Fan Motor W 35 Fan Motor RLA A 0 3 Fan Motor Capacitor μF 2 5 Air Flow Volume of Outdoor Unit m3 h 1800 Fan Type Axial flow Fan Diameter mm Φ394 5 Defrosting Method Automatic Defrosting Climate Type T1 Isolation I Moisture Protection IP24 Permissible Excessive Operating Pressure for the Discharge Side MPa 4 3 Permissible Excessive Operating Pressure for the Suction Side M...

Page 7: ...186 Indoor Unit Model of indoor unit Fan Type Cross flow Diameter Length DXL mm Φ98X710 Fan Motor Cooling Speed SH H M L SL r min 1350 1200 1050 900 Fan Motor Heating Speed SH H M L SL r min 1420 1250 1150 1050 Output of Fan Motor W 20 Fan Motor RLA A 0 31 Fan Motor Capacitor μF 1 5 Input of Heater W Evaporator Form Aluminum Fin copper Tube Pipe Diameter mm Φ7 Row fin Gap mm 2 1 4 Coil Length LXDX...

Page 8: ... mm 613X38 1X660 Fan Motor Speed rpm 780 Output of Fan Motor W 68 Fan Motor RLA A 0 75 Fan Motor Capacitor μF 2 5 Air Flow Volume of Outdoor Unit m3 h 2800 Fan Type Axial flow Fan Diameter mm Φ460 Defrosting Method Automatic Defrosting Climate Type T1 Isolation I Moisture Protection IP24 Permissible Excessive Operating Pressure for the Discharge Side MPa 3 8 Permissible Excessive Operating Pressur...

Page 9: ...24 18K 0 8 0 9 in 8 11 out 11 12 in 75 85 out 37 43 Super High High 24K 0 8 1 0 in 8 11 out 11 14 in 75 85 out 36 43 Rated heating condition C DB WB Model Pressure of gas pipe connecting indoor and outdoor unit Inlet and outlet pipe temperature of heat exchanger Fan speed of indoor unit Fan speed of outdoor unit Indoor Outdoor P MPa T1 C T2 C 20 7 6 18K 2 7 2 9 in 75 85 out 37 43 in 1 3 out 3 4 Su...

Page 10: ...7 Technical Information Service Manual 3 Outline Dimension Diagram 3 1 Indoor Unit 694 945 211 298 196 55 38 116 45 2XΦ55 Unit mm ...

Page 11: ...8 Technical Information Service Manual 3 2 Outdoor Unit 848 257 540 286 320 762 540 18K 24K 847 300 913 680 378 549 348 Unit mm Unit mm ...

Page 12: ...nit Outdoor unit COOLING HEATING Accumlator 4 Way valve COOLING Discharge Suction Heat exchanger evaporator Heat exchanger condenser Valve Valve Valve side Liquid pipe side Gas pipe side Compressor Strainer Strainer Capillary Strainer Capillary Connection pipe specification Liquid 1 4 6 mm Gas 1 2 12 mm ...

Page 13: ... OG Orange Note Jumper cap is used to determine fan speed and the swing angle of horizontal lover for this model 18K L 4 COMP 3 BU BK VT OG POWER EVAPORATOR PE PE EARTH PLATE BU BK XT VT OG 5 4 2 N 1 OUTDOOR UNIT CAP JUMP AP1 PRINTED CIRCUIT BOARD RT2 RT1 AP2 BU WH BN BK YEGN GN CONNECTING CABLE TEMP ROOM SENSOR YEGN YEGN TERMINAL BLOCK TEMP TUBE SENSOR M1 PGF PG FANMOTOR DISPLAYBOARD RECEIVERAND ...

Page 14: ...EARTH PLATE OFAN 4V 5 4 XT 2 N 1 OUTDOOR UNIT CAP JUMP AP1 PRINTED CIRCUIT BOARD ROOM RT2 RT1 TUBE SENSOR ROOM SENSOR TUBE BN BK BU WH L BU BK N YEGN GN N1 L101 RECEIVERAND DISPLAYBOARD DISP2 AP2 DISP1 TERMINAL CABLE BLOCK CONNECTING POWER TEMP TEMP M2 SWING UD STEPPINGMOTOR SWING M1 FANMOTOR PG PGF L AC L 0 0 ...

Page 15: ...12 Technical Information Service Manual Outdoor Unit 18K These wiring diagrams are subject to change without notice please refer to the one supplied with the unit YEGN 24K ...

Page 16: ...13 Technical Information Service Manual 5 2 PCB Printed Diagram Top view Bottom view 1 2 3 4 5 6 7 8 9 10 No Name 11 12 13 14 15 16 ...

Page 17: ...link once and the air conditioner will give out a de sound which means the signal has been sent to the air conditioner Under off status set temperature and clock icon will be displayed on the display of remote controller If timer on timer off and light functions are set the corresponding icons will be displayed on the display of remote controller at the same time Under on status the display will s...

Page 18: ...ontroller If remote controller sends the following three kinds of status that the swing status of main unit will be When the guide louver start to swing up and down if turn off the Swing the air guide louver will stop at current position which indicates the guide louver swings up and down between that all five positions 6 CLOCK Button Press this button the clock can be set up signal blink and disp...

Page 19: ...played firstly before display of H1 after 5 seconds Operation guide General operation 1 After putting through the power press ON OFF button on remote controller to turn on the air conditioner in AUTO FAN or HEAT mode 9 TEMP Button a Press this button could select displaying the indoor setting temperature or indoor ambient temperature When the indoor unit firstly power on it will display the settin...

Page 20: ...hown in the fig and then push out the cover of battery box along the arrow direction 2 Replace two 7 AAA 1 5V dry batteries and make sure the position of polar and polar are correct 3 Reinstall the cover of battery box Replacement of Batteries in Remote Controller battery Cover of battery box remove reinstall 2 Press MODE button to select your required mode AUTO COOL DRY FAN HEAT 3 Press or button...

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Page 23: ...al Information Service Manual Tpreset 4 Tpreset 2 Stop heating Original operating status Start heating valve Outdoor unit Intdoor unit Compressor min min min Tamb n i m n i m Set fan speed Set fan speed Reversing ...

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Page 25: ...22 Technical Information Service Manual E5 U8 Overcurrent protection Zero crossing inspection circuit malfunction of the IDU fan motor ...

Page 26: ...allation and maintenance 5 Have the unit adequately grounded The grounding wire can t be used for other purposes 6 Must apply protective accessories such as protective boards cable cross loop and wire clip 7 The live wire neutral wire and grounding wire of power supply must be corresponding to the live wire neutral wire and grounding wire of the air conditioner 8 The power cord and power connectio...

Page 27: ...ing tape 4 Electroprobe 7 Electronic leakage detector 10 Pipe pliers pipe cutter 2 Screw driver 5 Universal meter 8 Vacuum pump 11 Pipe expander pipe bender 3 Impact drill drill head electric drill 6 Torque wrench open end wrench inner hexagon spanner 9 Pressure meter 12 Soldering appliance refrigerant container ...

Page 28: ...At least 15cm At least 50cm At least 50cm At least 30cm At least 300cm At least 200cm Space to the obstruction Space to the obstruction Space to the obstruction Space to the ceiling Space to the obstruction Space to the obstruction At least 30cm At least 15cm At least 15cm Space to the wall Space to the wall Space to the wall ...

Page 29: ...oor unit Make the bound pipes pass through the wall hole and then connect outdoor unit Neaten the pipes Vacuum pumping and leakage detection Check after installation and test operation Finish installation Note this flow is only for reference please find the more detailed installation steps in this section Select outdoor unit installation location Install the support of outdoor unit select it accor...

Page 30: ...ecialized grounding device by a professional Please make sure it is always grounded effectively otherwise it may cause electric shock 2 The yellow green wire in air conditioner is grounding wire which can t be used for other purposes 3 The grounding resistance should comply with national electric safety regulations 4 The appliance must be positioned so that the plug is accessible 5 An all pole dis...

Page 31: ...o the wall above Space to the wall above Φ55mm 3 Install Wall mounting Frame 1 Choose the position of piping hole according to the direction of outlet pipe The position of piping hole should be a little lower than the wall mounted frame As show in Fig 1 2 Open a piping hole with the diameter of Φ55 on the selected outlet pipe position In order to drain smoothly slant the piping hole on the wall sl...

Page 32: ...n order to prevent blocking 7 Connect Wire of Indoor Unit 1 Open the panel remove the screw on the wiring cover and then take down the cover As show in Fig 11 8 Bind up Pipe 1 Bind up the connection pipe power cord and drain hose with the band As show in Fig 14 2 Reserve a certain length of drain hose and power cord for installation when binding them When binding to a certain degree separate the i...

Page 33: ... to the color fix them with screws As show in Fig 23 6 Neaten the Pipes 1 The pipes should be placed along the wall bent reasonably and hidden possibly Min semidiameter of bending the pipe is 10cm 2 If the outdoor unit is higher than the wall hole you must set a U shaped curve in the pipe before pipe goes into the room in order to prevent rain from getting into the room As show in Fig 24 2 Fix the...

Page 34: ...t It may cause condensation and water dripping 4 Is water drained well It may cause condensation and water dripping 5 Is the voltage of power supply according to the voltage marked on the nameplate It may cause malfunction or damage the parts 6 Is electric wiring and pipeline installed correctly It may cause malfunction or damage the parts 7 Is the unit grounded securely It may cause electric leak...

Page 35: ...U fan ODU fan compressor and electric heat tube stop operation Horizontal louver stops at the current position 1 The feedback terminal of PG motor is not connected tightly 2 The control terminal of PG motor is not connected tightly 3 Fan blade rotates unsmoothly 4 Malfunction of motor 5 Main board is broken 4 Malfunction protection of jumper cap C5 Blinks 15 times every 3s Operation of remote cont...

Page 36: ...r loosened or poorly contacted Insert the temperature sensor tightly yes Is malfunction eliminated Is there short circuit due to trip over of the parts Make the parts upright yes Is malfunction eliminated Replace the mainboard with the same model End no no Is the temperature sensor normal according to the Resistance Table no Replace it with a temperature sensor with the same model no yes yes Is ma...

Page 37: ...otor correctly Is malfunction eliminated no no yes yes Turn on the unit again measure whether the output voltage on control terminal for PG motor is more than 50V within 1 min after the louvers are opened no yes yes Is the motor started up no Is malfunction eliminated yes yes yes no yes Is malfunction eliminated Tighten the screw reassemble the blade motor and shaft bearing rubber base sub assy to...

Page 38: ...per cap inserted correctly and tightly Replace the jumper cap with the same model End yes yes Assemble the jumper cap with the same model no Is malfunction eliminated no yes Insert the jumper cap tightly Is malfunction eliminated no no yes Is malfunction eliminated no yes Replace the mainboard with the same model 3 Malfunction of Protection of Jumper Cap C5 ...

Page 39: ... shell too high etc Is the indoor outdoor heat exchanger too dirty or are the air inlet and outlet blocked Normal fluctuation is within 10 of the rated voltage on the nameplate Malfunction is eliminated no yes no yes no yes no no no yes no yes no yes yes yes yes yes yes yes Malfunction is eliminated Malfunction is eliminated Malfunction is eliminated Malfunction is eliminated Malfunction is elimin...

Page 40: ...g for U8 malfunction Re energize1 minute after de erergization U8 is still displayed The unit returns to normal Conclusion U8 is displayed due to instant energization afte de energization while the capacitor discharges slowly The zero cross detection circuit of the mainboard is defined abnormal Replace the mainboard with the same model End No Yes ...

Page 41: ... operate Refer to point 4 of maintenance method for details Malfunction of compressor Compressor can t operate Refer to point 5 of maintenance method for details 1 Air Conditioner Can t be Started Up 2 Poor Cooling Heating for Air Conditioner 3 Horizontal Louver Can t Swing Possible Causes Discriminating Method Air conditioner Status Troubleshooting No power supply or poor connection for power plu...

Page 42: ...in pipe Replace drain pipe Wrapping is not tight Water leaking from the pipe connection place of indoor unit Wrap it again and bundle it tightly 5 Compressor Can t Operate Possible causes Discriminating method air conditioner status Troubleshooting Wrong wire connection or poor connection Check the wiring status according to circuit diagram Connect wires according to wiring diagram to make sure al...

Page 43: ... Installation and Maintenance Service Manual 10 Exploded View and Parts List 10 1 Indoor Unit 2 3 4 5 6 7 8 9 21 18 19 20 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 1 10 11 12 14 13 16 15 17 ...

Page 44: ...1 16 Evaporator Assy 01002937 01002675 1 17 Evaporator Support 24212133 24212133 1 18 Pipe Clamp 2611216401 2611216401 1 19 Motor Press Plate 26112494 26112494 1 20 Fan Motor 15012146 15012146 1 21 Wall Mounting Frame 01252218 01252218 1 22 Drainage Hose 05230014 05230014 1 23 Step Motor 15012086 15012086 1 24 Crank 10582070 10582070 1 25 Air Louver 2 1051211702 1051211702 1 26 Axile Bush 10542036...

Page 45: ...42 Installation and Maintenance Service Manual 10 2 Outdoor Unit 22 23 1 2 3 5 6 8 10 11 12 13 14 15 16 18 19 20 21 24 25 26 27 28 4 9 7 17 18K ...

Page 46: ...ssy 03163101 1 11 Right Side Plate Assy 0130200404 1 12 Valve 07100004 1 13 Valve 07100006 1 14 Big Handle 26233433 1 15 Valve Support 01713041 1 16 Terminal Board 42010265 1 17 Electric Box Sub Assy 01403117 1 18 Capacitor CBB65 3300008108 1 19 Capacitor CBB61 33010026 1 20 Terminal Board 42010265 21 Electric Box Assy 02613325 1 22 Rear Grill 11123205 1 23 Condenser Assy 01163672 1 24 Top Cover P...

Page 47: ...44 Installation and Maintenance Service Manual 11 21 23 20 10 9 8 7 6 1 3 4 5 12 13 14 16 17 18 19 22 15 2 24K ...

Page 48: ... Cover 01255001 1 8 Clapboard Sub Assy 01233035 1 9 Electric Box Assy 02613155 1 10 Condenser Assy 01163524 1 11 Rear Grill 01473069 1 12 Capacitor CBB61 33010026 1 13 Capacitor CBB65 3300008105 1 14 Terminal Board 5 42010194 1 Terminal Board 1 42011147 1 15 Right Side Plate 01305095P 1 16 Handle 26235253 1 17 Valve Support Sub Assy 01713075 1 18 Valve 07130213 1 19 Valve 07100003 1 20 Capillary S...

Page 49: ...edure of Indoor Unit Caution discharge the refrigerant completely before removal Steps Procedure 1 Before disassembly Open the front panel to remove it Remove axial sleeve of horizontal louver and bend the louver slightly Then remove the louver b c a Filter Horizontal louver Axile Bush ...

Page 50: ...ction screw of indicator and then remove the indicator Remove connection screws between electric box cover 2 and front case Then remove the electric box cover 2 a Screw b 4 Removal of electric box cover 2 Remove rotating shaft of front panel and then remove the front panel Front Panel Assy Indicator Screw Electric Box Cover 2 ...

Page 51: ...ouver 5 Removal of front case 6 Removal of vertical louver Screw Clasp Remove connection screws between front case and rear case Release clasp connecting front case and rear case and then remove the front case Remove 10 clasps of vertical louver and rear case assy b a a b Vertical Louver Clasp ...

Page 52: ...ator Unplug indoor temp sensor Remove connection screws of electric box assy and rear case Release clasps and remove connection screws of earthing wire and evaporator assy Then remove electric box assy Turn over the rear case assy and remove connecting pipe clamp Release clasps between connecting pipe clamp and rear case assy Then remove connecting pipe clamp b a a b Pipe Clamp Indoor Temp Sensor ...

Page 53: ... the motor 9 Removal of cross flow fan and motor Remove screws of step motor and then remove the motor Remove 4 connection screws of motor clamp and rear case Then remove motor clamp Removal of ring of bearing sub assy b d a e Remove cross flow fan and motor c Step Motor Motor Press Plat Ring of Bearing Cross Flow Fan Fan Motor O Gasket Sub assy of Bearing ...

Page 54: ...Before disassembly 2 Remove big handle Remove the connection screw fixing the big handle and then remove the handle 3 Remove top cover plate Remove connection screws connecting the top panel with the front panel and the right side plate and then remove the top panel big handle top panel Steps ...

Page 55: ...t grille 5 Remove front panel Remove connection screws connecting the front panel with the chassis and the motor support and then remove the front panel 6 Remove right side plate Remove connection screws connecting the right side plate with the valve support and the electric box Then remove the right side plate Steps front grille front panel right side plate ...

Page 56: ...ing the motor and disconnect the leading wire insert of the motor Then remove the motor Remove the 2 tapping screws fixing the motor support and lift the motor support to remove it 9 Remove electric box Remove screws fixing the electric box subassembly loosen the wire bundle and unplug the wiring terminals Then lift the electric box to remove it motor motor support electric box axial flow blade St...

Page 57: ...crews fixing the isolation sheet and then remove the isolation sheet 11 Remove soundproof sponge Remove the soundproof sponge wrapping the compressor 12 Remove magnet coil Remove the screw fixing the magnet coil and then remove the coil isolation sheet soundproof sponge magnet coil Steps ...

Page 58: ...h welding slag during unsoldering Remove the 2 screws fixing the gas valve and unsolder the welding joint between the gas valve and the air return pipe to remove the gas valve NOTE Discharge the refrigerant completely before unsoldering when unsoldering wrap the gas valve with a wet cloth completely to avoid damage to the valve caused by high temperature Remove the 2 screws fixing the liquid valve...

Page 59: ...w fixing the handle and then remove the handle Remove screws fixing the top panel and the grille respectively and then remove the top panel and the grille top panel grille handle screw Steps 1 Before disassembly 2 Remove handle 3 Remove top panel and grille Procedure ...

Page 60: ... grille Remove screws connecting the front panel with the chassis and the motor support and then remove the right side plate Remove nut fixing the blade and then remove the blade screw right side plate axial flow blade nut screw screw panel rear guard grille screw Steps 4 Remove front panel and rear guard grille 5 Remove right side plate 6 Remove axial flow blade Procedure ...

Page 61: ... the soundproof sponge wrapping the compressor Remove the 2 screws fixing the electric box loosen the wire bundle pull out the wiring terminals and then pull electric box upwards to remove it screw motor support motor electric box assy soundproof sponge Steps 7 Remove motor and motor support 8 Remove electric box 9 Remove soundproof sponge Procedure ...

Page 62: ...the compressor the condenser the gas valve and the liquid valve connected to the compressor at first NOTE Before unsoldering the joints discharge the refrigerant completely Remove the 3 foot nuts fixing the compressor with wrench and then remove the compressor screw solenoid coil 4 way valve assy nut compressor gas valve liquid valve Steps 10 Remove solenoid coil 11 Remove compressor Procedure ...

Page 63: ...the isolation sheet Remove screws fixing the valve support and then remove the valve support Remove the screw fixing the condenser and then pull the condenser upwards to remove it screw screw isolation sheet condenser valve support Steps 12 Remove isolation sheet 13 Remove valve support and condenser Procedure ...

Page 64: ... 56 55 4 13 79 80 78 8 26 34 35 33 8 1 57 58 57 2 14 81 80 6 27 36 35 6 2 59 60 59 15 82 83 82 4 28 37 38 37 4 3 61 62 60 8 16 84 85 84 2 29 39 40 39 2 4 63 62 6 17 86 87 86 30 41 42 41 5 64 65 64 4 18 88 89 87 8 31 43 44 42 8 6 66 67 66 2 19 90 89 6 32 45 44 6 7 68 69 68 20 91 92 91 4 33 46 47 46 4 8 70 71 69 8 21 93 94 93 2 34 48 49 48 2 9 72 71 6 22 95 96 95 35 50 51 50 10 73 74 73 4 23 97 98 9...

Page 65: ...Cut the pip Confirm the pipe length according to the distance of indoor unit and outdoor unit Cut the required pipe with pipe cutter B Remove the burrs Remove the burrs with shaper and prevent the burrs from getting into the pipe C Put on suitable insulating pipe D Put on the union nut Remove the union nut on the indoor connection pipe and outdoor valve install the union nut on the pipe E Expand t...

Page 66: ...8 6 66 88 33 10 63 72 2 439 111 0 737 5 63 46 34 10 2 73 2 358 112 0 717 4 60 23 35 9 779 74 2 28 113 0 697 3 57 18 36 9 382 75 2 206 114 0 678 2 54 31 37 9 003 76 2 133 115 0 66 1 51 59 38 8 642 77 2 064 116 0 642 0 49 02 39 8 297 78 1 997 117 0 625 1 46 6 40 7 967 79 1 933 118 0 608 2 44 31 41 7 653 80 1 871 119 0 592 3 42 14 42 7 352 81 1 811 120 0 577 4 40 09 43 7 065 82 1 754 121 0 561 5 38 1...

Page 67: ... 0 983 5 84 61 34 13 59 73 3 144 112 0 956 4 80 31 35 13 04 74 3 04 113 0 93 3 76 24 36 12 51 75 2 94 114 0 904 2 72 41 37 12 76 2 844 115 0 88 1 68 79 38 11 52 77 2 752 116 0 856 0 65 37 39 11 06 78 2 663 117 0 833 1 62 13 40 10 62 79 2 577 118 0 811 2 59 08 41 10 2 80 2 495 119 0 77 3 56 19 42 9 803 81 2 415 120 0 769 4 53 46 43 9 42 82 2 339 121 0 746 5 50 87 44 9 054 83 2 265 122 0 729 6 48 42...

Page 68: ...74 62 11 32 101 3 22 15 362 9 24 51 41 63 10 93 102 3 13 14 342 8 25 49 19 64 10 54 103 3 04 13 323 9 26 47 08 65 10 18 104 2 96 12 306 2 27 45 07 66 9 83 105 2 87 11 289 6 28 43 16 67 9 49 106 2 79 10 274 29 41 34 68 9 17 107 2 72 9 259 3 30 39 61 69 8 85 108 2 64 8 245 6 31 37 96 70 8 56 109 2 57 7 232 6 32 36 38 71 8 27 110 2 50 6 220 5 33 34 88 72 7 99 111 2 43 5 209 34 33 45 73 7 73 112 2 37 ...

Page 69: ...Designed by Cooper Hunter International Corporation Oregon USA www cooperandhunter com E mail info cooperandhunter com ...

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