innovair Inverter FLEX24 DEV24H2R18 Service Manual Download Page 8

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SERVICE MANUAL

1.2 Electrical Parameters

SEV2040H2R18

208/230V-1Ph-60Hz

SEV3060H2R18

208/230V-1Ph-60Hz

Power Supply

Fuse Capacity

Circuit Breaker Capacity

Model

V/Ph/Hz

DEV24H2R18

208/230V-1Ph-60Hz

DEV36H2R18

208/230V-1Ph-60Hz

3.15

DEV48H2R18

208/230V-1Ph-60Hz

3.15

DEV60H2R18

208/230V-1Ph-60Hz

3.15

Power supply

Circuit breaker capacity

Model

V/Ph/Hz

Summary of Contents for Inverter FLEX24 DEV24H2R18

Page 1: ...proper tools and test instruments Installation or repairs made by unqualified persons can result in hazards to you and others Failure to carefully read and follow all instructions in this manual can result in equipment malfunction property damage personal injury and or death This service is only for service engineer to use SEV2040H2R18 SEV3060H2R18 DEV24H2R18 DEV36H2R18 DEV48H2R18 DEV60H2R18 ...

Page 2: ...ation methods Professional operators must abide by relevant national local safety requirements and technical specifications set forth in this manual during operations otherwise the air conditioning system may fail or be damaged and personnel safety accident may also occur Safety Notice Before using the air conditioner please first read the instruction manual Before installing the air conditioner p...

Page 3: ...m Diagram 55 4 2 Connection Pipe Vacuum Pumping 55 4 3 Refrigerant Charging 57 4 4 Maintenance of Major Components 59 4 5 Removal of Major Components 69 4 6 Explosive View and Lists of Parts 104 Appendices 110 1 Resistance Temperature Lists of Temperature Sensors 110 1 1 Voltage List of 15 KΩ Temperature Sensors 110 1 2 Voltage List of 20 KΩ Pipeline Temperature Sensors 112 1 3 Voltage List of 50 ...

Page 4: ...NG 1 If the working place is more than 2m s high please wear a safety helmet gloves and a safety belt 2 Never mix any other substances except the specified refrigerant into the refrigerant circuit 3 When re locating the appliance check whether the new location is strong enough to withstand the weight of the appliance 4 If there is refrigerant leak please fix the leak before charging in the refrige...

Page 5: ... be done according to applicable local rules and regulations Safety Notice on Operation PROHIBITED 1 Never try to modify the unit otherwise it may cause electric shock overheat or fire hazard 2 If the power cord or conducting wires are scratched please replace them 3 Never use connected or extended power cord or share the power socket with other appliances 4 Prepare a specialized power circuit for...

Page 6: ...SERVICE MANUAL 3 1 Product Introduction 1 1 Lists of Units 1 1 1 List of Outdoor Units SEV2040H2R18 208 230V 1Ph 60Hz SEV3060H2R18 208 230V 1Ph 60Hz Power Supply Model Appearance V Ph Hz ...

Page 7: ...000 208 230V 1Ph 60Hz Airhandler DEV36H2R18 36000 36000 208 230V 1Ph 60Hz Airhandler DEV48H2R18 48000 48000 208 230V 1Ph 60Hz Airhandler DEV60H2R18 54000 54000 208 230V 1Ph 60Hz NOTE 1 Ton 12000Btu h 3 517kW Power Supply Cooling Heating Model Appearance Capacity Btu h V Ph Hz ...

Page 8: ... 208 230V 1Ph 60Hz 45 Power Supply Fuse Capacity Circuit Breaker Capacity Model V Ph Hz A A DEV24H2R18 208 230V 1Ph 60Hz 5 15 DEV36H2R18 208 230V 1Ph 60Hz 3 15 15 DEV48H2R18 208 230V 1Ph 60Hz 3 15 15 DEV60H2R18 208 230V 1Ph 60Hz 3 15 15 Power supply Circuit breaker capacity Model V Ph Hz A ...

Page 9: ...6 SERVICE MANUAL 2 Control 2 1 Operation Mode 2 1 1 Cooling Mode ...

Page 10: ...2 1 2 Heating Mode SERVICE MANUAL 7 ...

Page 11: ... at the highest level 10 and the lowest level 1 By controlling the speed of outdoor fan the unit can achieve cooling at low temperature and heating at high temperature In fan mode outdoor fan will not work 2 2 1 4 4 way Valve Control After heating mode is turned on for a while 4 way valve will be energized to change the direction of refrigerant flow so that the system can run in heating and the in...

Page 12: ...s for the second time in a certain time period system will not restore operation You need to manually turn off the unit and clear the error before restarting up the unit If high pressure protection occurs frequently please send for professional personnel to repair 2 2 3 2 Low Pressure Protection Control System will enable low pressure protection control if the low pressure switch is detected open ...

Page 13: ...t the capacity of the outdoor unit through the four dip switches of the outdoor unit main control board Specific dip switch definition the first dip switch distinguishes the capacity Dip Switches 2 3 2 Set Defrost Mode The second dip switch is selecting the defrost mode The second dip switch is used to change the defrost setting factory default setting is standard defrost Under extremely low envir...

Page 14: ...r temperature to quickly reach the set temperature Energy saving mode is achieved by setting the condensing unit operating mode to operate the air conditioner within a small load range Operating mode Outdoor unit dip switches Standard mode Default Strong mode Energy saving mode 2 3 4 Set Indoor Fan Speed Set the indoor fan speed through the eight dip switches of the indoor main control board The h...

Page 15: ...rst level menu of the debugging mode the outdoor unit mainboard LED displayer flashes Under the first level menu short press SW1 to switch various functions After switching to 08 short press SW2 or SW3 to enter the refrigerant recovery control mode ON means open OF means close And then short press SW1 to save During debugging if no operation is performed within 10s the debugging mode interface wil...

Page 16: ...n the forced operation cooling mode 02 denotes that turn on the forced operation cooling mode OF indicates that shut down the forced cooling heating mode And then short press SW1 to save During debugging if no operation is performed within 10s the debugging mode interface will be exited SERVICE MANUAL 13 ...

Page 17: ...ooting 3 1 Wiring Diagrams The following electric diagram is for reference only Please refer to diagram sticked on the unit as the latest version 3 1 1 Wiring Diagrams of ODUS Model SEV2040H2R18 14 SERVICE MANUAL ...

Page 18: ...Model SEV3060H2R18 3 1 2 Wiring Diagrams of IDUs Model DEV24H2R18 DEV36H2R18 SERVICE MANUAL 15 ...

Page 19: ...Model DEV48H2R18 DEV60H2R18 16 SERVICE MANUAL ...

Page 20: ...put 9 X14 OFAN H OUT AC motor high speed output 3 CN3 Wired control communication interface 10 X11 OFAN H IN AC motor high speed input 4 CN1 DC motor output 11 X8 OFAN L IN AC motor low speed input 5 X7 Transformer Neutral wire input 12 X6 OFAN L OUT AC motor low speed output 6 X13 Transformer Live wire input 13 X3 C Transformer Neutral wire output 7 X10 O_SCAN 4 Way check 14 X4 R Transformer Live...

Page 21: ...Pinboard No Printing Interface No Printing Interface 1 DC MOTOR1 DC motor output 2 COM2 DC motor control signal input 18 SERVICE MANUAL ...

Page 22: ...ow pressure protection interface 3 HEAT_TIE_B Chassis electric heating belt 13 HPP System high pressure protection interface 4 HEAT_TIE_ C Compressor electric heating belt 14 T_SENSOR2 2 Outdoor tube temperature sensor interface 4 Outdoor ambient temperature sensor interface 6 Discharge temperature sensor interface 5 4WAY 4 way valve 15 T_LAC Low temperature cooling temperature sensing SERVICE MAN...

Page 23: ...rface 19 DC_MOTOR1 DC_MOTOR2 DC motor output 10 L PRESS Low pressure sensor interface 20 PWR1 310V DC power supply interface Drive Board Model SEV2040H2R18 Printing Interface No Printing Interface 1 L2 2 PFC induction wire blue 10 P OUT Reserved 2 AC L Live wire 11 L1 2 PFC induction wire white 3 L1 1 PFC induction wire brown 12 L2 1 PFC induction wire yellow 4 N Neutral wire 13 G OUT Reserved 5 C...

Page 24: ...el SEV3060H2R18 Interface No Printing Interface 1 L2 2 PFC induction wire blue 8 L1 2 PFC induction wire white 2 AC L Live wire 9 U Compressor U phase terminal 3 L1 1 PFC induction wire brown 10 V Compressor V phase terminal 4 N Neutral wire 11 W Compressor W phase terminal 5 JTAG1 Programming interface for testing 12 PWR Drive power supply terminal 6 COMM Communication terminal same with COMM 13 ...

Page 25: ...2 Filtering board grounding hole reserved No Printing Interface No Printing Interface 1 AC L Power input live wire terminal 6 N OUT1 Power output neutral wire terminal reserved 2 N Power input neutral wire terminal 7 N OUT Power output neutral wire terminal 3 E Filtering board ground wire terminal 8 L OUT1 Power output live wire terminal 4 E1 Filtering board grounding hole reserved 9 L OUT Power o...

Page 26: ...IPM module is normal If any measured valve is 0 it indicates the IPM is damaged 3 2 2 2 Method of Testing PFC Module Short Circuit 1 Preparation before test prepare a universal meter and turn to its diode option and then remove the wires L1 2 L2 1 after it is powered off for one minute 2 Testing Steps Step 1 Put the black probe on the place P and the red one on the wiring terminal L1 2 L2 1 respec...

Page 27: ...SEV2040H2R18 SEV4060H2R18 24 SERVICE MANUAL ...

Page 28: ...ction 17 P6 Master control and driver communication error 18 P7 Driver module sensor error 19 P8 Driver module high temperature protection 20 PA AC current protection 21 Pc Driver current error 22 PL Bus low voltage protection 23 PH Bus high voltage protection 24 PU Charge loop error 25 ee Drive memory chip error 26 e1 High pressure sensor error 27 C4 ODU jumper cap error If malfunction occurs dur...

Page 29: ...essure switch is cut off it is judged that high pressure is too high and the system stops operation for protection Possible reason Cut off valve of ODU is not fully opened High pressure switch is abnormal Outdoor or indoor fan is not working properly IDU filter or air duct is blocked heating mode Ambient temperature is too high Refrigerant charging amount is too much System pipeline is blocked 26 ...

Page 30: ...Troubleshooting SERVICE MANUAL 27 ...

Page 31: ...itch If the low pressure switch is cut off it is judged that low pressure is too low and the system stops operation for protection Possible reason Cut off valve of ODU is not fully opened Low pressure sensor is abnormal Outdoor or indoor fan is not working properly IDU filter or air duct is blocked cooling mode Ambient temperature is too low Refrigerant charging amount is insufficient System pipel...

Page 32: ... pumping and pressure retaining are passed Check if there is leakage in the pipeline Reconnect wire according to the circuit diagram or replace the pressure switch Yes 35 85 outdoor units are without low pressure switch and check if the wiring of mainboard is normal 100 160 outdoor units are with low pressure switch and check if the low pressure switch and its wiring are normal Replace the outdoor...

Page 33: ...ic expansion valve is abnormal Outdoor or indoor fan is not working properly IDU filter or air duct is blocked cooling mode Ambient temperature exceeds allowable operation range Refrigerant charging amount is insufficient System pipeline is blocked 30 SERVICE MANUAL ...

Page 34: ...oard LED displayer Error judgment condition and method Sample the AD value of temperature sensor through temperature sensor detecting circuit and judge the range of AD value If the sampling AD value exceeds upper limit and lower limit in 5 seconds continuously report SERVICE MANUAL 31 ...

Page 35: ...ly insert the temperature sensor on the needle stand Replace the temperature sensor Replace the outdoor mainboard Yes No No Yes NOTE Please refer to Appendix 1 for the relation between temperature and resistance of temperature sensor 3 4 5 F3 Outdoor Ambient Temperature Sensor Error Error display ODU mainboard LED displayer Error judgment condition and method Sample the AD value of temperature sen...

Page 36: ...elation between temperature and resistance of temperature sensor 3 4 6 F4 Discharge Temperature Sensor Error Error display ODU mainboard LED displayer Error judgment condition and method Sample the AD value of temperature sensor through temperature sensor detecting circuit and judge the range of AD value If the sampling AD value exceeds upper limit and lower limit in 5 seconds continuously report ...

Page 37: ...y insert the temperature sensor on the needle stand Replace the temperature sensor Replace the outdoor mainboard Yes No No Yes NOTE Please refer to Appendix 1 for the relation between temperature and resistance of temperature sensor 3 4 7 F6 ODU Tube Temperature Sensor Error Error display ODU mainboard LED displayer Error judgment condition and method Sample the AD value of temperature sensor thro...

Page 38: ...is normal Correctly insert the temperature sensor on the needle stand Replace the temperature sensor Replace the outdoor mainboard Yes No No Yes NOTE Please refer to Appendix 1 for the relation between temperature and resistance of temperature sensor 3 4 8 EE ODU Memory Chip Error Error display ODU mainboard LED displayer Error judgment condition and method If ODU mainboard cannot read the memory ...

Page 39: ...ment condition and method When condensing pressure is higher than the protection value system will report overload protection Possible reason Cooling ODU heat exchanger is blocked or heat exchange is bad Heating IDU heat exchanger is blocked or heat exchange is bad Operating temperature is too high System charging quantity is too much 36 SERVICE MANUAL ...

Page 40: ...he drive board Replace the compressor YES YES YES YES YES NO NO NO NO 3 4 10 H5 IPM Protection Error display ODU mainboard LED displayer Error judgment condition and method When power is connected and drive chip received IPM lead F0 that is of low level than it is IPM module malfunction System will shut down for protection Possible reason Compressor 3 phase wire connection is lack of phase or phas...

Page 41: ...ssor current sampling circuit element is damaged or drive chip current sampling AD terminal is abnormal Compressor is damaged Troubleshooting 3 4 11 H6 DC Fan Error Error display ODU mainboard LED displayer Error judgment condition and method Mainboard doesn t receive the signal of outdoor fan within 30s after the outdoor fan starts up 38 SERVICE MANUAL ...

Page 42: ...an motor Correctly connect the control wire of fan motor on the mainboard Operate the unit with the new motor Replace the outdoor mainboard Yes No No Yes 3 4 12 H7 Driver Out of Step Protection Error display ODU mainboard LED displayer Error judgment condition and method During operation it can t detect the rotor position and stops output Or the actual running speed differs too much from the set r...

Page 43: ...Drive board compressor current sampling circuit element is damaged or drive chip current sampling AD terminal is abnormal Compressor is damaged Troubleshooting 40 SERVICE MANUAL ...

Page 44: ...le reason Power grid voltage is abnormal Drive board PFC module is damaged Drive board PFC module s 15V power supply is lower than 13 5V Drive board PWM signal for PFC and the corresponding element are abnormal Drive board PFC current sampling circuit element is damaged or drive chip current sampling AD terminal is abnormal Troubleshooting HC PFC protection Normal protection Check whether power gr...

Page 45: ... Error judgment condition and method Check the error code on nixie tube of ODU main control board If PJ is displayed it indicates inverter compressor startup failure Possible reason Poor contact of compressor UVW wire Compressor is broken Compressor drive board is broken Troubleshooting ...

Page 46: ...protection 3 3V drive board voltage is normal or not Replace the drive board Re arrange the wires Heavy current wires s hould avoid the drive board chip NO YES 3 4 16 P5 Over Current Protection Error display ODU mainboard LED displayer Error judgment condition and method If compressor s instant current value is higher than the set current protection value then it can be judged that compressor over...

Page 47: ... display ODU mainboard LED displayer Error judgment condition and method If there is no other malfunction and the communication between master control and driver is cut off for 30s then it can be judged that the communication between master control and driver is faulted System will shut down for protection Possible reason Communication wire between master control and driver is not well connected o...

Page 48: ...Error display ODU mainboard LED displayer Error judgment condition and method If IPM or PFC module temperature is lower than the set protection value then it can be judged that driver module sensor error occurs and system will shut down for protection Possible reason Module temperature sensor is short circuited or broken circuited Drive board current sampling circuit element is damaged or drive ch...

Page 49: ...rature exceeds the set protection value then it can be judged that driver module temperature is too high and system will shut down for protection Possible reason Thermal grease is not applied or not evenly applied to the module or there is other substance on the back of the module The module securing screws are not tightened up Drive board temperature sampling circuit element is damaged or drive c...

Page 50: ...s too large Grid voltage is abnormal PFC module is damaged Drive board PFC current sampling circuit element is damaged or drive chip PFC current sampling AD terminal is abnormal Troubleshooting 3 4 21 Pc Driver Current Error Error display ODU mainboard LED displayer Error judgment condition and method After power charging if offset voltage average is detected to exceed 12 5 of 1 65V in 1s then it ...

Page 51: ...ition and method When compressor is running and there is no other malfunction if busbar voltage is lower than the set value for low voltage protection then it can be judged that bus low voltage protection occurs System will shut down for protection Possible reason Voltage of power grid is abnormal Drive board busbar voltage sampling circuit element is damaged or drive board busbar voltage sampling...

Page 52: ...rive board busbar voltage sampling AD terminal is abnormal Troubleshooting 3 4 24 PU Charge Loop Error Error display ODU mainboard LED displayer Error judgment condition and method When the charge loop starts to get charged and the busbar voltage cannot reach the set value in a certain period of time then it can be judged that charge loop error exists System will shut down for protection Possible ...

Page 53: ... memory chip cannot detect the memory chip or read the memory chip data correctly then it can be judged that drive memory chip error exists Possible reason The drive board that needs memory chip is not installed with the memory chip The lead or connector of memory chip is badly welded or short circuited Troubleshooting ee Drive memory chip error Drive board is installed with memory chip or not Ins...

Page 54: ...exceeds upper limit and lower limit in 30 seconds continuously report the error Poor contact between pressure sensor and terminal in mainboard interface Pressure sensor is abnormal Detecting circuit is abnormal Troubleshooting 3 4 27 C4 ODU Jumper Cap Error Error display ODU mainboard LED displayer Error judgment condition and method If jumper cap model doesn t match with mainboard report the erro...

Page 55: ...Possible reason Jumper cap is not installed Jumper cap model is wrong Detecting circuit is abnormal Troubleshooting 52 SERVICE MANUAL ...

Page 56: ...is loose Re insert the power plug Thermostat has low battery Replace the batteries Bad cooling or heating effect Air inlet and outlet of the units have been blocked Clear the obstacles and keep the room for the units well ventilated Improper temperature setting Reset a proper temperature Fan speed is too low Reset a proper fan speed Air flow direction is not right Change the direction of air louve...

Page 57: ...fter the valve changes its direction There is hissing sound when the unit is started or stopped and a slight hissing sound during and after operation It s the sound of gaseous refrigerant that stops flowing and the sound of drainage system There is a sound of crunching during and after operation Because of temperature change front panel and other components may be swelled up and cause abrasion sou...

Page 58: ...rigerant leak 3 Connect the hose used for evacuation to the vacuum pump 4 Open the switch at the lower pressure side of the manifold valve assembly and start the vacuum pump Meanwhile the switch at the high pressure side of the manifold valve assembly should be kept closed otherwise evacuation would fail 5 The evacuation duration depends on the unit s capacity generally Model Time min SEV2040H2R18...

Page 59: ...lly only after the manifold valve assembly is removed 8 Place back the caps of the liquid valve gas valve and also the service port NOTICE For large size units there are maintenance ports for liquid valve and gas valve During evacuation you may connect the two hoses of the branch valve assembly to the maintenance ports to speed up the evacuation Refrigerant should be reclaimed into the appropriate...

Page 60: ...gauge line Then tighten up the connector again and completely open the valve of refrigerant tank at the same time Step 4 Keep the refrigerant tank erect and put it on an electronic scale Record the current weight as m1 Step 5 Open the high pressure gauge valve Keep the low pressure gauge valve closed Then charge refrigerant into the system Meanwhile record the weight of refrigerant tank as m2 Step...

Page 61: ...n on the air conditioner and let it run for a while Step 5 Open the low pressure gauge valve Keep the high pressure gauge valve closed Then charge in the remaining charging quantity m Step 6 After all required refrigerant is charged in close the valve of refrigerant tank Step 7 Remove the pressure gauge to finish the refrigerant charging work Procedure of refrigerant charging Following is the supp...

Page 62: ... faulted compressor Use a pressure gauge to measure the pressure of the big and small valves Connect with a computer to monitor the data Refer to the following table based on the recommended working current The electric current of an inverter compressor will be different under different rotation speed or different working conditions If the compressor is working at 60Hz the working current correspo...

Page 63: ...alve will be reset every time when the unit is powered on or off Touch the valve and you can feel the movement of the valve spool In the last stage of the reset process you will hear the click of the valve and feel its vibration Touch the electronic expansion valve a Touch the top of the electronic expansion valve and you can feel its move as it is reset upon startup b Make sure the coil is fixed ...

Page 64: ...nd high temperature C S the pipeline is with low pressure and low temperature Because D is connected to the exhaust side it is with high pressure and high temperature regardless of the operating mode When the unit is powered on in defrosting or oil return mode the 4 way valve will produce some noise Do not touch the pipes directly with your hands and be cautious of the hot temperature Step 4 Check...

Page 65: ...resistance of each wiring terminal The resistance should be above 10 megohm If not we can judge that the compressor is faulted inside Step 3 On condition that the unit cannot be started up we also need to check the solenoid valve assembly of the system including the electronic expansion valve The checking method is the same as instructed above Step 4 Check whether the IPM module is normal Please r...

Page 66: ...r oil from contacting the air NOTICE Before replacement make sure the nameplates and models of the compressors are identical NOTICE Make sure the lubricant is sealed inside the compressors Make sure the rubber seals of the suction and exhaust openings of the compressor are in good condition Make sure the electric box cover of the compressor is in good condition SERVICE MANUAL 63 ...

Page 67: ...ing tape to wrap the power cable and put a notice board on the power switch to remind people to be cautious of electric shock Step 3 Neaten the electric components When you detach the compressor wires temperature sensors and electric heaters mark them correspondingly for the convenience of reconnecting them Step 4 Discharge refrigerant Discharge refrigerant from the system Discharge simultaneously...

Page 68: ...il quality 3 Put the container of compressor lubricant in a bright location and see if there is impurity and discoloration Sniff at the compressor lubricant Normally there is no pungent smell b If the oil is contaminated replace the compressor and the gas liquid separator NOTE Confirm whether the compressor needs to be replaced The pipe mouths of the faulted compressor must be sealed by adhesive t...

Page 69: ...rator or other abnormal conditions Confirm which parts of the system should be replaced Make sure the pipe mouths of the damaged parts or components are sealed by adhesive tape as soon as they are detached Keep them in the original condition for future analysis Step 7 Clear the pipeline After confirming which parts of the system should be replaced check the pipeline of the system Blow through the ...

Page 70: ...We recommend charging the nitrogen from the big and small valves at the same time The pressure of nitrogen should be above 20kgf Then use soapy water to check for leaks Check the welding points particularly 3 Finally retain the pressure of the system Fill high pressure nitrogen into the system and maintain the pressure above 25kgf Close the big and small valves and keep the pressure of indoor and ...

Page 71: ...or Set the universal meter at the DC voltage and measure the voltage between P and N as shown below If the voltage is below 36V proceed with the next step In case that a universal meter is not available disconnect power for 20min and then continue with the next step Step 3 Remove all the wires on the drive board of the compressor Step 4 Remove the screws on the drive board of the compressor The sc...

Page 72: ...er drive of the fan It enables the fan to run so as to provide smooth currents of air for forced convection and heat exchange of condenser and evaporator Fan It is used to provide smooth currents of air for forced convection and heat exchange of condenser and evaporator Gas liquid separator Installed at the suction side of compressor it can separate the liquefied refrigerant from the gaseous refri...

Page 73: ... so that the flow temperature can reach the specified index It is an energy exchanging device Electronic expansion valve It is used to lower the pressure and temperature of liquefied refrigerant and adjust the flow of refrigerant entering the evaporator Electromagnetic Valve Electromagnetic valve controls increased enthalpy switch 70 SERVICE MANUAL ...

Page 74: ...s of the upper cover plate with a screwdriver 2 Remove the front side plate Unscrew the screws of the upper and front side plate with a screwdriver 3 Remove the front grill Unscrew the screws of the front grill with a screwdriver 4 Remove the front panel Unscrew the screws that connect the front panel to the middle insulating board and screws around the front panel SERVICE MANUAL 71 ...

Page 75: ...ews around the right side plate 6 Install the right side plate Screw up the screws around the right side plate Be careful to handle well the clasps at the bottom of the right side plate 7 Install the front panel Install the front panel by mounting on 6 clasps on its both sides Please note that there is one screw on the lower right side 8 Install the grill Attach the grill back in place and tighten...

Page 76: ...s around the upper cover plate Model SEV2040H2R18 Removal of compressor gas liquid separator NOTE Before removing the compressor gas liquid separator make sure there is no refrigerant in the pipeline and power is cut off Step Picture Work instruction 1 Remove wires Loosen the securing screws of the wires with a screwdriver Remove the wires NOTE When removing the wires mark the wire terminals corre...

Page 77: ...gas liquid separator Then remove the pipes NOTE When welding the pipes do not let the flame burn the other components 3 Loosen the compressor s base connectors gas liquid separator s base nuts Screws Use a wrench to twist off the compressor gas liquid separator s base nuts 4 Remove the compressor gas liquid separator from the chassis Take away the compressor gas liquid separator and replace with a...

Page 78: ...compressor gas liquid separator tighten up the base screw nuts 6 Connect the welding interfaces of compressor gas liquid separator to the pipeline Weld the connection pipes of compressor so as to connect them to the compressor NOTE When replacing the compressor avoid touching the nearby pipeline and components 7 Connect the compressor wires Connect the compressor wires to the wire terminals on the...

Page 79: ...from the 4 way valve Use a soldering gun to loosen the 4 joints on the 4 way valve and then remove the connection pipes NOTE When welding the pipes the 4 way valve should be wrapped with wet cloth for cooling Do not let the flame burn the other components 3 Replace the 4 way valve and connect it to the connection pipes Replace the 4 way valve and then use a soldering gun to weld the 4 joints of th...

Page 80: ...s of the coil of 4 way valve with a screwdriver Model SEV2040H2R18 Removal of fan and motor Note Before removing the fan make sure power is cut off Step Picture Work instruction 1 Remove the grill Use a screwdriver to unscrew the two screws on the upper left and lower right corners 2 Remove the fan Use a wrench to remove the specialized nut and gasket of the fan NOTE Please keep the nut and gasket...

Page 81: ...Install the motor Replace with a new motor Then tighten up the screw bolt 5 Install the fan Install the fan in place Put on the gasket and use a wrench to secure the screw nut NOTE After installing the fan turn the fan by hand to see if it can run normally If not please check for the reason 6 Install the grill After replacing the motor use a screwdriver to tighten up the screw bolt that secures th...

Page 82: ...ruction 1 Remove the panels Remove the upper lower and front panels 2 Remove the electric box Loosen the wire clamp at the bottom of the electric box Unscrew the screws of electric box The connection wires inside and outside the electric box should be removed 3 Remove motor support When removing the motor support be careful to protect the components SERVICE MANUAL 79 ...

Page 83: ...ndenser are steel and copper welding points Be sure to maintain the welding quality 5 Take out the condenser Loosen the securing screws of condenser support Take off the plate type heat exchanger and the support as a whole 6 Install the new condenser Welding interface Secure the screws of condenser and support Then fix them together on the chassis Install the condenser by referring to the position...

Page 84: ...tion 7 Secure the electric box and arrange the wires according to the requirement Put the electric box in place and tighten up the screws of electric box Arrange and secure the wires as original 8 Check and open the upper and side panels Check whether each component and connection wire is well connected If everything is OK place back the upper left and right side panels ...

Page 85: ...rk instruction 1 Remove the electric box Remove the upper lower and front panels Loosen the wire clamp at the bottom of the electric box Unscrew the screws of electric box The connection wires inside and outside the electric box should be removed When removing the electric box be careful to protect the components 2 Remove the fixed block Remove the fixed block between the electronic expansion valv...

Page 86: ...n remove the connection pipe NOTE When welding the pipe do not let the flame bunt the other components 4 Take out the electronic expansion valve Take out the electronic expansion valve 5 Install the new electronic expansion valve Weld the connection pipe of electronic expansion valve When welding the electronic expansion valve the valve should be wrapped with wet cloth Nitrogen welding the pressur...

Page 87: ...back in place and tighten up the screws Arrange the wires as original 7 Check and open the upper and front panels Check whether each component and connection wire is well connected If everything is OK install the upper left and right panels Tighten up the screws Model SEV4060H2R18 Removal of front panel NOTE Before removing the front panel make sure power is cut off Step Picture Work instruction 1...

Page 88: ...late with a screwdriver 3 Remove the front grill Unscrew the screws of the front grill with a screwdriver 4 Remove the front panel Unscrew the screws that connect the front panel to the middle insulating board and screws around the front panel 5 Install the front panel Install the front panel by mounting on 6 clasps on its both sides Please note that there is one screw on the lower right side ...

Page 89: ...n up the screws 7 Remove the valve cover Unscrew the screws of the valve cover with a screwdriver 8 Remove the right side plate Unscrew the screws that connect the right side plate to the electric box and the screws around the right side plate 9 Install the right side plate Screw up the screws around the right side plate Be careful to handle well the clasps at the bottom of the right side plate ...

Page 90: ... front panel make sure power is cut off Step Picture Work instruction 10 Install the grill Attach the grill back in place and tighten up the screws 11 Install the upper cover plate Tighten up the screws around the upper cover plate SERVICE MANUAL 87 ...

Page 91: ...the wires NOTE When removing the wires mark the wire terminals corresponding to their color so as to avoid misconnection 2 Loosen the securing screws at the foot of compressor Use a wrench to twist off the screw nuts at the foot of compressor 3 Break off the pipes that connecting to the compressor Weld the pipes that are connected to the compressor Then remove the pipes NOTE When welding the pipes...

Page 92: ...When replacing the compressor avoid touching the nearby pipeline and components 5 Fix the new compressor back onto the chassis After replacing the compressor tighten up the screws at the foot of compressor 6 Connect the compressor suction port and exhause port with the pipes Weld the compressor connection pipes and connect them to the compressor NOTE When replacing the compressor avoid touching th...

Page 93: ...nals on the top of compressor NOTE When connecting the wires be sure to match the colors with the corresponding wire terminals Model SEV4060H2R18 Removal of 4 way valve NOTE Before removing the 4 way valve make sure refrigerant is fully discharged from the unit and power is cut off Step Picture Work instruction 1 Take off the coil of the 4 way valve Carefully unscrew the screws of electromagnetic ...

Page 94: ...lding the pipes the 4 way valve should be wrapped with wet cloth for cooling Do not let the flame burn the other components 3 Replace the 4 way valve and connect it to the connection pipes Replace the 4 way valve and then use a soldering gun to weld the 4 joints of the 4 way valve Note When welding the pipes the 4 way valve should be wrapped with wet cloth for cooling Do not let the flame burn the...

Page 95: ...r to unscrew the two screws on the upper left and lower right corners 2 Remove the fan Use a wrench to remove the specialized nut and gasket of the fan NOTE Please keep the nut and gasket safe after removing them from the fan 3 Remove motor Use a screwdriver to unscrew the bolt of motor NOTE Motor wire should be first removed from the electric box 92 SERVICE MANUAL ...

Page 96: ... up the screw bolt 5 Install the fan Install the fan in place Put on the gasket and use a wrench to secure the screw nut NOTE After installing the fan turn the fan by hand to see if it can run normally If not please check for the reason 6 Install the grill After replacing the motor use a screwdriver to tighten up the screw bolt that secures the motor SERVICE MANUAL 93 ...

Page 97: ...nels Loosen the wire clamp at the bottom of the electric box Unscrew the screws of electric box 2 Remove the electric box The connection wires inside and outside the electric box should be removed When removing the electric box be careful to protect the components 3 Remove the compressor gas liquid separator from the chassis Take away the compressor gas liquid separator and replace with a new one ...

Page 98: ...en welding the pressure of nitrogen is 0 5 0 1kgf cm relative pressure NOTE When welding the pipes do not let the flame burn the other components Tighten the screws of gas liquid separator 5 Secure the electric box and arrange the wires as required Put the electric box back in place and tighten up the screws Arrange the wires as original 6 Check and open the upper and side panels Check whether eac...

Page 99: ... Loosen the wire clamp at the bottom of the electric box Unscrew the screws of electric box 2 Remove the electric box The connection wires inside and outside the electric box should be removed When removing the electric box be careful to protect the components 3 Remove the electronic expansion valve Take off the coil of electronic expansion valve Loosen the connection pipe of electronic expansion ...

Page 100: ...alve Weld the connection pipe of electronic expansion valve When welding the electronic expansion valve the valve should be wrapped with wet cloth Nitrogen welding the pressure of nitrogen is 0 5 0 1kgf cm relative pressure NOTE When welding the pipes do not let the flame burn the other components Install the coil of electronic expansion valve 6 Secure the electric box and arrange the wires as req...

Page 101: ...er left and right panels Tighten up the screws 4 5 2 Removal of IDU Major Components 4 5 2 1 Airhandler Unit Disassembly and Assembly of the Electric Box Step Picture Work instruction 1 Remove the upper panel Loosen screws around the upper panel with a screwdriver Remove the upper panel away from the unit 2 Remove the electric box Disconnect the power cord and control line from the wiring terminal...

Page 102: ...roper position Tighten the screws around the electric element with a screwdriver Wire the electric element to the wiring terminal 5 Reinstall the electric box Place the electric box at the proper position Tighten screws around the electric box with a screwdriver Connect the power cord and control line properly Reassemble the unit as before Disassembly and Assembly of the Fan Motor Step Picture Wor...

Page 103: ...ixing the motor and fan blades Loosen screw bolts fixing the bracket Remove the motor rightward from the fan 4 Reinstall the fan Place the motor at the proper position Tighten screws fixing the motor and fan blades Tighten screw bolts fixing the motor bracket After the installation reassemble the unit as before Disassembly and Assembly of the Evaporator and Drain Pan Step Picture Work instruction ...

Page 104: ...ewdriver Remove the lower panel from unit 3 Remove the enhanced frame if applicable Remove the screws from enhanced frame Disassemble the enhanced frame from the unit 4 Remove the mounting plate of the drain pan Loosen screws at both side of the mounting plate with a screwdriver Remove the mounting plate from the unit 5 Remove the primary drain pan Remove the primary drain pan from the unit ...

Page 105: ... the secondary drain pan from the unit 7 Remove the evaporator Remove the evaporator away from the primary drain pan Reassemble the unit as before Disassembly and Assembly of the Filter Step Picture Work instruction 1 Remove the mounting plate Loosen screws fixing the mounting plate with a screwdriver Remove the mounting plate away from the unit ...

Page 106: ...y and Assembly of the Filter Step Picture Work instruction 2 Remove the filter screen Remove the filter screen away from the unit After replacing the filter screen reassemble the unit as before SERVICE MANUAL 103 ...

Page 107: ...3 4 5 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 29 30 31 32 28 34 35 36 37 39 41 42 43 44 45 46 47 49 50 51 52 54 55 56 57 6 40 38 33 53 48 Material name 1 Coping 2 Electric Box Assy 3 PFC Inductance 4 Filter Board 5 Reactor Sub Assy 6 Power Switch 7 Main Board 104 SERVICE MANUAL No ...

Page 108: ...assis Assy 28 Foot 29 Cut Off Valve 30 Fusible Plug 31 Gas liquid Separator 32 Accumulator 33 4 Way Valve Coil 34 Drainage Hole Cap 35 Temperature Sensor 36 Temperature Sensor 37 Electrical Heater Compressor 38 Electrical Heater Chassis 39 Electric Expansion Valve Sub Assy 40 Drainage Joint 41 Cut Off Valve 3 8 N 42 Strainer 43 Electric Expand Valve Fitting 44 One Way Valve 45 Electronic Expansion...

Page 109: ... 57 Rear Grill SEV4060H2R18 1 3 4 5 6 7 8 9 10 11 13 15 14 17 18 20 24 26 25 23 16 27 28 29 34 30 31 33 35 38 39 42 43 49 50 2 22 19 32 21 47 48 45 46 36 37 12 44 41 40 No Material name 1 Coping 2 Rear Grill 3 Left Side Plate 4 Electric Box Assy 5 Drive Board 6 Radiator 106 SERVICE MANUAL ...

Page 110: ...sor and Fittings 25 Accumulator 26 Foot 27 Chassis Sub Assy 28 Cut Off Valve Sub Assy 29 Strainer 30 Magnet Coil Electromagnetic Valve 31 Electric Expand Valve Fitting 32 One Way Valve 33 Cut off Valve 34 Electronic Expansion Valve 35 4 Way Valve Assy 36 Pressure Sensor 37 Strainer 38 Cut Off Valve 3 8 39 Pressure Protect Switch 40 Electrical Heater Compressor 41 Electrical Heater Compressor 42 4 ...

Page 111: ...V60H2R18 1 2 3 6 4 7 9 11 12 13 14 15 17 18 20 22 23 25 26 27 29 28 10 16 8 5 19 21 24 No Material name 1 Coping 2 Left Side Plate 3 Electric Box Assy 4 Terminal Board 5 Transformer 6 Terminal Board 7 Main Board 8 Terminal Board 9 Pinboard 108 SERVICE MANUAL ...

Page 112: ... Board Sub Assy 15 Bottom Cover Plate Assy 16 Right Side Plate 17 Bottom Cover Plate Assy 18 Water Tray 19 Strainer 20 Cut Off Valve 3 8 N 21 Thermal Expansion Valve 22 Cut Off Valve 23 Evaporator Assy 24 Evaporator Assy 25 Evaporator Assy 26 Water Tray Assy 27 Choke Plug 28 Water Tray 29 Filter Sub Assy SERVICE MANUAL 109 ...

Page 113: ... 1 811 2 945 9 78 43 0 53 82 1 754 2 955 8 74 35 0 554 83 1 699 2 964 7 70 5 0 579 84 1 645 2 974 6 66 88 0 605 85 1 594 2 983 5 63 46 0 631 86 1 544 2 992 4 60 23 0 658 87 1 497 3 001 3 57 18 0 686 88 1 451 3 009 2 54 31 0 714 89 1 408 3 017 1 51 59 0 743 90 1 363 3 025 0 49 02 0 773 91 1 322 3 033 1 46 8 0 801 92 1 282 3 04 2 44 31 0 835 93 1 244 3 047 3 42 14 0 866 94 1 207 3 054 4 40 09 0 899 ...

Page 114: ... 1 931 124 0 519 3 19 34 10 2 1 964 125 0 505 3 192 35 9 779 1 998 126 0 492 3 195 36 9 382 2 03 127 0 48 3 198 37 9 003 2 062 128 0 467 3 2 38 8 642 2 094 129 0 456 3 203 39 5 997 2 125 130 0 444 3 205 41 7 653 2 185 131 0 433 3 207 42 7 352 2 215 132 0 422 3 21 43 7 065 2 243 133 0 412 3 212 44 6 791 2 272 134 0 401 3 214 45 6 529 2 299 135 0 391 3 216 46 6 278 2 326 136 0 382 3 218 47 6 038 2 3...

Page 115: ...1 71 3 364 2 825 24 249 9 0 245 72 3 252 2 838 23 235 3 0 259 73 3 144 2 852 22 221 6 0 273 74 3 04 2 865 21 208 9 0 288 75 2 94 2 877 20 196 9 0 304 76 2 844 2 889 19 181 4 0 328 77 2 752 2 901 18 171 4 0 345 78 2 663 2 912 17 162 1 0 362 79 2 577 2 923 16 153 3 0 381 80 2 495 2 934 15 145 0 4 81 2 415 2 944 14 137 2 0 42 82 2 339 2 954 13 129 9 0 44 83 2 265 2 964 12 123 0 462 84 2 194 2 974 11 ...

Page 116: ... 0 8799 3 161 20 25 01 1 466 116 0 8562 3 165 21 23 9 1 503 117 0 8333 3 168 22 22 85 1 54 118 0 8111 3 171 23 21 85 1 577 119 0 7895 3 175 24 20 9 1 614 120 0 7687 3 178 25 20 1 65 121 0 7485 3 181 26 19 14 1 686 122 0 7289 3 184 27 18 32 1 722 123 0 7099 3 187 28 17 55 1 758 124 0 6915 3 19 29 16 8 1 793 125 0 6736 3 192 30 16 1 1 828 126 0 6563 3 195 31 15 43 1 863 127 0 6395 3 198 32 14 79 1 8...

Page 117: ...3 251 63 4 443 2 7 159 0 2956 3 252 64 4 289 2 717 160 0 2891 3 253 65 4 14 2 734 1 3 Voltage List of 50 KΩ Discharge Temperature Sensors including discharge air temperature sensor 30 911 56 0 036 61 11 736 1 518 29 853 66 0 038 62 11 322 1 548 28 799 98 0 041 63 10 925 1 577 27 750 18 0 043 64 10 544 1 606 26 703 92 0 046 65 10 178 1 635 25 660 93 0 049 66 9 8269 1 664 24 620 94 0 052 67 9 4896 1...

Page 118: ... 2 404 6 119 08 0 256 97 3 6194 2 423 7 113 37 0 267 98 3 5143 2 442 8 107 96 0 28 99 3 4128 2 46 9 102 85 0 292 100 3 3147 2 478 10 98 006 0 306 101 3 22 2 496 11 93 42 0 319 102 3 1285 2 514 12 89 075 0 333 103 3 0401 2 531 13 84 956 0 348 104 2 9547 2 547 14 81 052 0 362 105 2 8721 2 564 15 77 349 0 378 106 2 7922 2 58 16 73 896 0 393 107 2 715 2 595 17 70 503 0 41 108 2 6404 2 611 18 67 338 0 ...

Page 119: ...3 186 0 994 134 1 3474 2 908 44 22 286 1 022 135 1 3155 2 916 45 21 425 1 05 136 1 2846 2 924 46 20 601 1 078 137 1 2545 2 932 47 19 814 1 107 138 1 2233 2 94 48 19 061 1 136 139 1 1969 2 947 49 18 34 1 164 140 1 1694 2 955 50 17 651 1 193 141 1 1476 2 96 51 16 99 1 223 142 1 1166 2 969 52 16 358 1 252 143 1 0913 2 975 53 15 753 1 281 144 1 0667 2 982 54 15 173 1 311 145 1 0429 2 988 55 14 618 1 3...

Page 120: ...44 2650 15 483 15 1250 45 2710 14 504 16 1280 46 2770 13 520 17 1320 47 2840 12 538 18 1350 48 2910 11 556 19 1400 49 2980 10 579 20 1440 50 3050 9 598 21 1470 51 3100 8 618 22 1520 52 3180 7 639 23 1560 53 3250 6 660 24 1600 54 3320 5 682 25 1640 55 3400 4 705 26 1680 56 3480 3 728 27 1730 57 3540 2 752 28 1780 58 3630 1 777 29 1820 59 3720 3 Operation Tools The following tools will be used 1 Liq...

Page 121: ...design and specifications are subject to change without prior notice for product improvement Consult with the sales agency or manufacturer for details Any updates to the manual will be uploaded to the service website please check for the latest version ...

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