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PRODIGY Technical Manual

32

6.8 How to Remove the Evaporator

assembly

CAUTION:

Because the 24K indoor unit is

relatively large and heavy, it must have two

persons to implement the following steps.

Step1:

Remove the Electric control box.

Step2:

Remove the Chassis assembly

Step3:

Unfold the Pipe clamp board C, remove screw

A and B.

Step4:

Pull out the evaporator.

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Содержание KAE-26 DN7

Страница 1: ...PRODIGY 3D Inverter Technical Manual ...

Страница 2: ...or the first time 21 5 5 Adding the refrigerant after running the system for many years 23 5 6 Re installation while the indoor unit need to be repaired 24 5 7 Re installation while the outdoor unit need to be repaired 25 6 Disassemble Guide 27 7 Operation Characteristics 33 8 Electronic function 34 8 1 Abbreviation 34 8 2 Display function 34 8 3 Main Protection 35 8 4 Operation Modes and Function...

Страница 3: ...d Be sure the installation area does not deteriorate with age If the base collapses the air conditioner could fall with it causing property damage product failure and personal injury Do not let the air conditioner run for a long time when the humidity is very high and a door or a window is left open Take care to ensure that power cable could not be pulled out or damaged during operation There is r...

Страница 4: ...ion particularly on the condenser and evaporator fins could cause product malfunction or inefficient operation Operational Do not expose the skin directly to cool air for long time Do not sit in the draft Do not use the product for special purposes such as preserving foods works of art etc It is a consumer air conditioner not a precision refrigerant system There is risk of damage or loss of proper...

Страница 5: ...ual 5 2 Function and specifications Model Names of Indoor Outdoor Units 3D inverter Capacity Indoor units Outdoor units 9k KAY 26 DN7 KAE 26 DN7 12k KAY 35 DN7 KAE 35 DN7 18k KAY 52 DN7 KAE 52 DN7 24k KAY 71 DN7 KAE 71 DN7 ...

Страница 6: ...Average Pdesignh kW 2 4 2 6 SCOP W W 4 1 4 2 Energy Efficiency Class A A Tbiv 7 7 Heating Warmer Pdesignh kW 3 0 3 0 SCOP W W 5 1 5 2 Energy Efficiency Class A A Tbiv 2 2 Tol 15 15 Moisture Removal L h 1 0 1 2 Max input consumption W 2075 2200 Max current A 9 5 10 Starting current A Compressor Model ASN98D22UFZ ASN98D22UFZ Type ROTARY ROTARY Brand GMCC GMCC Capacity Btu h 10014 10014 Input W 748 7...

Страница 7: ... 21x13 37 21x13 37 c Fin spacing mm 1 2 1 2 d Fin type code Hydrophilic aluminium Hydrophilic aluminium e Tube outside dia and type mm Ф7 innergroove tube Φ7 innergroove tube f Coil length x height x width mm 744x504x13 37 870x504x13 37 g Number of circuits 2 2 Outdoor air flow m3 h 1900 2000 Outdoor sound pressure level dB A 55 56 Outdoor sound power level dB A 58 59 Outdoor unit Dimension W D H ...

Страница 8: ...y Efficiency Class A A Tbiv 7 7 Heating Warmer Pdesignh kW 4 7 7 2 SCOP W W 5 4 5 2 Energy Efficiency Class A A Tbiv 5 4 Tol 15 15 Moisture Removal L h 1 7 2 3 Max input consumption W 2550 3700 Max current A 11 5 17 Starting current A Compressor Model ASM135D23UFZ ATF235D22UMT Type ROTARY ROTARY Brand GMCC GMCC Capacity Btu h 13836 24345 Input W 1035 1970 Rated current RLA A 7 32 6 95 Locked rotor...

Страница 9: ...Hydrophilic aluminium Hydrophilic aluminium e Tube outside dia and type mm Φ9 52 innergroove tube Φ9 52 innergroove tube f Coil length x height x width mm 860x508x44 730x660x44 g Number of circuits 4 4 Outdoor air flow m3 h 2100 2700 Outdoor sound pressure level dB A 58 61 Outdoor sound power level dB A 63 65 Outdoor unit Dimension W D H mm 800x333x554 845x363x702 Packing W D H mm 920x390x615 965x...

Страница 10: ...PRODIGY Technical Manual 10 3 Dimensions 3 1 Indoor Unit Model W D H KAY 26 DN7 717 193 302 KAY 35 DN7 805 193 302 KAY 52 DN7 964 222 325 KAY 71 DN7 1106 232 342 ...

Страница 11: ...PRODIGY Technical Manual 11 For KAY 26 DN7 ...

Страница 12: ...PRODIGY Technical Manual 12 For KAY 35 DN7 For KAY 52 DN7 ...

Страница 13: ...PRODIGY Technical Manual 13 For KAY 71 DN7 ...

Страница 14: ...PRODIGY Technical Manual 14 3 2 Outdoor Unit ...

Страница 15: ...PRODIGY Technical Manual 15 For KAE 26 DN7 ...

Страница 16: ...PRODIGY Technical Manual 16 For KAE 35 DN7 KAE 52 DN7 ...

Страница 17: ...PRODIGY Technical Manual 17 For KAE 71 DN7 ...

Страница 18: ...am LIQUID SIDE GAS SIDE HEAT EXCHANGE EVAPORATOR HEAT EXCHANGE CONDENSER COMPRESSOR 2 WAY VALVE 3 WAY VALVE 4 WAY VALVE COOLING HEATING T2 Evaporator temp sensor T1 Room temp sensor ACCUMULATOR INDOOR OUTDOOR CHECK VALVE Heating Model only CAPILIARY TUBE ...

Страница 19: ... 479kgf cm Ф19 3 4 6500 663kgf cm 6700 683kgf cm 5 2 Connecting the cables The power cord of connect should be selected according to the following specifications sheet Rated current of appliance Nominal cross sectional area mm 3 and 6 0 75 6 and 10 1 10 and 16 1 5 16 and 25 2 5 The cable size and the current of the fuse or switch are determined by the maximum current indicated on the nameplate whi...

Страница 20: ...itional refrigerant g m Gas Liquid KAY 26 DN7 KAE 26 DN7 3 8 Ф9 52 1 4 Ф6 35 5 10 25 15 KAY 35 DN7 KAE 35 DN7 3 8 Ф9 52 1 4 Ф6 35 5 10 25 15 KAY 52 DN7 KAE 52 DN7 1 2 Ф12 7 1 4 Ф6 35 5 20 30 15 KAY 71 DN7 KAE 71 DN7 5 8 Ф15 9 3 8 Ф9 52 5 25 50 30 Caution The capacity test is based on the standard length and the maximum permissive length is based on the system reliability ...

Страница 21: ...d position 2 Connect the charge hose with the push pin of handle lo to the 3 way valves gas service port 3 Connect the charge hose of handle hi connection to the vacuum pump 4 Fully open the handle Lo of the manifold valve 5 Operate the vacuum pump to evacuate 6 Make evacuation for 30 minutes and check whether the compound meter indicates 0 1Mpa If the meter does not indicate 0 1Mpa after pumping ...

Страница 22: ...kage 5 Discharge the refrigerant Close the valve on the charging cylinder and discharge the refrigerant by loosening the flare nut on the 2 way valve approximately 45 until the gauge indicates 0 3 to 0 5 Mpa 6 Disconnect the charge set and the charging cylinder and set the 2 way and 3 way valves to the open position Be sure to use a hexagonal wrench to operate the valve stems 7 Mount the valve ste...

Страница 23: ...the refrigerant after running the system for many years Procedure 1 Connect the charge hose to the 3 way service port open the 2 way valve and the 3 way valve Connect the charge hose to the valve at the bottom of the cylinder If the refrigerant is R410A make the cylinder bottom up to ensure liquid charge 2 Purge the air from the charge hose Open the valve at the bottom of the cylinder and press th...

Страница 24: ...e charge hose for 5 seconds and then close it quickly 4 Set the 2 way valve to the close position 5 Operate the air conditioner at the cooling cycle and stop it when the gauge indicates 0 1MPa 6 Set the 3 way valve to the closed position immediately Do this quickly so that the gauge ends up indicating 0 3 to 0 5Mpa Disconnect the charge set and tighten the 2 way and 3 way valve s stem nuts Use a t...

Страница 25: ...d set the 2 way and 3 way valves to the open position Be sure to use a hexagonal wrench to operate the valve stems 7 Mount the valve stems nuts and the service port cap Be sure to use a torque wrench to tighten the service port cap to a torque 18N m Be sure to check the gas leakage 5 7 Re installation while the outdoor unit need to be repaired 1 Evacuation for the whole system Procedure 1 Confirm ...

Страница 26: ...n the valves Low side on the charge set and charge the system with liquid refrigerant If the system cannot be charge with the specified amount of refrigerant or can be charged with a little at a time approximately 150g each time operating the air conditioner in the cooling cycle however one time is not sufficient wait approximately 1 minute and then repeat the procedure 5 When the electronic scale...

Страница 27: ... the filter a little to loosen the fastener Step2 Pull the filter gently along the horizontal direction Step3 Pull out the filter 6 2 How to Remove the horizontal louver Step1 Open the horizontal louver push the locker towards right to open it Step2 Bend the horizontal louver lightly remove it from the indoor unit ...

Страница 28: ...aps A and B remove the two screws Step2 Open the panel assembly move the slider to fix the panel Step3 Press the locker A and B to lose the indoor from the installation plate Step4 Unfold the supporter of Installation plate then let it to hold the indoor unit helpful to do pipe connection in the back ...

Страница 29: ...to Remove the panel assembly Step1 Open the screw caps A and B remove the two screws Step2 Open the panel assembly loosen the display board connector Step3 Pull the panel assembly along the direction indicated in right image to remove it ...

Страница 30: ...ssary to remove the panel to remove the PCB in order to show clearly inside these pictures are without panel 6 6 How to Remove the Electrical control box Step1 Remove screw A B C pull out the coil temp sensor D from the sensor holders Step2 pull out the Electrical control box Note It is not necessary to remove the panel to remove the Electrical control box in order to show clearly inside these pic...

Страница 31: ...take for this sample you need to remove screw X to lift the E box a little Then you can remove the Screw E This problem will be solved before mass production Step3 Open the E box to lose the fan motor and louver motor connectors from the PCB Step4 Press the locker H and I to lose the indoor from the installation plate lift it a little and pull out it along the direction indicated in right image No...

Страница 32: ...ON Because the 24K indoor unit is relatively large and heavy it must have two persons to implement the following steps Step1 Remove the Electric control box Step2 Remove the Chassis assembly Step3 Unfold the Pipe clamp board C remove screw A and B Step4 Pull out the evaporator ...

Страница 33: ...may come into operation and cause the unit to operate abnormally 2 The room relative humidity should be less than 80 If the air conditioner operates beyond this figure the surface of the air conditioner may attract condensation Please set the vertical air flow louver to its maximum angle vertically to the floor and set HIGH fan mode 3 For units with auxiliary electric heater When outside temperatu...

Страница 34: ...ys the room temperature in Fan and Drying mode Displays the self diagnostic codes Dispalys for three seconds when Timer ON Fresh Swing Turbo or Silence feature is activated Dispalys for three seconds when Timer OFF is set Dispalys for three seconds when Fresh Swing Turbo or Silence feature is cancelled Dispalys under deforsting operation Dispalys when anti cold air feature is activated under heati...

Страница 35: ...bout current voltage and temperature If these protections happen the corresponding code will display on indoor unit and the unit will stop working 8 3 6 Indoor fan delayed open function When the unit starts up the louver will be active immediately and the indoor fan will open 7s later If the unit runs in heating mode the indoor fan will be also controlled by anti cold wind function 8 3 7 Compresso...

Страница 36: ...emperature compensation When the AC run in mute mode the compressor will run with low frequency When the current is more than setting value the current protection function will be activated and the compressor will stop 8 4 2 2 Outdoor fan running rules The outdoor unit will be run at different fan speed according to T4 For different outdoor units the fan speeds are different T4 A A B C D E 8 4 2 3...

Страница 37: ... compressor will stop 8 4 2 5 Evaporator temperature protection When Evaporator temperature temp is less than setting value the compressor will stop 8 4 3 Heating Mode 8 4 3 1 Compressor running rules When T1 Ts ΔT the compressor will stop when T1 TS ΔT 1 5 the compressor will be on ΔT is the programmed parameter of temperature compensation When the AC run in mute mode the compressor will run with...

Страница 38: ...w the anti cold air function will start and indoor fan motor will run at low speed the speed can t be changed when the temp is lower than setting value the indoor fan motor will stop When the indoor temp reaches the setting temp the compressor will stop the indoor fan motor will run at the minimum speed or setting speed The anti cold air function is valid The indoor fan is controlled as below Sett...

Страница 39: ...8 4 3 5 Evaporator coil temperature protection T2 Resume Off Decrease Hold When evaporator temperature temp is more than the setting protection value the compressor will stop 8 4 4 Auto mode This mode can be chosen with remote controller and the setting temperature can be changed between 17 C 30 C In auto mode the machine will choose cooling heating or fan only mode according to ΔT ΔT T1 Ts T1 Ts ...

Страница 40: ...emperature stops rising and indoor fan is fixed at low speed Anti cold wind function has the priority 8 4 7 3 Operation time in sleep mode is 7 hours After 7 hours the AC quits this mode and turns off 8 4 7 4 Timer setting is available 8 4 8 Auto Restart function The indoor unit is equipped with auto restart function which is carried out through an auto restart module In case of a sudden power fai...

Страница 41: ...ange information from remote controller signal but it will not affected by the setting temperature 4 When the unit is running with follow me function if the PCB doesn t receive any signal from remote controller for 7 minutes or pressing FOLLOW ME button again the follow me function will be turned off automatically and the temperature will control the unit according to the room temperature detected...

Страница 42: ...temp Targeted Frequency FT Targeted Frequency Actual Frequency Fr Actual Frequency Indoor fan speed IF Indoor fan speed Outdoor fan speed OF Outdoor fan speed EXV opening angle LA EXV opening angle Compressor continuous running time CT Compressor continuous running time Causes of compressor stop ST Causes of compressor stop Reserve A0 Reserve A1 Reserve 0 Reserve 1 Reserve 2 Reserve 3 Reserve 4 Re...

Страница 43: ...rbo For some big capacity motors 14 FF Actual fan speed Display value turns to decimal value and then multiply 10 The unit is RPM For some small capacity motors display value is from 14 FF hexadecimal the corresponding fan speed range is from 200 2550RPM EXV opening angle 0 FF Actual EXV opening value Display value turns to decimal value and then multiply 2 Compressor continuous running time 0 FF ...

Страница 44: ...l the unit will run in Auto mode Auto fan speed 24 setting temp When ON OFF control closed it will send switch off signal 8 5 3 3 Dip switch F2 setting status are as below Dip switch 2 Dip switch 1 Remote on off control status OFF ON Disconnected send ON closed send OFF ON ON Closed send OFF disconnected send ON 8 5 4 4 cored wired controller Central controller and Non polar wired controller Note ...

Страница 45: ...board must be set differently The connection method must be Bus type 8 5 2 The setting state are the same for all the indoor units connected to the same Non polar wired controller 8 5 6 Alarm port output 8 5 6 1 When the Air condition in off state the output signal is closed 8 5 6 2 When the Air condition in malfunction state the output signal is closed 8 5 6 3 When the Air condition in on state t...

Страница 46: ...ischarge the electricity power in capacitor Electrolytic Capacitors HIGH VOLTAGE CAUTION For other models please connect discharge resistance approx 100Ω 40W or soldering iron plug between terminals of the electrolytic capacitor on the contrary side of the outdoor PCB Note The picture above is only for reference The plug of your side may be different ...

Страница 47: ...on 1 times O F0 Overload current protection 2 times O F1 Outdoor ambient temperature sensor T4 open circuit or short circuit 3 times O F2 Condenser coil temperature sensor T3 open circuit or short circuit 4 times O F3 Compressor discharge temperature sensor T5 open circuit or short circuit 5 times O F4 Outdoor unit EEPROM parameter error 6 times O F5 Outdoor fan speed has been out of control 1 tim...

Страница 48: ...osed causes Installation mistake PCB faulty Trouble shooting Yes Replace the indoor outdoor main PCB Power off then restart the unit 2 minutes later EEPROM a read only memory whose contents can be erased and reprogrammed using a pulsed voltage For the location of EEPROM chip please refer to the below photos Note The two photos above are only for reference it s may be not same totally with the ones...

Страница 49: ... S Black pan N Yes Power off then restart the unit 2 minutes later Power off then restart the unit 2 minutes later No Replace the outdoor main PCB Power on Is the error extinguished Replace the outdoor main PCB Power on Is the error extinguished Check the outdoor wiring connection Check the outdoor wiring connection Replace the indoor main PCB Power on Is the error extinguished Replace the indoor ...

Страница 50: ...anual 50 Remark Use a multi meter to test the resistance of the reactor which does not connect with capacitor The normal value should be around zero ohm Otherwise the reactor must have malfunction and need to be replaced ...

Страница 51: ...he failure Supposed causes Wiring mistake Fan ass y faulty Fan motor faulty PCB faulty Trouble shooting Power off then restart the unit 2 minutes later Shut off the power supply Rotate the fan by hand The unit operates normally Find out the cause and have it solved Check the wiring of fan motor No Yes No Correct the connections No No Replace the fan motor Yes Yes Measure the voltage for the fan mo...

Страница 52: ...C Fan Motor control chip is in outdoor PCB Power on and check if the fan can run normally if the fan can run normally the PCB must has problems and need to be replaced If the fan can t run normally measure the resistance of each two pins If the resistance is not equal to each other the fan motor must have problems and need to be replaced otherwise the PCB must has problems and need to be replaced ...

Страница 53: ...ntinuous 3 minutes and this situation happens 3 times the display area will show EC and AC will turn off Supposed causes T2 sensor faulty Indoor PCB faulty System problems such as leakage or blocking Trouble shooting Check cool air blowing out from indoor air outlet Yes Yes Check if T2 sensor is well fixed No Check leakage of system No Power off then restart the unit 2 minutes later Replace indoor...

Страница 54: ...n 0 06V or higher than 4 94V the LED will display the failure Supposed causes Wiring mistake Sensor faulty PCB faulty Trouble shooting Check the connection between temperature sensor and PCB Correct the connection No Yes Replace indoor or outdoor main PCB Measure the resistance value of the sensor Repalce the sensor No Yes ...

Страница 55: ...pposed causes Power supply problems System blockage PCB faulty Wiring mistake Compressor malfunction Check the power supply Check the connections and wires Stop the unit No Yes No Correct the connections or replace the wires Yes Replace the outdoor unit Yes Check the reactor No Replace outdoor main PCB Check the blockage of system Yes No Clear the blockage Check the compressor resistance values Ye...

Страница 56: ...IPM malfunction Outdoor fan ass y faulty Compressor malfunction Outdoor PCB faulty Trouble shooting Check the wiring between main PCB and compressor Correct the connection or replace the wires and connectors Yes No Check the IPM No Yes Replace the IPM board or replace the main PCB Check the outdoor fan and the outdoor unit ventilation No Please refer to the solution of Fan Speed Has Been Out Of Co...

Страница 57: ... Error Code P1 Malfunction decision conditions An abnormal voltage rise or drop is detected by checking the specified voltage detection circuit Supposed causes Power supply problems System leakage or block PCB faulty Trouble shooting Check the power supply Check the connections and wires Stop the unit No Yes No Correct the connections or replace the wires Yes Replace the reactor Yes No Replace the...

Страница 58: ... PCB faulty Trouble shooting Check the air flow system of indoor and outdoor units Clear up the air inlet and outlet or the heat exchanger of indoor and outdoor units Yes No Yes Yes Power off then restart the unit 10 minutes later Check if the temperature of compressor No Check refrigerant system Yes Check the overload protector Correct the connection No Measure the resistance between the two port...

Страница 59: ... causes Wiring mistake IPM malfunction Outdoor fan ass y faulty Compressor malfunction Outdoor PCB faulty Trouble shooting Check the wiring between main PCB and compressor Correct the connection or replace the wires and connectors Yes No Check the IPM No Yes Replace the IPM board or replace the main PCB Check the outdoor fan and the outdoor unit ventilation No Please refer to the solution of Fan S...

Страница 60: ...rature sensor from PCB measure the resistance value with a tester Temperature Sensors Room temp T1 sensor Indoor coil temp T2 sensor Outdoor coil temp T3 sensor Outdoor ambient temp T4 sensor Compressor discharge temp T5 sensor Measure the resistance value of each winding by using the multi meter ...

Страница 61: ...359 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 80 176 1 17393 120 248 0 35982 1 34 33 3269 41 106 4 96392 81 178 1 13604 121 250 0 35042 2 36 31 5635 42 108 4 76253 82 180 1 09958 122 252 0 3413 3 37 29 9058 43 109 4 5705 83 181 1 06448 123 253 0 33246 4 39 28 3459 4...

Страница 62: ...8 084 115 239 2 422 4 25 222 8 36 97 34 32 76 169 7 82 116 241 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 6 859 120 248 2 117 1 34 171 9 41 106 28 81 178 6 641 121 250 2 061 2 36 163 3 42 108 26 9 82 180 6 43 122 252 2 007 3 37 155 2 43 109 25 86 83 181 ...

Страница 63: ...ual 63 2 Compressor checking Measure the resistance value of each winding by using the tester Position Resistance Value ASN98D22UFZ ASM135D23UFZ ATF235D22UMT Blue Red 1 57Ω 20 68 1 75Ω 20 68 0 75Ω 20 68 Blue Black Red Blue ...

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