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Specifications subject to change without notice. 38MGR-04SM

DISASSEMBLY INSTRUCTIONS SIZE 18

No.

Part name

Procedures

Remarks

Fan
assembly

How to remove the fan
assembly.

1) Turn off the air conditioner

and turn off the power

breaker.

2) Remove the screws (4) of

the air outlet grille.

3) Remove hex nut securing
the

fan.

4) Remove the fan.

5) Remove the top cover

screws (3), and remove the
top cover.

Screws of top

Содержание 38MGR Series

Страница 1: ...ING and CAUTION These words are used with the safety alert symbol DANGER identifies the most serious hazards which will result in severe personal injury or death WARNING signifies hazards which could...

Страница 2: ...UNIT MG ALL VOLTAGE 3 208 230 1 60 UNIT TYPE R OUTDOOR UNIT NOMINAL CAPACITY 18 1 1 2 TONS 24 2 TONS 30 2 1 2 TONS 36 3 TONS 48 4 TONS NOT USED B MAXIMUM NUMBER OF FAN COIL UNITS THAT CAN BE CONNECTE...

Страница 3: ...5 6 35 5 Pipe Connection Size Suction in mm 3 8 2 9 52 2 3 8 3 9 52 3 1 2 1 3 8 3 12 7 1 9 52 3 1 2 1 3 8 3 12 7 1 9 52 3 1 2 2 3 8 3 12 7 2 9 52 3 Refrigerant Type R410A Charge lbs kg 4 41 2 0 6 17 2...

Страница 4: ...es are not available on the 18K unit UNIT SIZE 18 24 30 36 48 Height in mm 27 6 703 31 89 810 31 89 810 52 48 1333 52 48 1333 Width in mm 37 31 948 41 22 1047 41 22 1047 41 14 1045 41 14 1045 Depth in...

Страница 5: ...38MGR 04SM Specifications subject to change without notice 5 DIMENSIONS CONT Fig 2 Size 24K Fig 3 Size 30K...

Страница 6: ...6 Specifications subject to change without notice 38MGR 04SM DIMENSIONS CONTINUED Fig 4 Size 36K...

Страница 7: ...38MGR 04SM Specifications subject to change without notice 7 DIMENSIONS CONT Fig 5 Size 48K...

Страница 8: ...24 609 C 24 609 D 4 101 E 6 152 A D B Air outlet Air inlet C E 59in 150cm or more when facing each other 19in 48cm or more on a multiple parallel unit arrangement 4in 10cm or more on a single parallel...

Страница 9: ...onto ground in the outdoor unit only UNIT SIZE SYSTEM VOLTAGE OPERATING VOLTAGE COMPRESSOR OUTDOOR FAN MCA MOCP VOLT PHASE HZ MAX MIN RLA FLA HP W 18 208 230 1 60 253 187 10 0 74 0 07 50 18 25 24 15...

Страница 10: ...or Unit B 208 230 1 60 Indoor Unit B Signal High Voltage 208 230 1 60 FIELD POWER SUPPLY 208 230 1 60 Main Power Supply 208 230 1 60 Power to Indoor Unit A Indoor Unit A Signal High Voltage L2 L1 A S...

Страница 11: ...38MGR 04SM Specifications subject to change without notice 11 CONNECTION DIAGRAMS CONT Fig 10 Size 30K 4 Zone Fig 11 Size 36K 4 Zone...

Страница 12: ...ndoor Unit A Signal High Voltage GND Ground CONNECTING CABLE OUTDOOR TO INDOOR S L1 L2 Indoor Unit B Power Supply 208 230 1 60 Indoor Unit B Signal High Voltage GND Ground CONNECTING CABLE OUTDOOR TO...

Страница 13: ...nt to the indoor heads to determine piping setup versus physical wiring When the controller has adjusted control so that each indoor unit is synced to its piping port approximately 5 10 minutes depend...

Страница 14: ...sor Temp CN29 L OUT Output 230VAC High voltage to IPM Board CN 21 Connect to IPM BOARD CODE PART NAME CN4 CN5 Input 230VAC High voltage from the Main Board CN2 CN3 Output Connection of the REACTOR U V...

Страница 15: ...OUT Output 230VAC High voltage to IPM Board Cn21 Connect to the IPM BOARD OUTDOOR UNIT IPM BOARD CODE PART NAME CN4 CN5 Input 230VAC High voltage CN2 CN3 Output Connection of the REACTOR U V W Connec...

Страница 16: ...3 Input Pin1 0 5VDC Pin2 5VDC Discharge Temp CN8 Input Pin3 Pin4 5VDC Pin2 0VDC Pin1 Pin5 0 5VDC T3 T4 CN9 Input Pin2 Pin4 0VDC Pin1 Pin3 0 5VDC H L Pressure Switches COMP FM1 MAIN BOARD U V W L DRIVE...

Страница 17: ...es 0 200VAC U V W Connect to compressor voltage among phases 0 200VAC CN51 CN52 CN51 EARTH CN52 EARTH Output 224 380VDC High voltage CODE PART NAME CODE PART NAME COMP COMPRESSOR L PFC INDUCTOR CAP1 F...

Страница 18: ...CH2 CN6 CN9 10 3 CN1 CN2 L YELLOW YELLOW U V W BLUE BLACK RED WIHTE RED BLACK RED BLACK Ferrite bead CH1 CT1 DCFAN2 DCFAN1 Y G Y G DC MOTOR DRIVER BOARD CON1 FAN1 CN1 FAN2 3 3 P6 2 CN6 CN3 Y G BLACK L...

Страница 19: ...High voltage to IPM PFC Board CN10 Input Pin2 Pin4 0VDC Pin1 Pin3 0 5VDC H L Pressure switch OUTDOOR UNIT PFC and IPM BOARD CODE PART NAME CN1 CN6 Output 224 380VDC High voltage CN2 CN6 Output 224 380...

Страница 20: ...YELLOW U V W BLUE BLACK RED WIHTE RED BLACK RED BLACK Ferritebead CH1 CT1 DCFAN2 DCFAN1 Y G Y G DC MOTOR DRIVER BOARD CON1 FAN1 CN1 FAN2 3 3 P6 2 CN6 CN3 Y G BLACK L2 L1 MAIN POWER SUPPLY XT1 N L P9 C...

Страница 21: ...igh voltage to IPM PFC Board CN10 Input Pin2 Pin4 0VDC Pin1 Pin3 0 5VDC H L Pressure switch OUTDOOR UNIT PFC AND IPM BOARD CODE PART NAME CN1 CN6 Output 224 380VDC High voltage CN2 CN6 Output 224 380V...

Страница 22: ...PILIARY A CHECK VALVE CAPILIARY TUBE EXV B CAPILIARY B LIQUID VALVE B GAS VALVE B Accumulator T2B A Evaporator temp sensor outlet T2B B LIQUID VALVE A GAS VALVE A HEAT EXCHANGE EVAPORATOR HEAT EXCHANG...

Страница 23: ...QUID VALVE C GAS VALVE C EXV D CAPILIARY D LIQUID VALVE D GAS VALVE D Accumulator High pressure switch Low pressure switch T2B A Evaporator temp sensor outlet T2B B T2B C T2B D LIQUID VALVE A GAS VALV...

Страница 24: ...gerant Calculation Sum Total Liquid Pipe ft m Additional Charge Required After ft m x Additional Charge oz ft g m 0 16 15 NOTES If the calculation results in a negative number no additional refrigeran...

Страница 25: ...25 Fig 25 Deep Vacuum Graph Triple Evacuation Method The triple evacuation method should be used Refer to Fig 26 and proceed as follows 1 Pump the system down to 1500 microns and allow the pump to co...

Страница 26: ...Low Voltage Protection Fig 27 Low Voltage Protection If these protections are triggered the A C unit stops and the LED displays the failure code The unit restarts three minutes after the protection m...

Страница 27: ...oil return process Low Outdoor Ambient Temperature Protection When the compressor is off and T4 is lower than 31 F 35 C for ten seconds the unit stops and displays LP When the compressor is on and T4...

Страница 28: ...3 TCDI1 and T3 T30SUBT3ONE T30 2 If the compressor cumulative running time reaches 35 minutes and T3 TCDI2 and T3 T30SUBT3TWO T30 3 If the compressor cumulative running time reaches 40 minutes and T3...

Страница 29: ...trol 1 EXV is fully closed when power is turned on The EXV will standby with the 350P open and then opens to the target angle after the compressor starts 2 EXV closes with 160P when the compressor sto...

Страница 30: ...elevant valve needs more 16p close If average 2 the T2 average 2 the relevant valve s open range remains If the T2 average 2 the relevant valve needs more 16p open This modification occurs every two m...

Страница 31: ...n power and repeat steps 5 6 and 7 12 Disconnect main power before reinstalling the board to avoid shock hazard and board damage Outdoor Unit Digital Display A digital display is featured on the outdo...

Страница 32: ...nd RO each appears for 0 5s Low ambient cooling mode LC or alternative displays between running frequency and LC each appears for 0 5s Forced cooling mode the LED displays FC or alternative displays b...

Страница 33: ...lower than 9 the digital display shows 9 If the temperature is higher than 70 the digital display shows 70 If the indoor unit is not connected the digital display shows 28 Indoor unit B evaporator tem...

Страница 34: ...er supply and turn it on 1 minute later Is it still displaying the error code Shut off the power supply rotate the fan by hand Does it rotate properly The unit operates normally Determine the cause an...

Страница 35: ...ing mode has the priority Supposed Causes Suppose indoor unit A is operating under the Cooling or Fan mode and indoor unit B is set to the Heating mode then unit A turns off and unit B operates in the...

Страница 36: ...ODE E0 F4 MALFUNCTION DECISION CONDITIONS Indoor or outdoor PCB main chip does not receive feedback from EEPROM chip SUPPOSED CAUSES Installation mistake PCB faulty If the EEPROM chip is welded on the...

Страница 37: ...feedback from the outdoor unit during 120 seconds or the outdoor unit does not receive feedback from any indoor unit during 180 seconds SUPPOSED CAUSES Indoor or outdoor PCB faulty Wiring mistake uni...

Страница 38: ...Use a multimeter to test the DC voltage between the L2 port and S port of the outdoor unit The red pin of the multimeter connects with the L2 port while the black pin is for the S port When AC is runn...

Страница 39: ...OLUTION CONT Fig 45 IPM for four or five zone Fig 46 Main Board The main board LED when power is on and the unit is in standby Fig 47 Main Board Check the point button Press one time to determine how...

Страница 40: ...UNCTION DECISION CONDITIONS When PCB does not receive zero crossing signal feedback for four minutes or the zero crossing signal interval is abnormal SUPPOSED CAUSES Connection mistake PCB faulty No Y...

Страница 41: ...ED CAUSES Wiring mistake PCB faulty Communication malfunction between IPM board and outdoor main board Is there at least one LED in the IPM board that is illuminated Check the signal wire between the...

Страница 42: ...ltage Remark Use a multimeter to test the DC voltage between black pin and white pin of signal wire The normal value should be around 5V Use a multimeter to test the DC voltage between black pin and r...

Страница 43: ...ck the Sensor Value ERROR CODE E4 F1 F2 F3 F4 F5 F6 MALFUNCTION DECISION CONDITIONS If the sampling voltage is lower than 0 06V or higher than 4 94V the LED displays the failure SUPPOSED CAUSES Wiring...

Страница 44: ...em leakage or block PCB faulty Voltage Protection Check the voltage of the outdoor unit power supply Is the voltage between L L1 and N L2 about 187 253VAC Check the power supply Check if the voltage o...

Страница 45: ...SOLUTION CONT Fig 52 IPM Board for 2 zone 3 zone Fig 53 Bridge rectifier for 2 zone 3 zone IPM board for 2 zone 3 zone P or E1 E2 E3 N GND for 2 zone 3 zone Bridge rectifier for 2 zone 3 zone Remark M...

Страница 46: ...hout notice 38MGR 04SM DIAGNOSIS AND SOLUTION CONT Fig 54 Bridge Rectifier for 2 zone 3 zone and IPM Module for 2 zone 3 zone Fig 55 IPM Board for 4 zone Bridge rectifier for 2 zone 3 zone IPM Module...

Страница 47: ...tice 47 DIAGNOSIS AND SOLUTION CONT Fig 56 Bridge Rectifier for 5 zone Fig 57 IPM Module for 5 zone IPM board for 5 zone Bridge rectifier for 5 zone Remark Measure the DC voltage between and port The...

Страница 48: ...faulty Inductance of PFC module faulty PFC module malfunction PFC Module Protection Check whether the connecting line between the main board and the PFC module is well connected Yes Check if the volt...

Страница 49: ...38MGR 04SM Specifications subject to change without notice 49 DIAGNOSIS AND SOLUTION CONT Fig 58 Inductance Fig 59 Inductance Inductance Two ports of the inductance...

Страница 50: ...e Fan assembly faulty Fan motor faulty PCB faulty No Yes No No Yes Yes No Yes No Power off then restart the unit 3 minutes later Is it still displaying the error code The unit operates normally Shut o...

Страница 51: ...t is in standby measure the voltage of pin1 pin3 pin4 pin3 in fan motor connector If the value of the voltage is not in the range showing in the table below the PCB needs to be replaced Fig 60 DC Fan...

Страница 52: ...ction of the compressor top Check the air flow system of the indoor and outdoor units Clear up the air inlet and outlet or the indoor and outdoor heat exchanger Power OFF then restart the unit minutes...

Страница 53: ...38MGR 04SM Specifications subject to change without notice 53 DIAGNOSIS AND SOLUTION CONT Fig 62 Test the voltage Fig 63 Test the voltage...

Страница 54: ...l connected well or correct Connect it well Is the high pressure protector broken Method Disconnect the plug Measure the resistance of the high pressure protector if the protector is normal the value...

Страница 55: ...38MGR 04SM Specifications subject to change without notice 55 DIAGNOSIS AND SOLUTION CONT Fig 64 Test the voltage...

Страница 56: ...well connected Connect the main board correctly Is the low pressure protector broken Check if the outdoor ambient temperature is too low Method Disconnect the plug Measure the resistance of the low p...

Страница 57: ...38MGR 04SM Specifications subject to change without notice 57 DIAGNOSIS AND SOLUTION CONT Fig 65 Test the voltage...

Страница 58: ...an 12 5A 18K For 24K it is 17 For 30K it is 18 5 For 36K it is 23A Replace the outdoor main board Check if the refrigerant system is working as designed Judge 2 Check if the outdoor ambient temperatur...

Страница 59: ...38MGR 04SM Specifications subject to change without notice 59 DIAGNOSIS AND SOLUTION CONT Fig 66 Test the voltage...

Страница 60: ...y Outdoor PCB faulty No Yes Yes No No Yes Yes No No Ch k h h h g Temperature Protection of the Compressor Discharge Check if the compressor discharge temp is higher than 239 F 115 C Check if the refri...

Страница 61: ...ndenser High Temperature Protection Check if the condenser temp is higher than 149 F Check if the outdoor ambient temp is higher than 122 F Check if the outdoor unit ventilation is good Check if the o...

Страница 62: ...t ok or not Replace the IPM module Check whether the system works normally No No Replace the main board Check whether the system works normally No Replace the compressor Check whether the system works...

Страница 63: ...oor unit frosts When heating the non operating indoor unit gets warm Probable causes EXV faulty Wire and tubing connected in reverse Check the EXV Temperature Sensor Checking Disconnect the temperatur...

Страница 64: ...5878 37 99 5 87359 77 171 1 29078 117 243 0 38991 2 28 39 8239 38 100 5 62961 78 172 1 25423 118 244 0 37956 1 30 37 1988 39 102 5 39689 79 174 1 2133 119 246 0 36954 0 32 35 2024 40 104 5 17519 80 17...

Страница 65: ...116 241 2 357 3 27 211 4 37 99 32 94 77 171 7 566 117 243 2 294 2 28 200 7 38 100 31 62 78 172 7 321 118 244 2 233 1 30 190 5 39 102 30 36 79 174 7 086 119 246 2 174 0 32 180 9 40 104 29 15 80 176 6...

Страница 66: ...Measure the resistance value of each winding by using the tester Fig 68 Measure the Resistance Table 36 Compressor Check Fig 69 Test the voltage POSITION RESISTANCE VALUE COMPRESSOR ATM150D23UFZ ATF23...

Страница 67: ...ng Table 39 Resistance Value DIGITAL TESTER NORMAL RESISTANCE VALUE DIGITAL TESTER NORMAL RESISTANCE VALUE Red Black Several M Red Black Several M P N U U V N V W W Red POSITION RESISTANCE VALUE RPG20...

Страница 68: ...hen the unit operates in cooling it is 0V When the unit operates in the Heating mode it is about 230VAC If the value of the voltage is not in the range the PCB needs to be replaced Fig 71 Test the vol...

Страница 69: ...nge without notice 69 EXV Check 1 Disconnect the connectors Fig 73 Disconnect the connectors Fig 74 Disconnect the connectors Table 40 Resistance to EXV Coil LEAD WIRE COLOR NORMAL VALUE Red Blue Abou...

Страница 70: ...70 Specifications subject to change without notice 38MGR 04SM EXV Check CONT Fig 75 EXV Check...

Страница 71: ...38MGR 04SM Specifications subject to change without notice 71 EXV Check CONT Brown Orange Brown White...

Страница 72: ...name Procedures Remarks 1 Fan assembly How to remove the fan assembly 1 Turn off the air conditioner and turn off the power breaker 2 Remove the screws 4 of the air outlet grille 3 Remove hex nut sec...

Страница 73: ...Remove the fan motor after unfastening the screws 4 2 Panel plate How to remove the panel plate 1 Remove the front panel screws 6 then remove the front panel Remove the electrical control box cover D...

Страница 74: ...S SIZE 18 CONT 2 Remove the big handle screws 4 and remove the big handle 3 Remove the terminal board screws 2 and the right rear panel screws 7 then remove the right rear panel Front panel screws Big...

Страница 75: ...Unfasten the reactor connector 4 Unfasten the compressor connector 5 Disconnect the following three 3 connection wires and connectors between the IPM and the main control PCB CN1 5p white CN14 3p whit...

Страница 76: ...ion valve A B 6p 6p red red CN25 CN23 S A S B 3p 3p white white Wires CN1 CN2 4 way valve blue blue CN5 CN6 Crankcase heating cable red red CN3 L IN red CN4 N IN black 8 Disconnect the grounding wire...

Страница 77: ...18 2 Remove the electrical control box cover 3 Extract the refrigerant gas 4 5 6 7 8 Lift the compressor Remove the compressor terminal cover and disconnect the crankcase electric heater and compresso...

Страница 78: ...the electrical parts see the Electrical parts section 4 Remove the screw securing the coil and remove the coil 5 Detach the welded parts of the 4 way valve and pipe Coil Welded parts Complete the step...

Страница 79: ...8 CONT 7 The expansion valve How to remove the expansion valve 2 Remove the electrical parts per the Electrial Parts section 3 Remove the coils 4 Detach the welded parts of the expansion valves and pi...

Страница 80: ...e 1 2 3 4 5 Remove the big handle screws 4 then remove the big handle Remove the top cover screws and remove the top cover Remove the right front side panel screw 1 and remove the right front side pan...

Страница 81: ...LY INSTRUCTIONS SIZE 24 CONT 6 Front panel screws Right front side panel screws Front panel screws Front panel screws Front panel screws Remove the terminal board screws 2 the water collector screws a...

Страница 82: ...82 Specifications subject to change without notice 38MGR 04SM DISASSEMBLY INSTRUCTIONS SIZE 24 CONT Right rear panel screws Terminal board screws...

Страница 83: ...sembly 1 Remove the top cover right front side panel and the front panel See How to Remove the Panel Plate 2 Remove the hex nut securing the fan 3 Remove the fan 4 Remove the electrical control box 5...

Страница 84: ...3 Unfasten the reactor connector 4 Unfasten the compressor connector 5 Disconnect the following connection wires and connectors between the IPM and the PCB CN1 5p white CN14 3p white CN3 red or brown...

Страница 85: ...ure sensor 2p white CN15 T2B A B C temperature sensor 2p 2p 2p white CN18 CN19 CN22 Electronic expansion valve A B C 6p 6p 6p red red red CN25 CN23 CN20 S A S B S C 3p 3p 3p white white white Wires CN...

Страница 86: ...ove the electrical control box and partition plate 3 Extract the refrigerant gas 4 Remove the sound insulation material and crankcase heating cable 5 Remove the compressor terminal cover the compresso...

Страница 87: ...he inductance cover 4 Disconnect the two wires connected to the inductance cover 5 Remove the reactor screws 4 then remove the reactor 6 The 4 way valve How to remove the 4 way valve 1 Compete the ste...

Страница 88: ...E 24 CONT 7 The expansion valve How to remove the expansion valve 1 Complete steps in the Panel Plate and Fan Assembly sections 2 Remove the electrical parts See the Electrical Parts section 3 Remove...

Страница 89: ...plate How to remove the panel plate 1 Turn off the air conditioner Turn off the power breaker 2 Remove the big handle screws 3 Remove the top cover screws and then remove the top cover 4 screws 4 Rem...

Страница 90: ...Remove the terminal board screws 2 the water collector screws and the right rear panel screws 15 and then remove the right rear panel 5 Remove the front panel screws 8 and remove the front panel Fron...

Страница 91: ...EMBLY INSTRUCTIONS SIZE 30 CONT 2 Fan assembly How to remove the fan assembly 1 Remove the top cover right front side panel and the front panel as described in the Panel Plate section 2 Remove the hex...

Страница 92: ...cal control box 5 Disconnect the fan motor connector CN19 3P white from the driver board 6 Remove the screws 4 and then remove the fan motor 3 Electrical parts How to remove the electrical parts 1 Com...

Страница 93: ...Connectors CN8 T3 T4 temperature sensor 2p 2p white CN33 Discharge temperature sensor 2p white CN13 T2B A B C D temperature sensor 2p 2p 2p 2p white CN18 CN17 CN21 CN20 Electronic expansion valve A B...

Страница 94: ...te Fan Assembly and Electrical Parts sections 2 Remove the electrical control box and the partition plate 3 Extract the refrigerant gas 4 Remove the sound insulation material and the crankcase heating...

Страница 95: ...e Panel Plate and Fan Assembly sections 2 Extract the refrigerant gas 3 Remove the electrical parts See the Electrical Parts section 4 Remove the coil screw and remove the coil 5 Detach the welded par...

Страница 96: ...48 No Part name Procedures Remarks 1 Fan assembly How to remove the fan assembly 1 Turn off the air conditioner Turn off the power breaker 2 Remove the air outlet grille screws 8 3 Remove the hex nut...

Страница 97: ...hen remove the front side panel 7 Disconnect the fan motor connectors FAN1 3p white and FAN2 3p white from the DC motor driver board 8 Remove the fan screws and remove the fan motor 2 Panel plate How...

Страница 98: ...teps 5 and 6 from the Fan Assembly section and all the steps from the Panel Plate section 2 Disconnect the fan motor connector 5p white from the IPM board IPM board PCB board DC Fan Driver board 2 Rem...

Страница 99: ...9 10p white 4 Remove the screws and then remove the IPM board 5 Disconnect the connectors and wires connected from the PCB and the other parts Connectors CN8 Discharge temperature sensor 2p white CN12...

Страница 100: ...sis orange orange CN1 L IN red CN3 N IN black 6 Disconnect the grounding wire yellow green after removing the big handle 7 Remove the PCB board 4 Compressor How to remove the compressor 1 Complete ste...

Страница 101: ...securing the compressor to the bottom plate 7 Lift the compressor 5 The 4 way valve How to remove the 4 way valve 2 Extract the refrigerant gas 3 Remove the electrical parts see section 3 4 Remove the...

Страница 102: ...ut notice and without incurring obligations Replaces 38MGR 03SM DISASSEMBLY INSTRUCTIONS SIZES 36 AND 48 CONT 6 The expansion valve How to remove the expansion valve 1 Complete the steps in the Fan As...

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