ob207t-1qxp 25/9/97 8:51 pm page 1...

TAC-09CSC/K TAC-09CHSC/K

WALL MOUNTED SPLIT-TYPE AIR CONDITIONERS

CONTENTS

1. IMPORTANT NOTICE ···································2 2. TECHNICAL SPECIFICATION ·····················33. DIMENSIONS ················································84. REFRIGERATING CYCLE SYSTEM ············· 9 5. PERFORMANCE CURVES ····························126. OPERATION DETAILS ·············167. WIRING DIAGRAM ······························238. EXPLOSION VIEW ···················299. PARTS LIST ·································33

10. ANNEX 1 THERMISTOR CHARACTERISTIC11. ANNEX 2 GENERAL12. ANNEX 3 TROUBLE SHOOTING13. ANNEX 4 R407C REFRIGERANT

Models

TAC-07CS/K TAC-07CHS/K TAC-09CS/K TAC-09CHS/K TAC-12CS/K

TAC-12CHS/K TAC-24CS/K TAC-24CHS/K

OB207t-1qxp 25/9/97 8:51 PM

TCL

14. ANNEX 5 INSTALLATION INSTRUCTION Part 1

SERVICE MANUAL

TAC-07CSC/K TAC-07CHSC/K

TAC-12CSC/K TAC-12CHSC/KTAC-18CSC/K TAC-18CHSC/KTAC-24CSC/K TAC-24CHSC/K

No.TE031229

TAC-18CS/K TAC-18CHS/K

IMPORTANT NOTICE

This service manual is intended for use by individuals possessing adequate backgrounds of electrical, electronic and mechanical experience. Any attempt to repair the appliance may result in personal injury and property damage. The manufacturer or seller cannot be responsible for the interpretation of this information, nor can it assume any liability in connection with its use.

The information, specifications and parameter are subject to change due to technical modification or improvement without any prior notice. The accurate specifications are presented on the nameplate label.

How to order spare parts To have your order filled promptly and correctly, please furnish the following information:

1. Model No. with Indoor or Outdoor

2. No. in the Explosion View

3. Part Name

4. The quantity you ordered

TCL Air Conditioner Service ManualTCL Air Conditioner Service ManualTCL Air Conditioner Service Manual

TCL Air Conditioner Service Manual

2


3

Technical Specifications

Model No. TAC-07CS/K TAC-07CHS/K TAC-09CS/K TAC-09CHS/K Type Cooling Only Heating Pump Cooling Only Heating Pump Control type Remote Remote Remote Remote Rated cooling capacity Btu/h 7,000 7,000 9,000 9,000 Rated heating capacity Btu/h N/A 7,500 N/A 9,500 EER for cooling Btu/h.w 9.6 9.6 9.6 9.6 COP for heating W/W N/A 2.8 N/A 2.8 Moisture removal Liters/h 0.8 0.8 0.8 0.8

High dB(A) 36 36 36 36 Med. dB(A) 32 32 32 32

Indoor noise level at cooling

Low dB(A) 29 29 29 29 Outdoor noise level dB(A) 50 50 50 50 Electrical Data Power supply 220-240V~/50Hz Voltage Range V 198~264 198~264 198~264 198~264

Cooling A 4.2 4.2 4.2 4.2 Rated current

Heating A N/A 4.1 N/A 4.1 Cooling W 895 895 900 900

Rated input Heating W N/A 880 N/A 880

Refrigerating System Refrigerant/Charge Gram R22/700g R22/700g R22/700g R22/700g

Type Rotary Rotary Rotary Rotary Model ------------------ ----------------- ------------------ ------------------ LRA A ------ ------- ------ ------

Compressor

MFG ----------------- ----------------- ---------------- ----------------- Evaporator Louver fin and Grooved tube type (φ7) Condenser Corrugated fin and Grooved tube type (φ9.53) Expansion device Capillary tube Defrosting system Microcomputer controlled reverse system Fan System Indoor air circulation m3/h 430 430 430 430 Indoor fan type Cross flow Cross flow Cross flow Cross flow

Cooling rpm 1000/950/900 1000/950/900 1000/950/900 1000/950/900 Heating rpm N/A 970/900/800 N/A 970/900/800

Dry rpm 900 900 900 900 Indoor fan speed H/M/L

Sleep rpm 650 650 650 650 Indoor fan motor output W 12 12 12 12 Outdoor air circulation m3/h --- --- --- --- Outdoor fan type Propeller fan Propeller fan Propeller fan Propeller fan Outdoor fan speed rpm 895 895 895 895 Outdoor fan motor output W 31 31 31 31 Connections Refrigerant coupling Flare type

Gas Inches 5/8 5/8 5/8 5/8 Connecting Pipe

Liquid Inches 7/16 7/16 7/16 7/16

Connecting Wiring Size × Core number

Drainage Pipe O.D 16mm Others Suitable area m2 12~19 12~19 12~19 12~19

Indoor mm 710×250×179 710×250×179 710×250×179 710×250×179Net dimensions (W x H x D) Outdoor mm 600×500×232 600×500×232 600×500×232 600×500×232

Indoor kg 7.5 7.5 7.5 7.5 Net weight

Outdoor kg 25 25 25 25 Indoor mm 805×325×270 805×325×270 805×325×270 805×325×270Packing dimensions

(W x H x D) Outdoor mm 745×352×542 745×352×542 745×352×542 745×352×542Indoor kg 10 10 10 10

Gross weight Outdoor kg 28 29 28 29

Loading Capacity 40’/40’HC 132/280/318 132/280/318 132/280/318 132/280/318


4

Model No. TAC-07CSC/K TAC-07CHSC/K TAC-09CSC/K TAC-09CHSC/KType Cooling Only Heating Pump Cooling Only Heating Pump Control type Remote Remote Remote Remote Rated cooling capacity Btu/h 7,000 7,000 9,000 9,000 Rated heating capacity Btu/h N/A 7,500 N/A 9,500 EER for cooling Btu/h.w 11.0 11.0 11.0 11.0 COP for heating W/W N/A 3.2 N/A 3.2 Moisture removal Liters/h 0.8 0.8 0.8 0.8

High dB(A) 38 38 38 38 Med. dB(A) 36 36 36 36






Refrigerating System Refrigerant/Charge Gram R407C/700g R407C/700g R407C/700g R407C/700g


Compressor


Cooling rpm 1230/1150/1000 1230/1150/1000 1230/1150/1000 1230/1150/1000 Heating rpm N/A 1230/1150/1000 N/A 1230/1150/1000 Dry rpm 1000 1000 1000 1000

Indoor fan speed H/M/L


Gas Inches 7/16 7/16 3/4 3/4 Connecting Pipe Liquid Inches 3/4 3/4 7/16 7/16




Indoor kg 8.0 8.0 8 8 Net weight Outdoor kg 31 32 31 32 Indoor mm 863×325×270 863×325×270 863×325×270 863×325×270Packing dimensions

(W x H x D) Outdoor mm 803×380×598 803×380×598 803×380×598 803×380×598Indoor kg 10 10 10 10 Gross weight Outdoor kg 35 36 35 36



5

Model No. TAC-12CS/K TAC-12CHS/K TAC-18CS/K TAC-18CHS/K Type Cooling Only Heating Pump Cooling Only Heating Pump Control type Remote Remote Remote Remote Rated cooling capacity Btu/h 12,000 12,000 18,000 18,000 Rated heating capacity Btu/h N/A 12,800 N/A 19,000 EER for cooling Btu/h.w 9.2 9.2 8.8 8.8 COP for heating W/W N/A 2.65 N/A 2.65 Moisture removal Liters/h 1.0 1.0 1.0 1.5

High dB(A) 38 38 42 42 Med. dB(A) 36 36 40 40






Refrigerating System Refrigerant/Charge Gram R22/870g R22/870g R22/1700g R22/1700g


Compressor

MFG ----------------- ----------------- ---------------- ----------------- Evaporator Louver fin and Grooved tube type (φ7) Condenser Corrugated fin and Grooved tube type (φ9.53) Expansion device Capillary tube Defrosting system Microcomputer controlled reverse system Fan System Indoor air circulation m3/h 530 530 800/850 800/850 Indoor fan type Cross flow Cross flow Cross flow Cross flow

Cooling rpm 1150/1060/900 1150/1060/900 1300/1200/1100 1300/1200/1100Heating rpm N/A 1150/1060/900 N/A 1300/1200/1100Dry rpm 900 900 840 840


Sleep rpm 650 650 900/1000 900/1000 Indoor fan motor output W 12 12 25 25 Outdoor air circulation m3/h --- --- --- --- Outdoor fan type Propeller fan Propeller fan Propeller fan Propeller fan Outdoor fan speed rpm 860 860 820 820 Outdoor fan motor output W 55 55 90 90 Connections Refrigerant coupling Flare type

Gas Inches 7/16 7/16 3/4 3/4 Connecting Pipe

Liquid Inches 3/4 3/4 7/16 7/16




Indoor kg 8.0 8.0 14 14 Net weight

Outdoor kg 31 32 42 43 Indoor mm 863×325×270 863×325×270 1103×395×280 1103×395×280Packing dimensions

(W x H x D) Outdoor mm 803×380×595 803×380×595 863×376×605 863×376×605Indoor kg 10 10 19 19

Gross weight Outdoor kg 34 35 44 45



6

Model No. TAC-12CSC/K TAC-12CHSC/K TAC-18CSC/K TAC-18CHSC/KType Cooling Only Heating Pump Cooling Only Heating Pump Control type Remote Remote Remote Remote Rated cooling capacity Btu/h 12,000 12,000 18,000 18,000 Rated heating capacity Btu/h N/A 12,800 N/A 1,9000 EER for cooling Btu/h.w 10.9 10.9 9.5 9.5 COP for heating W/W N/A 3.2 N/A 2.8 Moisture removal Liters/h 1.0 1.0 1.5 1.5

High dB(A) 38 38 43 43 Med. dB(A) 36 36 40 40






Refrigerating System Refrigerant/Charge Gram R407C/1450g R407C/1450g R407C/1800g R407C/1800g


Compressor


Cooling rpm 1230/1150/1000 1230/1150/1000 1060/970/880 1060/970/880 Heating rpm N/A 1230/1150/1000 N/A 1060/970/880 Dry rpm 1000 1000 880 880







Indoor kg 8.0 8.0 13 13 Net weight Outdoor kg 37 37 48 48 Indoor mm 863×325×270 863×325×270 1103×395×280 1103×395×280Packing dimensions




7

Model No. TAC-24CS/K TAC-24CHS/K TAC-24CSC/K TAC-24CHSC/KType Cooling Only Heating Pump Cooling Only Heating Pump Control type Remote Remote Remote Remote Rated cooling capacity Btu/h 24,000 24,000 24,000 24,000 Rated heating capacity Btu/h N/A 26,000 N/A 26,000 EER for cooling Btu/h.w 9.0 9.0 9.2 9.2 COP for heating W/W N/A 2.55 N/A 2.8 Moisture removal Liters/h 2.2 2.2 2.2 2.2

High dB(A) 47 47 47 47 Med. dB(A) 44 44 44 44



Cooling A 13 13 11.8 11.8 Rated current



Refrigerating System Refrigerant/Charge Gram R22/2500g R22/2500g R407C/2540g R407C/2540g


Compressor


Cooling rpm 1300/1200/1100 1300/1200/1100 1300/1250/1150 1300/1250/1150Heating rpm N/A 1300/1200/1100 N/A 1300/1250/1150Dry rpm 1000 1000 1150 1150







Indoor kg 16 16 16 16 Net weight Outdoor kg 57 60 57 60 Indoor mm 1103×395×280 1103×395×280 1103×395×280 1103×395×280Packing dimensions


Loading Capacity 40’/40’HC 66/142/162 66/142/162 66/142/162 66/142/162 Note: The technical specifications is only reference.

Product Dimensions

Outdoor Unit

OB207t-1qxp 25/9/97 8:51 PM Page 12

Indoor Unit

A

B

16mm

124mm

54 mm

C

HGF

I

KJ

D

E

Unit: mm

Capacity A B C D E F G H I J K 7K&9K 710 250 179 600 500 231 271 296 52 365 55

12K 770865 250 179 700 540 255 290 320 40 439 55 18K 1036 313 204 760 540 255 340 370 62 635 63 24K 1036 313 204 860 730 307 340 370 62 635 63


8

Heat Pump

INDOOR UNIT OUTDOOR UNIT

Indoorheatexchanger

Room temperaturethermistor

Refrigerant pipe(Option)(with heat insulator)

Flared connection

Flared connection

Indoor coilthermistor

Refrigerant pipe(Option)(with heat insulator)

Checkvalve

Capillary tube

Capillary tube

DefrostthermistorCompressor

Accumulator

Outdoorheatexchanger

Refrigerant flow in cooling or Defrosting

Refrigerant flow in heating

Distributor

Reversing valve(4- way valve)

OB207t-1qxp 25/9/97 8:53 PM Page 26

Cooling Only


Refrigerant pipe(Optional)(with heat insulator)

Stop valve(with service port)

Strainer

Refrigerant pipe

(Option)(with heat insulator)

Stop valve Capillary tube

Refrigerant flow in cooling

Outdoorheatexchanger

Room temperaturethermistor

Indoor coilthermistor

Flared connection Compressor

Indoorheatexchanger

Refrigerating Cycle System


22

9

富日

富日

富日

Models Piping size O.D : mm Length of connecting pipe : m

Refrigerant piping

Max. length : m

A

10

15

Indoor unit

0.40

Gas

9.52

12.7

15.88

Liquid

6.35

9.52

Outdoor unit

0

07K

09K

12K

18K

24K

Models Refrigerant piping length (one way)Outdoor unit precharged

(up to 7m) 15m

160

7m

0

10m

60

07K

09K

12K

18K

MAX. HEIGHT DIFFERENCE

ADDITIONAL REFRIGERANT CHARGE(R-22 : g)

MAX. REFRIGERANT PIPING LENGTH

Calculation : Xg=20g/m (A-7)m

Calculation : Xg=30g/m (A-7)m

ModelsOutdoor unit precharged

(up to 7m)

Refrigerant piping length (one way)

15m

240

7m

0

10m

90 24K

OB207t-1qxp 25/9/97 8:53 PM Page 27

see <<Specification>>




10


EVACUATION PROCEDURES(AIR PURGE)

Pipe length :7m maximum

No gas chargeis needed

Pipe lengthexceeding 7m

Charge the prescribedamount of gas

Tighten the cap to the service port to obtain the initial status.

Retighten the cap.

Leak test

After refrigerant pipes are connected and evacuated, fully open all stop valves on gas and liquid pipe sides.Operating without fully opening lowers the performance and causes trouble.

Remove the gage manifold valve quickly from the service port of the stop valve.

Leave it as it is for one or two minutes. Make sure the pointerof the gage manifold valve remains in the same position.

Check the vacuum with the gage manifold valve, then closethe gage manifold valve, and stop the vacuum pump.

Run the vacuum pump for more than 15 minutes and at thistime confirm that the pressure gage indicates –0.1 Mpa.

When vacuuming

Connect the gage manifold valve and the vacuum pump tothe service port of the stop valve on the liquid pipe side of theoutdoor unit.

Connect the refrigerant pipes (both the liquid and gas pipes)between the indoor and the outdoor units.

Remove the service port cap of the stop valve on the side of the outdoor unit gas pipe.(The stop valve will notwork in its initial state fresh out of the factory (totally closed with cap on))

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11


12

The standard data contained in these specifications apply only to the operation of the air conditioner under normal conditions,since operating conditions vary according to the areas where these units are installed. The following information has been pro-vided to clarify the operating characteristics of the air conditioner under the conditions indicated by the performance curve.

(1) GUARANTEED VOLTAGE Rated voltage : ±10% (198 ~ 264V),50Hz

(2) AIR FLOWAir flow should be set at MAX.

(3) MAIN READINGS

(1) Indoor intake air wet-bulb temperature : °CWB(2) Indoor outlet air wet-bulb temperature : °CWB(3) Outdoor intake air dry-bulb temperature : °CDB(4) Total input: W(5) Indoor intake air dry-bulb temperature : °CDB(6) Outdoor intake air wet-bulb temperature : °CWB(7) Total input : W

Indoor air wet/dry-bulb temperature difference on the left side of the chart on next page shows the difference between theindoor intake air wet/dry-bulb temperature and the indoor outlet air wet/dry-bulb temperature for your reference at service.

How to measure the indoor air wet-bulb/dry-bulb temperature difference1. Attach at least 2 sets of wet-and dry-bulb thermometers to the indoor air intake as shown in the figure, and at least 2 sets

of wet-and dry-bulb thermometers to the indoor air outlet. The thermometers must be attached to the position where airspeed is high.

2. Attach at least 2 sets of wet-and dry-bulb thermometers to the outdoor air intake.Cover the thermometers to prevent direct rays of the sun.

3. Check that the air filter is cleaned.4. Open windows and doors of room.5. Press the EMERGENCY OPERATION switch once(twice) to start the EMERGENCY COOL(HEAT) MODE.6. When system stabilizes after more than 15 minutes, measure temperature and take an average temperature.7. 10 minutes later, measure temperature again and check that the temperature does not change.


Cooling

Heating

Wet-and dry-bulbthermometers

Wet-and dry-bulbthermometers

OB207t-2qxp 25/9/97 8:54 PM Page 29


PERFORMANCE CURVES

13

0.7

0.6

0.5

0.4

0.3

7

6

5

4

3

Out

door

low

pre

ssur

e

Ambient temperature(˚C)Ambient humidity(%)


07K 07K

Out

door

uni

t cu

rren

t (A

)

220V

240V220/240V

(kgf/F•G)(MPa•G)

9.1

11.4

7.6

8.5

9.4

10.4

12.0

12.7

8.1

9.2

10.3

11.5

14.0

24

25.5

23.5

21.6

19.6

17.6

15.6

13.7

11.7

28.7

26.5

24.3

22.5

19.9

17.7

15.5

13.2

28.0

25.9

23.7

21.6

19.4

17.2

15.1

12.9

28.0

25.9

23.7

21.6

19.4

17.2

15.1

12.9

19.9

18.4

16.9

15.3

13.8

12.3

10.7

9.2

24

NOTE:The above curves are for the heating operation without any frost.

OUTDOOR LOW PRESSURE AND OUTDOOR UNIT CURRENTCOOL operation① Both indoor and outdoor unit are under the same temperature/humidity condition.

➁ Air flow should be set at MAX.

Dry-bulb temperature Relative humidity(%)

20 50

25 60

30 70

③ The unit of pressure has been changed to MPa on the international system of units(SI unit system).The conversion factor is : 1(MPa • G) =10.2(kgf/ff • G)

OB207t-2qxp 25/9/97 8:54 PM Page 30


0.7

0.6

0.5

0.4

0.3

7

6

5

4

3

12K 12K

Out

door

low

pre

ssur

e



Out

door

uni

t cu

rren

t (A

)

220V

240V

0.7

0.6

0.5

0.4

0.3

7

6

5

4

3

09K 09K

Out

door

low

pre

ssur

e220V

240V



Out

door

uni

t cu

rren

t (A

)

220/240V

220/240V



0.7

0.6

0.5

0.4

0.3

0.2

7

6

5

4

3

2

18K18K

Out

door

low

pre

ssur

e



220V

240V

220/240V

Out

door

uni

t cu

rren

t (A

)


0.7

0.6

0.5

0.4

0.3

0.2

7

6

5

4

3

2

24K

Out

door

low

pre

ssur

e


220V

12

13

24K


220V

240V

Out

door

uni

t cu

rren

t (A

)


OB207t-2qxp 25/9/97 8:54 PM Page 31


14

HEAT operationCondition indoor:Dry bulb temperature 20.0°C

Wet bulb temperature 14.5°COutdoor:Dry bulb temperature 7,15,20°C

Wet bulb temperature 6,12,14.5°C

18K

Out

door

uni

t cu

rren

t (A

)

Out

door

uni

t cu

rren

t (A

)

Out

door

uni

t cu

rren

t (A

)

Out

door

uni

t cu

rren

t (A

)

Ambient temperature(˚C) Ambient temperature(˚C)

Ambient temperature(˚C) Ambient temperature(˚C)

220V

240V

09K

07K 12K

220V

240V

13

12

11

10

9

Out

door

uni

t cu

rren

t (A

)

Ambient temperature(˚C)

24K

220V

240V

220V

240V

220V

240V

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15

16

Note: Each mode and relevant function will be further specified in following pages.

SLEEP FAN

TIMER SWING

ON/OFFMODE

MID

SWING

AUTO

DRYFANHEAT

COOLFEEL

SLEEP TIMER ON

HIGH

LOW

TMIER OFF

The remote controller transmits signals to the system.

Remote controller

1

2

4

3

5

6

7

8

8

4

MODE button

FAN SPEED control button

UP button (TOO COOL button)

DOWN button (TOO WARM button)

ON/OFF button

SLEEP button

VANE control button

TIMER button

Used to select the type of operation mode: Feel, Cooling, Dry, Fan and Heating(Only for Heat Pump).

Used to select the indoor fan motor speed: Auto, High, Mid and Low.

Used to increase the set room temperature

and time.

Used to decrease the set room temperatureand time.

Used to set or cancel sleep mode operation.

Used to start and stop operation when pressed.

Used to adjust airflow direction.

Used to select TIMER operation.

Remote controller

62

5

3

7

1

11


Operation Details

Remote Controller presettinger presetting presetting as Cooling Only Air Conditioner or Heat Pump by

manufacturer.Each time after the remote controller replace batteries or is energized, the arrowhead will flashes on the front of

Heat or Cool on LCD of the remote controller.User can preset the remote controller type depending on the air conditioner type you have purchased as follows:Press any button when the arrowhead flashes on the front of Cool , Cooling Only is set.

The remote controller is not

Press any button when the arrowhead flashes on the front of Heat , Heat Pump is set.If you don t press any button within 10 seconds, the remote controller is preset as Heat Pump automatically.

Note :If the air conditioner you purchased is a Cooling Only one, but you preset the remote controller as Heat Pump, it doesn t bring any matter. But if the air conditioner you purchased is a Heat Pump one, and you preset the remote controller as Cooling Only, then you CAN NOT preset the Heating operation with the remote controller.


17

Elctronic Controller 1. Safety Control

(1) Time Delay Safety Control 3 minutes delay for compressor---The compressor is ceased for 3minutes to balance the pressure in the

refrigeration cycle in order to protect the compressor. 2 minutes delay for 4-way valve---The 4-way valve is ceased for 2 minutes to prevent the

refrigerant-gas abnormal noise when the HEATING operation is OFF or switch to the other operation mode.

20 seconds delay for indoor fan--- When the assistant thermistor turns off, the indoor fan operates in low speed for 20 seconds to release the heat of indoor unit.

(2) Indoor Pipe Temperature Sensor Frost Prevention Control When the indoor pipe temperature sensor reads 0 or below for 5 minutes, the indoor pipe temperature sensor frost prevention control starts. The compressor and outdoor fan stop and indoor fan operates at high speed for 3 minutes. After that, if the indoor pipe temperature sensor reads less than 5 this control prolonged until the indoor pipe temperature sensor reads 5 or more.

(3) High Temperature Protection Control During HEATING operation, the outdoor fan motor and compressor are controlled by the indoor pipe temperature to prevent the high temperature of compressor. Outdoor fan OFF: 52 Outdoor fan ON:48 Compressor OFF:62 Compressor ON:48

2. “I Feel” Mode Operation (1) When the “I Feel” mode is selected, the operation mode and initial set temperature are determined by the

initial room temperature at start-up of the operation except to turn off the air conditioner and operates it again.

(2) If the mode is change to “I Feel” mode from other mode, the “I Feel” mode doesn’t operate until compressor stop for more than 3 minutes.

In the “I Feel” mode , when the controller receives the up or down single of temperature, the set temperature can adjust by 1 upper or lower. The biggest you can adjust by 2 upper or lower.

3. “COOLING” Mode Operation (1) When the COOLING mode is selected without setting temperature, the system will set the set temperature at

26 automatically with the AUTO FAN speed. (2) When selecting the COOLING mode operation, the system will operate according to the setting by the

remote controller and the operation is as following:

Mode Initial room temperature

COOLING

DRY

HEATING for Heat Pump Type FAN for Cooling Only Type

26 or more

20 to 25

Less than 20

Initial set temperature

24

18

23


18

Room Temp. Set TEMP. ＋1 Set TEMP. －1

Time More than 2 min More than 2 min More than 2 min More than 2 min More than 2 min

Indoor Fan Set Speed Set Speed Set Speed Set Speed Set Speed Compressor ON OFF ON OFF ON Outdoor Fan ON OFF ON OFF ON

4. “DRY” Mode Operation

(1) The system for DRY operation used the same refrigerant circle as the cooling circle. (2) When the system operates in DRY mode ,at first it operates in cooling mode at 18 for 3 minutes, and

then, the system operates in cooling mode with low speed that regards the temperature of the room temperature sensor reads decrease 2 as the set temperature. During the course of this, the fan speed setted operation is failing but the vane motor can be controlled.

5. “HEATING” Mode Operation (Only available for Heat Pump) (1) When the HEATING mode is selected without setting temperature, the system will set the temperature at 23 automatically with the AUTO FAN speed.

(2) When selecting the HEATING mode operation, the system will operate according to the setting by the remote controller and the operation is as following:

Set Temp. ＋1 Set Temp. －1

Room Temp. Time More than 2 min More than 2 min More than 2 min More than 2 min More than 2 min

Compressor ON OFF ON OFF ON Outdoor fan ON OFF ON OFF ON

(3) In HEATING mode, the indoor fan motor is controlled by Cold Air Prevention Control. (4) Cold Air Prevention Control

The function is intend to prevent cold air from being discharged when the heating operation starts or when defrosting.

The indoor fan speed will be controlled as following: The vane angle is at the angle C(100°).

34 30 27 25 23

OFF UL Set Speed UL OFF UL

Indoor Pipe Temperature


19

(5) Defrost Defrosting of the outdoor heat exchange is controlled by the microprocessor with detection by the defrost sensor. Defrost starting conditions

When the conditions of a) or b) is satisfy, the defrosting operation starts. a) Under the heating operation, the compressor cumulative operation time exceeds 50 minutes and the temperature of the outdoor defrost sensor reads lower than －8 b) Under the heating operation, the compressor cumulative operation time exceeds 50 minutes, if the indoor pipe temperature sensor reads lower than 40 continuously for 2minutes. Note: If haven’t the outdoor pipe temperature sensor that use the condition b) to defrost, against use the condition a).

Defrost terminating conditions When the condition c) or d) is satisfy, the defrosting operation stops. c) The outdoor defrost sensor reads 15 or more. d) The defrosting time exceeds 10 minutes.

Defrosting time chart

Outdoor Fan ON OFF ON Revering Valve ON OFF ON

Compressor Relay ON OFF ON OFF ON 39S 5S Defrost Count MAX 12min 19S 15S t

(6) Assistant Thermistor Function Assistant thermistor is add the thermitor of the electricity to rise the heating capacity automatically not effected by the signal of the remote controller about assistant thermistor ON/OFF buttons.

1) When the condition all of A~G are satisfy, the assistant thermistor opens. A. Under the heating operation, the compressor operates over than 3 minutes. B. The indoor fan operates in normal. C. The system operates not in defrosting. D. The assistant thermistor turn off over than 30 seconds. E. The set temperature is 3 or more than the room temperature. F. The room temperature sensor reads less than 22. G. The indoor pipe temperature reads 43 or less.

2) When one of the conditions of A~E is satisfy, the assistant thermistor is off. A. The compressor is turned off. B. The room temperature sensor reads 24 or more. C. The indoor pipe temperature sensor reads 48 or more. D. The indoor fan is stopped.

6. “FAN” mode operation


20

The indoor fan motor always turns on at the set speed and the vane motor turns on at the set fattle. 7. 4-way Valve contro

HEATING ON COOLING/DRY OFF The 4-way valve reverses for 5 seconds right before start-up of the compressor as following chart: COOLING/DRY HEATING Compressor 4-way Valve 5s 5s Outdoor Fan

8. “SLEEP” mode When the SLEEP button is pressed, the SLEEP mode is selected as following: The indoor fan speed is set at the super low speed. When selecting COOLING/DRY operation with SLEEP mode, the set temperature will be raised by 1 1

hour later and by 2 2 hour later. When selecting HEATING operation with SLEEP mode, the set temperature will be dropped by 1 1

hour later and 2 2hour later. After the System operates in SLEEP mode for 8 hours, it will stop automatically.

9. Fan motor control (1) Rotational frequency feedback control

The indoor fan motor is equipped with a rotational frequency sensor, and outputs signal to the microprocessor to feedback the rotational frequency. Comparing the current rotational frequency with the target rotational frequency, the microprocessor adjusts fan motor electric to make the current rotational frequency close to the target rotational frequency. With this control, when the fan speed is switched, the rotational frequency changes smoothly.

(2) When the rotational frequency feedback signal has not output for 5 seconds (or when the microprocessor can’t detect the signal for 5 seconds), the fan motor is regarded locked-up. Then the electric current to the fan motor is shut off. 10 seconds later, the electric current is applied to the fan motor again. During the fan motor lock-up, the POWER indicator lamp flashes on and off to show the fan motor abnormality.

10. Auto Fan Speed Control (1) When the auto fan speed is selected, the indoor fan motor speed is automatically controlled by the room

temperature and the set temperature. (2) In COOLING mode, the indoor fan motor operates as following:

Fan Speed Hi Me Lo Room temperature minus set temperature: 1 2 4

(3) In HEATING mode, the indoor fan motor operates as following; Fan Speed Hi Mi

Lo Room temperature minus set temperature 1 2 4


21

11. Auto Vane Operation Control (1) Vane motor drive

The unit is equipped with a stepping motor for the vane. The rotating direction, speed and angle of the motor are controlled by pulse signal transmitted from indoor microprocessor.

(2) Positioning The vane is once pressed to the vane stopper below to confirm the standard position and then set to the desired angle. The positioning is decided as follow: When the ON/OFF button is pressed. When the vane control is change from AUTO to MANUAL. When the SWING is finished. When the test run starts. When the power supply turns ON.

(3) The auto vane changes as follows by pressing the VANE CONTROL button. (4) VANE AUTO mode

In vane auto mode, the microprocessor automatically determines the vane angle and operation to make the optimum room-temperature distribution.

(5) SWING mode When presses the SWING button, the vane swings.

12. TIMER Operation How to set the timer

Press ON/OFF button to start the air conditioner. Press TIMER CONTROL button for once in timer on--- SET the TIME of TIMER; press for second

time---START operation for SHUT OFF; press third time---CANCEL operation for TIMER. Press TIMER CONTROL button for once in timer off---SET the TIME of TIMER; press for second

time---START operation for TURN ON; press for third time---CANCEL operation for TIMER. Press UP and DOWN button to set the time, time setting is 30-minutes units. After setting the timer, check that TIMER INDICATOR lamp of the indoor unit lights. Press the ON/OFF button for the air conditioner operates in timer, the timer will be cancelled. TIMER setting can be cancelled by power failure or breaker functioning.

13. EMERGENCY-TEST Operation When the EMERGENCY Operation switch is press once, COOLING mode is selected and if in 3 seconds the

EMERGENCY Operation switch is pressed again, HEATING mode is selected. Then presses once again, the unit switch off.

When the remote controller is missing, has failed or the batteries run down, press the EMERGENCY Operation switch on the front of the indoor unit, The unit will start.

The first 30 minutes of operation will be the test run operation. The operation is for servicing in set mode. The indoor fan runs at high speed and the system is in continuous operation. The vane motor is ON and the timer is reset to normal.

After 30 minutes of test run operation the system shifts to AUTO COOLING/HEATING mode. and the indoor fan runs in outomatic speed. The vane motor is on. The operation continues until the EMERGENCY operation switch is pressed or a button on the remote controller is pressed, the normal operation will start.

NOTE: Do not press the EMERGENCY Operation switch during normal operation. 14. AUTO RESTART function (Option) When the indoor unit is controlled with the remote controller, the operation mode, set temperature, and the

fan speed are memorized by the indoor electric control PCB. The AUTO RESART function sets to work the


22

moment power has restored after power failure. Then, the unit will restart automatically. Auto-restart presetting: The appliance is preset as no auto-restart function by manufacture. If Auto-restart function is needed, follow the below step to active this function: 1) Make sure air conditioner is turned off. 2) Press down and hold the Emergency button (ON/OFF) on the indoor unit white turn on the air conditioner. 3) Keep pressing the Emergency button for over 10s until three short beeps are heard.

Then Auto-restart function is activated. To cancel the Auto-restart function, repeat above procedure until four short beeps are heard.

15. Failure Display and Handling a) The failure of the resistance of heat sensitive:

When the resistance of heat sensitive reads the temperature is lower than －50 or over than 110 that judge the heat sensitive is bad.

b) The Outdoor Protection Control When the system checks the signal from outdoor of the voltage is 0V, the system delay 1second to start for check the signal again, if checks the signal of the voltage is 0V too, that the system not to star, or operates on normal.

c) Failure Display When the controller is failure, the buzzer will voice long for three times, and displays the failure from the failure lamp.

d) Failure Code If have the digital pipe that display the failure code for digital pipe, or display for the run lamp. Type of failure The lamp flash Display of digital pipe The failure of room temperature sensor Once/cycle E1 The failure of indoor pipe temperature sensor Twice/cycle E2 Outdoor protection function 5 times/cycle E5 The failure of indoor fan 6 times/cycle E6

e) Failure Handling When the room temperature sensor or the indoor pipe temperature sensor is failure, the system will be

shut off, the compressor will be OFF, and the outdoor fan and the indoor fan will be OFF. The system doesn’t receive the signal of remoter controller except the signal of shut off it. When the failure disappear, the controller can operate in normal mode. before this, presses the “ON/OFF” to start the system, and it will operate in COOLING or HEATING for 30 minutes, and follows shut off. During this, it displays the failure and the protction is failing. You must be give the electric again to operate it. In the failure, you can operate the FAN mode.

When the outdoor protects in the COOLING or DRY, the outdoor unit stops, the indoor fan operates in set speed ; and in the HEATING, the outdoor unit stops, the assistant thermistor stops, the indoor fan operates in cold air prevention control. The system doesn’t receive the signal of remoter controller except the signal of shut off it. When the system check the voltage is 220V and the delay control is finished, it operates at normal again.

When the indoor fan motor is failure, the compressor is stopped, the outdoor fan and indoor fan is stopped and display the failure. The system doesn’t receive the signal of remoter controller except the signal of shut off it.

f) Display Of The Control In the display board the lamp from left is the POWER lamp(Red), the SLEEP lamp(Yellow), the TIMER lamp(Yellow), the RUN lamp(Green).

(7) When gives the control electric, the buzzer voices a long for 0.3 second per cycle.


23

Wiring Diagram Mode No.: TAC-07CS/K, TAC-09CS/K, TAC-12CS/K TAC-07CSC/K, TAC-09CSC/K, TAC-12CSC/K INDOOR UNIT

Pipe Temp.Sensor

Room Temp.Sensor

Display PCB

transformer

protector

Fan MotorVane Motor M

M

θ

Indoor Unit

Power supply

Brown

Yellow/Green

evaporator

K1

TH2

TH1CN6

CN8

CN3CN4CN5

3COM

CN1

CN2

4N.O.P2-2

P2-1

PCB

BrownBlue

Yellow/Green

Out

door

U

nit

Blue

1N

OUTDOOR UNIT

BrownBlue

Yellow/Green

Compressor

WhiteRed Blue

Blue

BlackWhite

Blue

Yellow/Green

Blue

Yellow/Green

Fan MotorOutdoor UnitIndoor Unit

Fan Capacitor

Compressor Capacitor

Ora

nge

θ

Protector

R(M)CS

CM

1N

M


24

Mode No.: TAC-07CHS/K, TAC-09CHS/K, TAC-12CHS/K TAC-07CHSC/K, TAC-09CHSC/K, TAC-12CHSC/K INDOOR UNIT

Protecter

Fan MotorNote: The thermistor is only with the assistant thermistor type.

Vane MotorIndoor Unit

Evaporator

Yellow/Green

BrownRedYellowBlueYellow/Green

Display PCB

Pipe Temp. sensor

Room Temp. sensor

Theimistor

Transformer

Power Supply

Brown

Blue

PCBCN1

CN2

TH1

TH2

P2-1P5P4

P2-2CN11

CN10 NOK1

COM

4

3CN8

CN6

CN5 CN4 CN3

MM

θ

N321

Out

door

U

nit

OUTDOOR UNIT

θ

Compressor4-way Vane

W hite

CMR(M)C S

BlueCompressor Capacitor

Red

ProtecterBlack

Brown(W hite)Red

YellowBlue

Yellow/Green Blue

Yellow/Green

Outdoor UnitIndoor Unit Fan Motor

BlueFan Capaciter

Blue

Yellow/Green

123N

Blu

e

Blu

e

Ora

nge

M


25

Mode No.: TAC-18CS/K, TAC-18CSC/K INDOOR UNIT

PCBTransformer

Brown

Blue

White

Blue

Yellow/Green Yellow/Green


AC(N)

N.O

COMRelay

1N

N

LDisplay PCB

Fan Motor

FM

SM

SMVane Motor

To T

he O

utdo

or

Room Temp. Sensor

Pipe Temp. Sensor

Blue

Brown

Blue

Brown

L

N 1 2 3 4

12345

12345

OUTDOOR UNIT

BrownBlue

Yellow/Green

Compressor

WhiteRed Blue

Blue

BlackWhite

Blue

Yellow/Green

Blue

Yellow/Green

Fan MotorOutdoor UnitIndoor Unit

Fan Capacitor

Compressor Capacitor

Ora

nge

θ

Protector

R(M)CS

CM

1N

M


26

Mode No.: TAC-18CHS/K, TAC-18CHSC/K INDOOR UNIT

1

N

LN

NTo T

he O

utdo

or U

nit

Yellow

Blue

PCB23

White

RedBrown

Yellow

Yellow/Green

To The Outdoor Sensor

Red

Blue

O.FANN.O

COMVAL

AC(N)

Rel

ay

Transformer

Fan Motor

Vane Motor

Room Temp. Sensor

Pipe Temp. Sensor

FM

SM

Display PCB

SM

Yellow/Green


Blue Blue

BrownBrown

L

OUTDOOR UNIT

θ

Compressor4-way Vane

White

CMR(M)C S

BlueCompressor Capacitor

Red

ProtecterBlack

Brown(White)Red

YellowBlue

Yellow/Green BlueYellow/Green

Outdoor UnitIndoor Unit Fan Motor

BlueFan Capaciter

Blue

Yellow/Green

123N

Blu

e

Blu

e

Ora

nge

MPipe Temp. Sensor


27

Mode No.: TAC-24CS/K, TAC-24CSC/K INDOOR UNIT

Blue N

Brown

Yellow/Green

L

WhiteWhite1

PCB

Yellow/Green

Brown

Blue

N.OCOM

AC(N)

Rel

ay

Transformer

FM

SM

Fan Motor

SMVane Motor

Display PCBRoom Temp. Sensor

Pipe Temp. Sensor

1 2 3 4

45

32

1

54

32

1

To O

utdo

or U

nit

OUTDOOR UNIT

ConpressorWhite

White

Yellow/Green

Blue

Brown

Yellow/Green

Brown

Blue

Blu

e

Brown

Bro

wn

Brown

Yel

low

/Gre

en

RedWhite

Yel

low

Red

C1

Blue

Blue

White

Fan CapacitorCapacitor

Red Blu

e

C2

To P

ower

Sup

ply

To In

door

Uni

t

Yel

low

/Gre

en

Relay Fan Motor ConpressorMotor

C S RFM CM

1NL

LN


28

Mode No.: TAC-24CHS/K, TAC-24CHSC/K INDOOR UNIT

White

Red

White

Yellow

Blue

Brown

Yellow/Green

Red

Yellow

Blue

Brown

O.FAN

Yellow/Green

PCBVAL

N.O

COM Rel

ay

AC(N)

To Outdoor Unit

Display PCB

Transformer

FM

SM

SM

Fan Motor

Vane Motor

Room Temp. Sensor

Pipe Temp. Sensor

To O

utdo

or U

nit

123NL

1 2 3 4

5

1234

54321

OUTDOOR UNIT

WhiteWhite

RedYellow Blue

Brown

Yellow/Green

White White

Red

Brown

Yellow/Green

Brown

BlueBlue

Brown

Blue

To P

ower

Sup

ply

To In

door

Uni

t

4-way Vane

Yel

low

Red

C1Fan Capacitor Blue

Blu

e

Red

CompressorCapacity

White

C2

Yel

low

/Gre

en

Compressor

Blue

MotorFan Motor

Relay

Pipe Temp. Sensor

FM FMC S R

1

2

3

N

L

L

N

Yellow/Green


29

INDOOR UNIT

TAC-07CS/K,TAC-07CSH/K,TAC-07CSC/K,TAC-07CHSC/K,TAC-09CS/K,TAC-09CHS/K,TAC-09CSC/K, TAC-09CHSC/K, TAC-12CS/K, TAC-12CHS/K, TAC-12CSC/K, TAC-12CHC/K,

12

3

5

14

6

7

8

910

15

16

17

18

19

20

2122

23

24

25

26

27

11

12

13

4

28

29

30


30

INDOOR UNIT TAC-18CS/K, TAC-18CSC/K, TAC-18CHS/K, TAC-18CHSC/K TAC-24CS/K, TAC-24CSC/K, TAC-24CHS/K, TAC-24CHSC/K

1

2

3

4

5

6

7

8

9

10

11

12

13

29

28

27

26

25

24

23

22

21

20

19

18

1714

15

30

16


31

Outdoor Unit： TAC-07CS/K, TAC-07CSC/K, TAC-09CS/K, TAC-09CSC/K, TAC-12CS/K, TAC-12CSC/K, TAC-18CS/K, TAC-18CSC/K, TAC-24CS/K, TAC-24CSC/K

1

2

3

5

4

67

9

1011

12

13

1415

1617

20～28

8

18

19


32

Outdoor Unit: TAC-07CHS/K, TAC-07CHSC/K, TAC-09CHS/K, TAC-09CHSC/K, TAC-12CHS/K TAC-12CHSC/K, TAC-18CHS/K, TAC-18CHSC/K, TAC-24CHS/K, TAC-24CHSC/K

1

2

3

45

67

9

1011

12

13

14

1516

19～ 28

8

17

18


33

Parts List Indoor Unit- TAC-07CS/K, TAC-09CS/K

No. Part No. Part Name Q’ty Remark 1 1080030003 Installation Plate 1 2 1210250103 Base 1 3 1070020017 Cross Fan 1 4 1070100010 Bearing Mount 1 5 1210230101 Evaporator 1 6 1070250102 Water Drainage Assembly 1 7 1070320105 Vertical Vane Assembly 2 8 1070250104 Face Frame 1 9 1070320112 Screw Cover 2

10 1090320102 Display PCB 1 11 1070320115 Display PCB Box 1 12 1070250106 Air Filter 2 13 1070251801 Front Panel 1 14 1070251001 Display PC Board Cover 1 15 1170120042 Power Supply Cord 1 16 1070250103 Vane 1 17 1070110008 Drainage Hose 1 18 1070040006 Electrical Box Cover 1 19 1070040004 Cable Clamp 1 20 1170200039 Terminal 1 21 1070250109 Terminal Fixing Board 1 22 1170020011 Vane Motor 1 23 1090250602 Main PCB 1 24 1110040001 Sensor Holder 1 25 1070320113 Electrical Box 1 26 1070320111 Indoor Motor Cover 1 27 1170030052 Indoor Motor 1 28 1170240001 Transformer 1 29 1170230001 Pipe Temp. Sensor & Room

Temp. Sensor Assembly 1

30 1070320101 In And Out Pipe Fixer 1 31 1090010071 Remote Controller 1 31 1073030303 Remote Controller Supporter 1 32 1190250204 Indoor Carton 1 33 1190060008 Left Foaming 1 34 1190060009 Right Foaming 1

Not shown in Explosion view


34

Indoor Unit- TAC-07CHS/K, TAC-09CHS/K







35

Indoor Unit- TAC-07CSC/K , TAC-09CSC/K







36

Indoor Unit- TAC-07CHSC/K, TAC-09CHSC/K







37

Indoor Unit- TAC-12CS/K, TAC-12CSC/K







38

Indoor Unit- TAC-12CHS/K , TAC-12CHSC/K







39

Indoor Unit- TAC-18CS/K ,TAC-18CSC/K , TAC-24CS/K , TAC-24CSC/K


10 1093090102 Display PCB 1 11 1073090126 Display PCB Box 1 12 1073090112 Air Filter 2 13 1070500205 Front Panel 1 14 1070500208 Display PCB Cover 1 15 1073090122 Electrical Box Cover 1 16 1170120006 Power Supply Cord 1 17 1073090108 Vane A 1 18 1073090125 Vane B 1 19 1070110008 Drainage Hose 1 20 1070040003 Cable Clamp 2 21 1170020011 Vane Motor 1 22 1170200038 Terminal 2 23 1083090108 Terminal Fixing Board 1 24 1110040001 Sensor Holder 1 25 1093090201 Main PCB 1 26 1073090120 Indoor Motor Cover 1 27 1170030045 Indoor Motor 1 28 1093090201 Electrical Box 1 29 1173090107 Transformer 1 30 1170230001 Pipe Temp. Sensor & Room


31 1090010071 Remote Controller 1 31 1073030303 Remote Controller Supporter 1 32 1130120008 Indoor Carton 1 33 1073030303 Left Foaming 1 34 1190250204 Right Foaming 1 35 1190060002 Middle Pasteboard Supporter 1 36 1190060021 Middle Foaming Supporter 1



39

Indoor Unit- TAC-18CHS/K,TAC-18CHSC/K, TAC-24CHS/K, TAC-24CHSC/K


10 1093090102 Display PCB 1 11 1073090126 Display PCB Box 1 12 1073090112 Air Filter 2 13 1070500205 Front Panel 1 14 1070500208 Display PCB Cover 1 15 1073090122 Electrical Box Cover 1 16 1170120006 Power Supply Cord 1 17 1073090108 Vane A 1 18 1073090125 Vane B 1 19 1070110008 Drainage Hose 1 20 1070040003 Cable Clamp 2 21 1170020011 Vane Motor 1 22 1170200040 Terminal 2 23 1083090108 Terminal Fixing Board 1 24 1110040001 Sensor Holder 1 25 1093090101 Main PCB 1 26 1073090120 Indoor Motor Cover 1 27 1170030045 Indoor Motor 1 28 1093090201 Electrical Box 1 29 1173090107 Transformer 1 30 1170230001 Pipe Temp. Sensor & Room


31 1090010071 Remote Controller 1 31 1073030303 Remote Controller Supporter 1 32 1130120008 Indoor Carton 1 33 1073030303 Left Foaming 1 34 1190250204 Right Foaming 1 35 1190060002 Middle Pasteboard Supporter 1 36 1190060021 Middle Foaming Supporter 1



40

Outdoor Unit- TAC-07CS/K, TAC-09CS/K

No. Part No. Part Name Q’ty Remark 1 1083510901 Grille 1 Optional

2 1080050016 Top Cover 1

3 1210250112 Condenser 1

4 1080050015 Outdoor Motor Supporter 1

5 1170040062 Outdoor Motor 1

6 1070030006 Propeller Fan 1

7 1080050012 Left Plate 1

8 1080050018 Front Plate 1

9 1080050019 Fan Guard 1

10 1210250101 Capillary Assembly 1

11 --------------- Compressor and its Accessories 1

12 1120250608 Discharge Pipe 1

13 1123521402 Suction Pipe 1

14 1213530414 Base 1

15 1120120008 Two-way Valve 1

16 1080050014 Valve Supporter 1

17 1120130011 Three-way Valve 1

18 1080050013 Right Plate 1

19 1073521301 Electrical Box Cover 1

20 1080020001 Electrical Parts Box 1

21 1080010002 Capacitor Strip 1

22 1170100014 Compressor Capacitor 1

23 1170100031 Fan Motor Capacitor 1

24 1170200019 Terminal 1

25 1070040002 Cable Clamp(φ7) 1

26 1173570501 Compressor Power Supply Wiring

1

27 1173570502 Earthing Wiring 1

28 1190070014 Base Carton 1

29 1190250201 Cabinet Carton 1 30 1190070016 Base Foaming 1 31 1190070015 Cover Forming 1

Not shown in the Explosion

view.


41

Outdoor Unit- TAC-07CSC/K, TAC-09CSC/K


2 1080050011 Top Cover 1

3 1210350207 Condenser 1




7 1080050012 Left Plate 1

8 1080050009 Front Plate 1

9 1080320112 Fan Guard 1

10 1210250101 Capillary Assembly 1 Consist The Filter For Dry



13 1123521402 Suction Pipe 1

14 1210500106 Base 1

15 1120120017 Two-way Valve 1



18 1080050002 Right Plate 1






24 1170200019 Terminal 1

25 1070040002 Cable Clamp1(φ7) 1


1


28 1190070020 Base Carton 1



view.


42

Outdoor Unit- TAC-07CHS/K , TAC-09CHS/K

No. Part No. Part Name Q’ty Remark 1 1083510901 Grille 1

2 1080050016 Top Cover 1

3 1210250112 Condenser 1




7 1080050012 Left Plate 1

8 1080050018 Front Plate 1

9 1080050019 Fan Guard 1

10 1213530404 4-way Assembly 1



13 1123521402 Suction Pipe 1

14 1213530414 Base 1

15 1120120008 Two-way Valve 1



18 1080050013 Right Plate 1






24 1170200020 Terminal 1

25 1070040001 Cable Clamp(φ6) 1

26 1070040002 Cable Clamp(φ7) 1


1


29 1190070014 Base Carton 1 30 1190250201 Cabinet Carton 1 31 1190070016 Base Foaming 1 32 1190070015 Cover Forming 1


view.


43

Outdoor Unit- TAC-07CHSC/K, TAC-09CHSC/K


2 1080320105 Top Cover 1

3 1210320101 Condenser 1




7 1080050001 Left Plate 1

8 1080320113 Front Plate 1

9 1080320112 Fan Guard 1



12 1210250606 4-way Vane Assembly 1

13 1210320103 Base 1

14 1120120017 Two-way Valve 1



17 1080050002 Right Plate 1






23 1170200020 Terminal 1

24 1070040001 Cable Clamp(φ6) 1

25 1070040002 Cable Clamp(φ7) 1



28 1190070017 Base Carton 1



view.

dry Consist the filter for


44

Outdoor Unit- TAC-12CS/K


2 1080320105 Top Cover 1

3 1210320106 Condenser 1




7 1080050001 Left Plate 1

8 1080320113 Front Plate 1

9 1080320112 Fan Guard

10 1210320701 Capillary Assembly 111 --------------- Compressor and its Accessories 1


13 1120320702 Suction Pipe 1

14 1210320103 Base 1

15 1120120016 Two-way Valve 1



18 1080050002 Right Plate 1






24 1170200019 Terminal 1

25 1070040002 Cable Clamp 1


1




view.


45

Outdoor Unit- TAC-12CSC/K


2 1080050011 Top Cover 1

3 1210350207 Condenser 1




7 1080050012 Left Plate 1

8 1080050009 Front Plate 1

9 1080320112 Fan Guard 1

10 1210250101 Capillary Assembly 1 Consist The Filter For Dry



13 1123521402 Suction Pipe 1

14 1210500106 Base 1

15 1120120017 Two-way Valve 1



18 1080050002 Right Plate 1






24 1170200019 Terminal 1

25 1070040002 Cable Clamp(φ7) 1


1


28 1190070020 Base Carton 1



view.


46

Outdoor Unit- TAC-12CHS/K


2 1080320105 Top Cover 1

3 1210320101 Condenser 1




7 1080050001 Left Plate 1

8 1080320113 Front Plate 1

9 1080320112 Fan Guard 1




13 1210320103 Base 1

14 1120120016 Two-way Valve 1



17 1080050002 Right Plate 1






23 1170200020 Terminal 1

24 1070040001 Cable Clamp(φ6) 1

25 1070040002 Cable Clamp(φ7) 1



28 1190070017 Base Carton 1



view.


47

Outdoor Unit- TAC-12CHSC/K


2 1080050011 Top Cover 1

3 1210350207 Condenser 1




7 1080050001 Left Plate 1

8 1080050009 Front Plate 1

9 1080320112 Fan Guard 1




13 1210500106 Base 1

14 1120120017 Two-way Valve 1



17 1080050002 Right Plate 1






23 1170200020 Terminal 1

24 1070040001 Cable Clamp(φ6) 1

25 1070040002 Cable Clamp(φ7) 1



28 1190070020 Base Carton 1



view.

Consist dryforfilterthe


48



2 1080050011 Top Cover 1

3 1210500107 Condenser 1




7 1080050001 Left Plate 1

8 1080050009 Front Plate 1

9 1080320112 Fan Guard 1




13 1120500101 Suction Pipe 1

14 1210500106 Base 1

15 1120120016 Two-way Valve 1



18 1080050002 Right Plate 1






24 1170200019 Terminal 1

25 1073570503 Up Cable Clamp 1

26 1073570502 Lower Cable Clamp 1


1




view.


49



2 1084530504 Top Cover 1

3 1210700102 Condenser 1




7 1084530516 Left Plate 1

8 1084530514 Front Plate 1

9 1084530515 Fan Guard 1



12 1210700102 Suction Pipe 1


14 1214561809 Base 1

15 1120120011 Two-way Valve 1



18 1084530503 Right Plate 1






24 1170200010 Terminal 1

25 1074060118 Cable Clamp 1


1


28 1174561801 AC Contactor 1

29 1190070003 Base Carton 1 30 1190070013 Cabinet Carton 1 31 1190070004 Cover Carton 1


view.

Consist forfilterthe dry


50



2 1080050011 Top Cover 1

3 1210500107 Condenser 1




7 1080050001 Left Plate 1

8 1080050009 Front Plate 1

9 1080320112 Fan Guard 1



12 1210500102 4-way Vane assembly 1

13 1210500106 Base 1

14 1120120016 Two-way Valve 1



17 1080050002 Right Plate 1






23 1170200020 Terminal 1

24 1073570503 Up Cable Clamp 1

25 1073570502 Lower Cable Clamp 1


1


28 1174561802 Outdoor Pipe Sensor 1



view.


51



2 1084530504 Top Cover 1

3 1210700202 Condenser 1




7 1084530516 Left Plate 1

8 1084530514 Front Plate 1

9 1084530515 Fan Guard 1




13 1214561809 Base 1

14 1120120011 Two-way Valve 1



17 1084530503 Right Plate 1






23 1170200036 Terminal 1

24 1074060118 Cable Clamp 1


1


27 1174561801 AC Contactor 1




view.

Consist dryfilter forthe


52



2 1084530504 Top Cover 1

3 1210700102 Condenser 1




7 1084530516 Left Plate 1

8 1084530514 Front Plate 1

9 1084530515 Fan Guard 1



12 1210700102 Suction Pipe 1


14 1214561809 Base 1

15 1120120011 Two-way Valve 1



18 1084530503 Right Plate 1






24 1170200010 Terminal 1

25 1074060118 Cable Clamp 1


1


28 1174561801 AC Contactor 1



view.


53



2 1084530504 Top Cover 1

3 1210700102 Condenser 1




7 1084530516 Left Plate 1

8 1084530514 Front Plate 1

9 1084530515 Fan Guard 1



12 1210700102 Suction Pipe 1


14 1214561809 Base 1

15 1120120011 Two-way Valve 1



18 1084530503 Right Plate 1






24 1170200010 Terminal 1

25 1074060118 Cable Clamp 1


1


28 1174561801 AC Contactor 1



view.

Consist forfilterthe dry


54



2 1084530504 Top Cover 1

3 1210700202 Condenser 1




7 1084530516 Left Plate 1

8 1084530514 Front Plate 1

9 1084530515 Fan Guard 1




13 1214561809 Base 1

14 1120120011 Two-way Valve 1



17 1084530503 Right Plate 1






23 1170200036 Terminal 1

24 1074060118 Cable Clamp 1


1


27 1174561801 AC Contactor 1




view.


55



2 1084530504 Top Cover 1

3 1210700202 Condenser 1




7 1084530516 Left Plate 1

8 1084530514 Front Plate 1

9 1084530515 Fan Guard 1




13 1214561809 Base 1

14 1120120011 Two-way Valve 1



17 1084530503 Right Plate 1






23 1170200036 Terminal 1

24 1074060118 Cable Clamp 1


1


27 1174561801 AC Contactor 1




view.

Consist the filter dryfor

INDEX

1. Type of air conditioner

2. Four elements of air conditioning

3. Principle of refrigerating cycle

4. Definition of terms

5. The term of unit

6. The term of function

7. Mollier diagram

8. Psychrometric chart

9. Noise characteristics

10. Load calculation

11. The coordination coefficient of cooling capacity

ANNEX 2 GENERAL


1. Type of air conditioner1.1 Distribution according to function

Cooling

Cooling + Heating (Electric heater)

Cooling + Heating (Heat pump)

Window Window

Skinny

PTAC

Split Split

Floor Standing

Multi

Cassette

Duct

Convertible

27 c 20 c

40 c

Cooling Cooling+Heating

19 c

CassetteSplit

Window

Floor StandingSkinny

Convertible

PTAC

1.2 Distribution according to installation type

Duct

Multi


2

2. Four elements of air conditioning

1) Temperature : The dry-bulb temperature by cooling or heating room air.

2) Humidity : A comfortable humidity condition of room air is generally kept by the relative humidity ofair, and the room air is controlled into a given relative humidity condition.

3) The degree of purity : Remove dusts in the air, and keep smoke from exceeding the allowable degree ofconcentration.

4) Air flow : To disperse properly the air regulated in temperature, humidity and the degree of purityinto indoor, make an appropriate air flow and keep uniformly the temperature/humiditycondition of room unit.

• Standard for feeling comfortable

3. Principle of refrigerating cycle3.1 Principle of refrigerating : It is as follows.

1) Sprinkling with water in summer causes to cool surroundings.

• Because water absorbs the heat of surroundings with evaporating.

2) Gasifying a liquid (R-22) which is easier to evaporate than water makes cooler.

• Because water evaporates at 100°C under 1 atmosphere but freon gas (R-22) does a very low temperature of-40°C

3) It is an Airconditioner that the principle is used for.

Classification Summer Winter

Temperature 21 ~ 28°C 20 ~24°C

Relative humidity 30 ~ 60% 30 ~ 60%

Air flow 0.2m/s or less 0.2m/s or less


3

3.2 Refrigerating cycle1) Refrigerating cycle

2) The principle of refrigerating cycle

3) The role of each cycle

(1) Compression : The gasified refrigerant evaporated is absorbed into compressor through the suction pipe,and then compressed by a piston in cylinder and turned into a gas of high temperature andhigh pressure which is able to be liquified in a room temperature.

(2) Liquification : The gas of high temperature and high pressure in compressor is cooled by air in condenserand liquified by a condensing heat.

(3) Expansion : With passing through the capillary tube, the high pressure refrigerant liquified in condenserturns into a low pressure condition, which is easy to evaporate.

(4) Evaporation : The liquid refrigerant of low temperature and low pressure passed though the capillary tubeabsorbs the room air heat in evaporator and evaporates into a gas.

MOTOR

COMPRESSOR

OIL

(LIQUID REFRIGERANT)

CAPILLARY TUBE

OUTSIDE COOLINGAIR FOR REFRIGERANTPASS THROUGH

SUCTION LINECOOL LOW PRESSURE VAPOR

COOLEDAIR

COMPLETE LIQUIDBOIL OFF POINT

LIQUIDPRESSUREDROP

ROOM AIR HEAT LOAD

VAPOR INLETHOTDISCHARGEDAIR

LIQUID OUTLET

HIGH PRESSURE VAPOR

LIQUID REFRIGERANT

LOW PRESSURE VAPOR

ROOM AIR CONITIONER

EVAPORATOR COILS CONDENSER COILS

CYCLE OF REFRIGERATION

Compressor

(Mid. Temp) (Hi. Temp)

Emission Absorbing

(Hi. Temp) (Low Temp) (Mid. Temp)

Compression Liquification Expansion EvaporationLowPressGas

HighPressGas

HighPressLiquid

LowPressLiquid

LowPressGas

Condenser Capillary Evaporator


4

4. Definition of terms1) Air conditioning : Keeping room air in an optimum condition, depending on the use or purpose. (Cooling, heat-

ing, humidity regulating, air cleaning, etc.)

2) Cooling (Heating) capacity : Calorie which is able to be released (or added) per a unit time in room.It is expressed in Kcal/h, BTU/h or W.

3) Absolute humidity : The amount of vapor contained in the air. Generally it is equal to the amount of vapor by gunit contained in 1m3 air, and is expressed in g/m3.

4) Relative humidity : The ratio between the amount of vapor contained in the air and the maximum amount (theamount of saturated vapor) of vapor capable of containing at that temperature in %.

* Relative humidity = Actual vapor pressure/Saturated vapor pressure x 100or

= Actual vapor pressure of dew point temperature /saturated vapor pressure of dry-bulbtemp. x 100

5) Dew point temperature : The surface temperature which starts dewing on the surface when cooling a sub-stance in the air.

6) Latent heat and sensible heat : Heat which causes a change in the state of a substance, with its temperatureconstant, is called latent heat whereas heat which changes the temperature ofa substance is called sensible heat. Latent heat is expressed in terms of calo-ries needed to cause a change of state of a substance per 1 kg. The followingequation shows that Q Kcal is needed to change state of a substance weightG Kg when the latent heat is L Kcal/kg.

Q = GL

7) Thermal flow

(1) Radiation : A phenomenon which thermal energy as an electro-magnetic wave is transmitteddirectly from a thermal source.

(2) Conductive emission : A phenomenon which transmits from high to low temperature when there is atemperature difference partially in a substance.(Example : When one tip of iron rod becomes hot.)

(3) Convection : When the temperature of a fluid like gas or liquid changes by heat, the high tem-perature part expands and thus the density drops to cause to be light whereasthe low temperature part is to be heavy. It means a phenomenon that heat istransmitted together when floating happens by the weight difference of air.

Liquid

Solid GasSublimation Heat

Fusion

Hea

t

Solidif

icatio

n

Heat

Condensation

Vaporization HeatHeat

Three States of a Substance


5

5. The term of unit1) Kcal : Adding or releasing heat to or from a substance changes its temperature. This change of temperature is

in proportion the heat added or released. This heat is called calorie which is expressed in Kcal or cal.

1 Kcal is equal to the amount of heat required to raise the 1°C temperature of 1kg water 4°C.

2) BTU : 1 BTU is equal to the amount of heat required to raise the 1°F temperature of 1 lb water.

• 1 Kcal = 3.968 BTU, 1 BTU = 0.252 Kcal

3) RT : 1 RT (Refrigerating Ton) is equal to the capacity which makes 1 Ton water 0°C into ice 0°C in 24 hours. It

is expressed in calorie required to freeze water 1 Ton water 32°F(2000 lb) into ice 32°F, and when using

the solidification latent heat of water, 1RT is as follows

• 1 RT = 144BTU/lb x 2000 lb/24hr = 12,000 BTU/hr = 3,024 Kcal/hr = 3.517 KW

4) Hp : Horse Power

• 1 Hp = 0.75 KW = 645 Kcal/h, 1W = 0.86 Kcal/h

5) Temperature conversion (°C ↔ °F)

• °F = 9/5°C + 32, °C = 5/9 (°F-32)

6) Area or volume conversion

• 1m2 = 10.764 ft2, 1m3 = 35.3165 ft3

7) Weight conversion

• 1Kg = 2.2 lb, 1 lb = 0.45 Kg

8) Unit conversion table

Classification BTU/h Kcal/h W KJ Hp RT

1BTU/h 1 0.252 0.293 1.055 0.00039 0.000083

1Kcal/h 3.968 1 1.163 4.186 0.00155 0.000329

1W 3.413 0.86 1 3.601 0.00133 0.000283

1KJ 0.948 0.239 0.278 1 0.00037 0.000079

1Hp 2559 645 750 2700 1 0.212

1RT 12000 3024 3516 12660 4.68 1


6

6. The term of function1) Compressor : Absorb and compress the low pressure refrigerant gasified in evaporator and flow into con-

denser. At this time, the low pressure needed is kept in evaporator and the refrigerant gas flows into con-denser as high pressure condition. The most economical condition of compressor for an operating reasonis when the refrigerant gas absorbed into compressor is in dry-saturated condition. The overly-heated suc-tion gas may cause the mechanical ability of compressor to be reduced and the cylinder clearance of com-pressor to be re-expanded, and as a result, the refrigerant may be used without its refrigerating effect.The types of compressor is Recipro. type, Rotary type, Scroll type, Screw type, etc. and consists of cylin-der, piston, vane, shaft, bearing, case and accumulator for structure reason.

2) Condenser : The high temperature/high pressure refrigerant gas compressed by compressor is sucked intocondenser and liquified by cooling. The condenser is cooled by the forced-convection of fan.The calorie emitted from condenser is equal to the sum of the heat absorbed in evaporator and the calorieused for compressor operating.

3) Evaporator : Absorb the heat from room air by forced-convection.The liquid refrigerant in evaporator is evaporated by absorbing heat from room air and flowed into compres-sor as a gasified state. The evaporating temperature of refrigerant is decided by pressure, which is decidedby the wet-bulb temperature of suction air and the wind flow, and the pressure in evaporator is normally5Kg/cm2G and the evaporating temperature is 5~8°C.

4) Capillary : Regulate the refrigerant flow into evaporator, lower the pressure of refrigerant, and expand into a liq-uid of low temperature and low pressure. The type of capillary is generally a thin and long copper tube of0.6~2.0mm2 inner diameter and 1~2m long. The resistance of tube causes to turn into a liquid of low pres-sure and low temperature.

5) Dryer : Any moisture in refrigerating cycle may cause the compressor motor to be damaged or the refrigerant tobe an ice state in the middle of cycle, which blocks the flow of refrigerant. Dryer is installed in a cycle for thepurpose of removing such moisture.There are two types of dryer ; a liquid line dryer which is connected serially to the condenser outlet and asuction line dryer which is connected serially to the suction line, with a desiccative in dryer.The dryer is designed for uni-directional flowing of the refrigerant.

6) Muffler : Since Recipro. type compressor discharges the compressed gas discontinuously, a pulsating sound orvibration occurs through pipe. Muffler is installed in the discharged part of compressor for the purpose ofabsorbing the vibration of the discontinuously-discharged gas.

7) Strainer : Strainer serves to remove foreign substances from refrigerant by a metal net pelt of fine grid or aglass wool being inserted into metal vessel and refrigerant being passed through between the interval.The mounted position is between condenser and temperature auto expansion valve.

8) Service valve : SVC valve is used for vacuum working and refrigerant filling. Front seat is called a state whichcap is opened and valve is completely rotated clockwise and refrigerant stops flowing in that condition,whereas back seat is called a state which valve is rotated completely counter-clockwise and refrigerantflows. In case of pressure measurements or vacuum work from service valve, the back seat condition ischanged into some front seat condition. Product is released in front seat condition, so the back seat bybrake-in is not needed.


7

9) Motor : Drive a rotating force by electric power and supply the driving force to fan and blower in both indoor and

outdoor of air conditioner.

10) Fan : Serve to blow air through condenser and blow out the heat generated with refrigerant liquified in con-

denser. Its structure is similar with a motor fan.

11) Blo wer (Cross Flow Fan: C.F.F) : Suck room air, blow into evaporator, make evaporator absorb the heat, and

disperse the cooled air into room. Blower is placed indoor unit, so a small size, high wind flow and low

noise type is used.

12) Thermostat (Thermistor) : Sense the suction air into room and regulate automatically room temperature by

compressor on/off depending on temperature. Thermostat is used for a mechanical type model and ther-

mistor for a micom type control method.

13) Capacitor : Supply a driving torque to the compressor motor or fan motor for aircon and make the operating

efficiency better during operation.

14) Over load protector (O.L.P) : A protective device of automatic return type which is placed in the wire of com-

pressor and shuts off the power of compressor motor against the overheat and overcurrent of compressor.

At this time, compressor is stopped operating by power off and fan only is at work. Generally the working

temperature is 115±5°C and the return temperature is 93±5°C.

15) High pressure switch (H.P.S/W) : A protective device of automatic return type which protects compressor

from overload by sensing the discharge pressure of compressor, working at an abnormal high temperature,

and shutting off the electric circuit. Generally the working pressure is 28kg/cm2G and the return pressure is

23 kg/cm2G.

16) Sump heater : A cord heater which is wound around the compressor bottom, and its type is decided depend-

ing on the capacity of compressor. If compressor is not at work at power on, sump heater is at work

whereas if compressor works, sump heater does not work, so be sure to always keep the compressor

temperature higher than any other unit.

17) Acc umulator : A kind of liquid refrigerant separator which prevents the liquid refrigerant from sucking into

compressor and is installed in the suction inlet of compressor.

18) Reversing valve (4 way valve) : Convert the flow of refrigerant upon cooling/heating switch-over, electrically

power on when heating and off when cooling, be installed in outdoor, and have four connecting valves as

shown in the name. The refrigerant passing through compressor always flows to a constant direction and

is able to reverse-operate completely the refrigerating cycle of both cooling and heating by a reversing

valve. Consist of reversing valve and solenoid valve. The main valve in reversing valve uses a nylon resin

which is deformed by heat 120°C or over and thus causes valve not to work, so be cautious while

operating or when welding.


8

19) Solenoid valve : Regulate the refrigerant flow by refrigerant on/off in cycle which refrigerant flows according

as the valve operates through a coil unit being powered on. Mainly it is used when reversing the 4 way

valve of a cooling/heating model or constructing each unit cycle of multi model.

20) Check valve : Prevent refrigerant from reverse flow in refrigerating cycle. It is installed in a place where it is

necessary to prevent the reverse flow of refrigerant in a copper pipe. It has a mechanical structure and

attached to the opposite of a heating capillary to expand the heating/cooling model by two speeds, and is

constructed so as to flow through capillary in heating and through the check valve in cooling only.


9

7. Mollier diagram7.1 Refrigerant state transition on Mollier diagram1) Refrigerant changes iso-barically and iso-thermally in evaporator, so enthalpy (the heat absorbed from evapora-

tor) increases as shown in Figure 7.1 below.

2) In compressor, as the running speed of compressor is fast, it is thought there is no thermal input/output from orto the outside within a short time, which is regarded as an adiabatic change. Accordingly the compressionprocess rises upto the discharge pressure along the iso-entropic line and the amount of energy of the compressor is the same as the enthalpy change of refrigerant between compressor cylinder inlet and outlet.

3) In condenser, the overheated vapor is cooled as much as thedegree of overheat, saturated, and then condensed and somewhat over-cooled. The process is established by an isobarprocess, so an enthalpy down (the calorie emitted from condenser) happens horizontally on diagram.

4) Expansion process is a throttle expansion which there is noenthalpy change before and after the expansion valve and thepressure and temperature drop, so the process changes vertically downward.

7.2 How to draw a refrigerating cycle For example, draw a refrigerating cycle under the following operating condition.

1) Evaporation & condensation temperature : Find an evaporation temperature 8°C on the saturatedliquid line or saturated vapor line in Mollier diagramand draw a horizontal line, isobar line (pressure 6.54kg/cm2 abs) from that point. In the same manner, drawa isobar line at condensation temperature 46°C, andthe evaporation and condensation process changesstates between two isobar lines.

2) Suction gas state of compressor : The state of compressor suction gas is the same as that of refrigerant atevaporator outlet, and the evaporation temperature and is 8°C and the degree of superheat is 8°C, so the temperature of suction gas is to be 16°C Accordingly the state point of compressor suction gas is theintersection between pressure 6.54 kg/cm2 abs at wet vapor 8°C and superheat vapor 16°C, and is a point of

pressure 6.54 kg/cm2 abs, temperature 16°C, enthalpy 152.0 Kcal/kg, non-volume 0.0024m3 /kg, entropy 1.182Kcal/kg °K. (See Figure 7.3)

P

i

Com

pres

sion

Evaporation

Expansion

Condensation

Figure 7.1 Refrigerating cycle

Refrigerant R-22

Evaporation temp. 8°C

Condensation temp. 46°C

Overheat temp. of suction gas. 8°C

Temp. just before expansion valve. 40°C

P

46 C

8°C

tc = 46 C

46 C

8 C

tc = 8 C

=18.1kg/cm, abs

cm, abs

= 6.54kg/

2

2

d

Ps

P

i

P

8 °C

16 °

C

tc = 16°C

Evaporation

Com

pres

sion

A

16°C

152kcal/kg8°C

s

P

iFigure 7.2 Evaporation & condensation temperature Figure 7.3 Suction gas state of compressor


10

3) Discharged gas state (the state at compressor outlet or condenser inlet) : An adiabatic change is almostseen in compressor, so the state of discharged gas follows the isentropic line at point B of Figure 7.4.Accordingly the state point of discharge gas is the intersection with wet-vapor pressure 18.1 kg/cm2 abs entro-phy 1.138kcal/kg °K at condensation temperature 46°C, and is a point of pressure 18.1kg/cm2 abs, temperature75°C, enthalpy 158.0 Kcal/kg, specific volume 0.00152m3 /kg, entropy 1.182 Kcal/kg °K, and superheat 30°C.(Figure 7.4)

4) State of condensed liquid : The temperature of refrigerant liquid just before expansion valve in the design con-dition is 40°C, so the state point is the intersection between 46°C wet air pressure 18.1kg/cm2 abs and 40°Cisothermic line (point C of Figure 7.5) in pressure 18.1kg/cm2 abs, temperature 40°C, enthalpy 112.0 Kcal/kg,supercooling 6°C.

5) State of expansion valve outlet (The state of evaporator inlet) : The state is changed on isentropic line with-out thermal input/output in expansion valve, so the state point is the intersection between enthalpy 112.0Kcal/kg line and evaporation temperature 8°C isothermal line (point D of Figure 7.6) at pressure 6.54kg/cm2

abs, temperature 8°C, enthalpy 112.0 Kcal/kg, specific volume 1.0080m2/kg, entrophy 1.025 Kcal/kg °K, and thedegree of dryness 0.2.

P

Ptd = 46°C

158.0kcal/kg

B

75 C

i

d

P

P

112kcal/kg

td = 46°C C

i

40°C

46°C

40

°C

d

Isenthalpy line

Supercooling=6°C

P

8°C tc=

112.0 kcal/kg

40°C

D

Pd

Ps

i

P

O q1 = (ia

q3 = (ia-ig)

Evaporation

Evaporation temp.= 8°C

Condensation temp=46°CCondensation

Suction gas temp. = -16°C Dry saturated vapor

q2

46°C 40

-if)

c

a

de

f g

b

Al

Compre

ssion

Expa

nsion

Temperaturejust before

expansion v/v=40°C

Isenthalpy line

Figure 7.4 A state of discharge gas Figure 7.5 A state of condensed liquid

Figure 7.6 A state of expansion valve outlet Figure 7.7 A standard refrigerating cycle


11

For the refrigerating cycle abef as shown in Figure 7.7, if the cooling capacity of condenser increases by thetemperature down of saturated liquid, cooling water or air and then the temperature of condenser outlet refrigerant liquid decreases, the refrigerating cycle will be abef. Likewisely, the temperature difference whenthe temperature of condenser outlet refrigerant liquid is below the temperature of saturated liquid at that pressureis called the degree of supercooling, which enhances the refrigerating effect. The effect of supercooling is as follows.

2) Work of compression : The heat equivalent of work whichhas compressed refrigerant 1kg is the difference of enthalpybetween compressive process AB as shown in Figure 7.9,and the equation of calculation is as follows.

Al = iB - iA ............................................................... (7.4)

3) Calorie of condensation : The calorie emitted from condenser is the sum of the refrigerating effect and the heatequivalent of work. (Figure 7.10)

qe' = qe + Alqe = (iA - iD) + (iB - iA) = iB - iD.................................. (7.5)

7.3 Calculation of refrigerating cycle1) Refrigerating effect : Calories which evaporator absorbes, and the refrigerant flowing through evaporator is a

wet vapor and at outlet a superheat vapor. In DA process in Figure 7.8, refrigerant absorbs Calorie qe fromsurroundings with evaporating.

qe = iA - iD .......................................................................................................................................... (7.1)

The refrigerating effect is one which is calculated by equation (7.1), and is expressed in calories which refrigerant 1kg absorbs from evaporator during ABCD cycle.

The refrigerating effect when the state of refrigerant gas sucked into compressor is changed into A', A'' inFigure 7.8 is as follows.

qe' = iA' - iD ......................................................................................................................................... (7.2)

qe" =iA" - iD ......................................................................................................................................... (7.3)

Standard Supercooling rise

Refrigerating effect qe=ia-ig < qe'=ia-i f

Coefficient of performance <qe

=ia-id

Al i b-ia

qe'=

ia-i f

Al i b-ia

P

C B

Aq"

A"D

A'

e

i"A i'A i A

q'eqe

Ci Di i

P C B

A

AI

D

iA iB

qe

i

P C

D

B

i A i B

q e

q e'= q e AI

AAI

CiDi

i

Figure 7.8 Refrigerating effect Figure 7.9 Work of compression

Figure 7.10 Calorie of condensation


12

4) Circulation amount of refrigerant : An amount of refrigerant to be evaporated in evaporator to obtain therefrigerating capacity needed. It is expressed in the weight by the unit time.

G: Circulation amount of refrigerant (kg/h)

Q: Refrigerating capacity needed (Kcal/h)

qe: Refrigerating effect by the refrigerant 1kg (Kcal/kg)

To decide the capacity of compressor, the circulation amount of refrigerant should be converted into the suctiongas amount of compressor.

V: Suction gas amount of compressor (m3/h)

VA: Specific volume of refrigerant at compressor inlet (m3/kg)

The amount of piston extrusion is calculated as follows.

D: Diameter of cylinder (m)

n: Rotational speed of compressor (rpm)

L: Piston stroke (m)

N: No. of cylinder

5) Coefficient of performance : The efficiency of refrigerating cycle. It is expressed in COP as the abbreviationof Coefficient of Performance.

G =Q ............................................................................................................................................. (7.6)qe

COP =Refrigerating effect

¡Refrigerating effect

Heat equivalent of work Shaft power for compressor(KW) x 860

COP =qe

=iA-iD

...................................................................................(7.9)Al iB-iA

V = GvA = Q

vA= QvA

(m3/h).......................................................................................................... (7.7)qe iA - iD

V' = π D2L X 60nL ............................................................................................................................................. (7.8)4

Al : Heat equivalent of work for compression (Kcal/kg)

qe : Refrigerating effect (Kcal/kg)

COP is greater than 1, and the greater COP is, the better the performance is.

For the general COP of refrigerator, compressive efficiency hc and machine efficiency hm should be considered.

COP'= COP x hc x hm ............................................................................................................................(7.10)


13

Example) By using the Mollier diagram of R-22, find the compression ratio, refrigeratiny effect, work of compres-sion, calorie of condensation, circulation amount of refrigerant, coefficient of performance, and refriger-ating effect per 1KW.

Condensation pressure : Pd = 18.1kg/cm2abs

Evaporation pressure : Ps = 6.5kg/cm2abs

Compression ratio : Pr = Pc/Pe = 18.1/6.5 = 2.78

Enthalpy : iA = 148.5kcal/kg

iB = 158.5kcal/kg

iC = 110kcal/kg

iD = 110kcal/kg

iC' = iD'= 112kcal/kg

iE = 148kcal/kg

Accordingly, Refrigerating effect : q1 = iA - iD = 148.5 - 110 = 38.5 [kcal/kg]

Work of compression : A1 = iB - iA = 158.5 - 148.5 = 10 [kcal/kg]

Calorie of condensation : q2 = iB - iC = 158.5 - 110 = 48.5 [kcal/kg]

Circulation amount of refrigerant : G=Q/q1 = 3320/38.5 = 86.2 [kg/h.RT] (per 1 Refrigerating Ton)

COP : q1/A1 = 38.5/10 = 3.85

Refrigerating effect per 1KW : k = 860 x 3.85 = 3311 [kcal/h. KW]

D

E

A

C C' B

D'

8°C

15.0

3.0

38°C 46°C

16°C

40°C

75°C

110 112 148 148.5 158.5

0.0016m /kg3

0.0024m /kg3

Abs

olut

e P

ress

ure(

kg/c

m2

abs)


14

Mol

lier

diag

ram

p-h

grap

h of

R22

p-h

grap

h of

R22

S=1.35

kcal/

kg.K

v= 0

.001

5m3

/kg

P (kgf/cm2)

150.

015

0.0

7080

9010

011

012

013

014

015

016

017

018

019

0

60.0

40.0

20.0

10.0

6.0

4.0

2.0

1.0

0.6

0.4

0.2

0.1

0.06

0.04

0.02

t=-9

0°C

t=-9

0°C

-80

-70

-60

-50

-40

x=0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

-30

-20

-10

0

10

20

30

4050

6070

80t=

90°C

t=90

°C 50°C

50°C

50°C

100°C

150°C

200°C

0.00

2

100°C

150°C

200°C

1.30

1.25

1.20

0.00

3 0.00

4 0.00

5 0.00

6

0.00

8

0.01

0.06

0.1 0.15

0.2

0.4 1.0

0.02

0.03

0.04

1.15

0°C

80

-80

70 60

-60

-70

50

-50

40

-40

30

-30

20

-20

10

-10

0

100.

0

60.0

40.0

20.0

10.0

6.0

4.0

2.0

1.0

0.6

0.4

0.2

0.1

0.06

0.04

0.02

7080

9010

011

012

013

0

h

k

cal/k

g

140

150

160

170

180

190

s=1.10kcal/kg.K

150.

0

v= 2

.0m

3 /kg


15

8. Psychrometric chart8.1 Psychrometric chart

Psychrometric chart shows the characteristics of moistair by a diagram, including i-x, t-x, and t-i diagram. Thei-x diagram is shown in the right side. A point express-ing the state of air in the psychrometric chart is calleda state point, which is used for finding a dry-bulb tem-perature,wet-bulb temperature, dew point temperature,relative humidity, absolute humidity, enthalpy, etc. Forexample, at dry-bulb temperature 26°C, and relativehumidity 50%, the enthalpy, absolute humidity, wet-bulb temperature, dew point temperature and specificvolume is found from the psychrometric chart as fol-lows.

Enthalpy I = 12.6 (Kcal/kg)

Absolute humidity x = 0.0105 (kg/kg)

Wet-bulb temperature t’ = 18.71 (°C)

Dew point temperature t” = 14.70 (°C)

Specific volume v = 0.862 (m3/kg)

8.2 Discomfort index (DI)In summer, Discomfort Index is frequently used in the weather forecast on TV or newspapers. Man feels hotor dry according as the relative humidity is high or low, but not the absolute humidity. Generally, now that wefeel discomfortable at high relative humidity, the state which is felt uncomfortable at both dry-bulb and wet-bulb temperature may be expressed empirically as an equation, Discomfort Index (DI), which is used as anemotional index for summer temperature and humidity condition.

* DI = (Wet-bulb temperature + Dry-bulb temperature) x 0.72 + 40.6

* Degree of DI

Figure. Psychrometric chart

0.0105V=0.862

t'=18.71I=12.6

t"=14.70

=50%

26[°C]

DI Degree of DI

86

80

75

70

68

Intolerable discomfort (Unable to bear the sultry weather.)

Everybody feels uncomfortable. (Sweat at hot weather.)

Half or more people feel uncomfortable. (Feel the heat a little.)

Start to feel uncomfortable.

Comfortable


16

8.3 Dewing The most damp condition of air is at the saturated air condition of relative humidity 100% which is unable tocontain moisture any longer. As a result, the water vapor (moisture) in the air is condensed and turned intoliquid as waterdrop which can be seen. Such phenomenon is called dewing or condensation, commonly“sweating”.

Dew point temperature means the temperature of air when starting to form dew. For example, when takingout a bottle of beer from refrigerator in summer, you have probably seen several times the surface of beerbottle sweats, that is, waterdrop form. The phenomenon is because the moist air around the bottle of beer ischanged rapidly into a state beyond relative humidity 100% with rapid cooling below the dew point tempera-ture, and the vapor in the air not contained forms dew. Maybe you have ever experienced damages that sum-mer cooling in your house caused the bedclothes in wardrobe to be damp by de wing or the winter heatingcaused to form dew on window and waterdrop to flow into wall or floor carpet.

Dewing prevention

Such a fine particle (vapor in air) that its shadow or shape has never appeared is rapidly cooled when ittouches a cold substance below dew point temperature. That is, shocking or starting by rapid coolingcauses waterdrops to be emerged out; dewing.

It is necessary to prevent from dewing in room because it gives trouble. For example, in order to keeproom windows from dewing in heating, insulation effect should be increased by making room humiditydown or using a double window.

Americans frequently does not humidify when heating, and if humidifying, they lower room humidity con-siderably.

Relative humidity in room to prevent inner area from dewing

Heat loss rate[Kcal/m2h°C]

Outdoor temperature [°C]

-10 -7.5 -5 -2.5 0 2.5 5

22[%] 25[%] 29[%] 33[%] 38[%] 43[%] 48[%]

29 32 36 40 45 50 55

37 41 44 48 53 58 62

48 52 55 59 62 66 70

62 65 67 70 73 76 79

79 80 82 83 85 87 89

6

5

4

3

2

1


17

Psychrometric chart

PS

YC

HR

OM

ETR

IC C

HA

RT

NO

RM

AL T

EMPE

RAT

UR

ES A

TMO

S PH

ERIC

PR

ESSU

RE

760m

m H

g(-1

0~+5

0°C

, ATM

OS

PHER

IC P

RES

SUR

E 76

0mm

Hg)

Heat

inhe

rent

mois

ture

ratio

¡

=dh/

dx[kc

al/kg

]

Sens

ible

Heat

Fac

tor

Enthalp

y h[kc

al/kg(D

A)]

Specific volume v [m

3/kg(DA)]

0.75

0.7

6

0.7

7

0

.78

0.7

9

0.80

0.

81

0.8

2

0.83

0

.84

0.8

5

0

.86

0.

87

0.88

0.8

9

0.90

0

.91

-10

-9

-8

-

7

-6

-5

-4

-3

-

2

-1

0

1

2

3

4

5

6

7

8

9

10

11

12

1

3 1

4

15

16

17

18

19

20

21

2

2

23

24 2

5 2

6 2

7 2

8

29

30

31

32

33

34

35

36

37

38

39

4

0

41

42

43

44

45

46

47

48

49

50

Relative

humidit

y ø[%

]

Saturat

ed de

gree ø

[%]

Wet

Bulb

tempe

ratur

e t'

[°C]

Dry

Bul

b te

mpe

ratu

re

t' [°

C]

Ice w

ater

Absolute humidity x [kg/kg(DA)]

40 35 30

Steam partial pressure Pw [mmHg]

25 20 15 10 5 1 00.

000

0.00

1

0.00

2

0.00

3

0.920.930.940.950.96

0.00

4

0.00

5

0.00

6

0.00

7

0.00

8

0.00

9

0.01

0

0.01

1

0.01

2

0.01

3

0.01

4

0.01

5

0.01

6

0.01

7

0.01

9

0.02

0

0.02

1

0.02

2

0.02

3

0.02

4

0.02

5

0.02

6

0.02

7

0.02

8

0.02

9

0.03

0

0.03

1

0.03

2

0.03

3

0.03

4

0.03

5

0.03

6

0.03

7

0.01

8

1

0 -8-6

-4-2

-10

12

34

56

78

910

1112

1314

15

1617

18

20

2122

23

24

25

26

27

28

29

30

31

32

33

34

19

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30


18

9. Noise characteristics9.1. Sound composition :

The physical amount of sound is expressed in a logarithm and the sound level (dB) is calculated by simpleaddition or subtraction.

Lc, the sum of n sounds L1, L2, ....Ln (dB) is calculated by the following equation.

Lc = 10 log (10 L1/10 + 10 L2/10 + ..... 10 Ln/10)

Generally, the noise level by composing two sounds of L1 (dB) and L2 (dB) is found in the following figure.

Example) When composing 60dB and 57dB sounds, the level of complex sound is calculated as follows.L1-L2=60-57=3n the left figure, ∆L¡ 1.7Complex sound level : L3 = L1+∆L

= 60+1.7=61.7dB

L3 = L1+10log(1+10-(L1-L2)/10)= L1+∆L(L1≥L2)

The equation is applied to the sound decomposition method.

When complex sound (measured sound) is L3(dB) and background noise is L2(dB), the object sound L1 (dB) is calculated as follows.

L1= L3 + 10 log (1-10-(L3-L2)/10)= L3 - ∆L'(L3 ≥ L2)

Example) While machine sound is measured 65dB, the noise atmachine stopping is 63dB.Accordingly the noise level of machine itself is

L3-L2 = 65-63 = 2

In the right figure, ∆L' ¡ 4.33

Noise level of machine is

L1 = L3-∆L' = 65-4.33 ¡ 60.7

(Figure: Calculation chart of dB composition)

(Figure: Calculation chart of dB decomposition)

3.0

2.8

2.4

2.0

1.5

1.2

0.8

0.4

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

L1 L2 (dB)

∆L

6.87

4.33

3.00

2.19

1.65

1.25

10

1

2

3

4

5

6

7

2 3 4 5 6 7 8 9 10

L3 L2

11 12

0.96

0.36

0.46

0.580.75

0.26

(dB)

∆L'


19

9.2 Sound attenuation The sound pressure level Lp[dB] at r[m]from a point sound source is composed of the following equation.

Lp = Lw + 10 log (Q/4πr2 + 4/R)Lw : Power level of sound sourceR : Real integerQ : Directional factor (Spherical sound : 1, Semi-spherical sound: 2)

Generally the noise level Lpr (dB) at r[m] from the sound source is

Lpr = Lps - 20 log r + C* Lps : Sound source level (dB)C: Characteristics of sound sources including a point sound source and plane sound source

And the noise level Lp1 and Lp2 at r1 and r2 from noise source is

Lp1 = Lps-20 log r1 + C, Lp2 = Lps - 20 log r2 + C

Therefore, eliminate Lps, and Lp2 = Lp1 + 20 log r1/r2

Example ) In a condition the four condensers of noiselevel 50dB are placed parallelly, what is thecomplex noise at point A? And what is thesum of noise at background noise 35dB and1m distance?

1) The noise level at point A of each aircon is ;Lpa = Lpb = 50+20 log 1/2 = 44.0Lpc = 50 + 20 log 1/3 = 40.5Lpd = 50 + 20 log 1/4 = 38.0

2) Considering the noise source, the complex noise level is;L =10 log(1044/10+1044/10+1040.5/10+1038/10+1035/10)

= 48.5(dB)

9.3 Allowable level of noise1) NC curve

NC curve as an abbreviation of Noise Criteria is acurve expressing the allowable level by frequency fornoise evaluation.

For NC 50, the band level at octave frequency band1200-2400Hz is at 50dB and the high level is allowedat low sound side. To inhibit to NC50, the result ofoctave band analysis at that sound should be belowNC50 curve.

2) Allowable level of noise

a

2m 2m 3m

Point A

4m

b c d

90

80

70

60

50

40

30

20

10 20 75 150 300 600 1200 2400 480075 150 300 600 1200 2400 4800 10000

NC-20

NC-30

NC-40

NC-50

NC-70

NC-60

Oct

ave

freq

uenc

y ba

nd le

vel (

dB)

(0 d

B=

0.00

002

µ ba

r)

Octave frequency band level (c/s)

NC Curve

Studio 15-20 25

Music hall 20 30

Theater 20-25 35

Classroom 25 40

Conference room 25 40

Apartment, Hotel 25-30 40

House 25-30 40

Hospital 30 35

Library 30 40

Small office room 30-35 45

Large office room 45 50

Factory 50 60-70

dB(A) dB(A)Place PlaceNCCurve

NCCurve


20

10. Load calculation10.1 Cooling/Heating load calculation

1) Calorie from wall body

2) Calorie from glass

3) Calorie by clearance wind

4) Calorie generated from human body

5) Calorie generated from thermal instruments

6) Shaft heat load of wall body

7) Acquired calorie within machine

8) Others (Outdoor load)

The cooling load is calculated by summing up from item 1 through item 8. As a reference, the calorie generated from human body is as follows.

Table 10.1 Calorie from human body (Kcal/h. person)

Note : SH : Sensible heat, LH : Latent heat

28(°C) 27(°C) 26(°C) 24(°C) 21(°C)

SH LH SH LH SH LH SH LH SH LH

44 44 49 39 53 35 58 30 65 23

45 56 49 52 53 48 61 40 69 32

45 68 50 63 54 59 62 51 72 41

45 81 50 76 55 71 64 62 73 53

48 91 56 83 62 77 71 68 81 58

48 141 56 133 62 127 74 115 92 97

56 159 62 153 69 146 82 133 101 114

68 184 76 176 83 169 96 156 116 136

113 252 117 248 121 244 132 233 153 212

Sit upright

Studying

Office work/light walking

Erect, sit upright, walk

Business

Seated work

Normal dancing

Walking 4.8 (km/h)

Balling

Theater 88

School 101

Hotel Dept. 113

Bank 126

Restaurant 139

Light work at factory 189

Dance hall 215

Heavy work at factory 252

Balling 365

Working postureRoom temp

Example Total


21

Example) Calculation of simple cooling capacity

By using a simple cooling capacity calculation table, calculate the cooling load.

0.9

2.50.5

15

7

4

2.3

Double window(Without pent roof)

( unit : m )

Entrance door (Opening/shutting door)

Wall (inner wall)

Living room

Wall

No sunshine

North

Condition : .• Apartment living room (middle layer)

• 4 persons in room

• 2 fluorescent light 20W

• One TV set 150W

Sunshine

Veranda

Sliding door

(Double window)

(Curtain)


22

10.2 Simple cooling capacity calculation table

Item Area (m2) Coeff. Load(Kcal/h) Calculation method

1.Window

2.Outerwall

3.Compartment

4.Ceiling

5.Floor

6.Ventilation

7.Person

8.Heater

Total

Max.direction ofsunshineload(Doublewindow:Coeffi.x4)

Others

Sunshine

North,Shade

Slidingdoor, glass

Wall,Open/closedoor(APTentrance)

Upper is room.

Upper isroof.

Lower isground.

Lower is room

Korean-stylehouse

Western-stylehouse

Fluorescentlight

Electricheaters

Gas instruments

50252510

10

151510

10

10

35

0

10

25

15

1

0.86

Sun-shine

NoSun-shine

E

S

W

E

S

W

(1) Calculate each window load for one direction only of maximum load.

(2) For all the other windows, calculate as“Others” item.

(The sunshine window not max.load, theeast, west & south windows all day shade,and north window are calculated as others.

(1) For outer wall area, subtract the windowarea.

(2) All of each outer wall to the directions (east,west,south) with sunshine is calculated as “sunshine” and the outerwall to north or shade direction is calcu-lated as north and shade.

(1) For sliding doors and glass, calculate allthe movable part.

(2) Calculate wall except sliding door andglass area.

(3) Do not calculate saparately wall andsliding door.

(1) Use the area of ceiling.

(2) The upper part of the top floor or onestory building is roof.

(1) If the space beneath floor is ventilatedeven though it is ground, calculate as“room”.

(1) Be ventilated by a clearance wind ordoor open/close. If using a fan, this cal-culation is not applicable.

(1) Calculate maximum number of personsif possible, but fol low customer’srequest.

(2) Unless otherwise specified, generalhousing is based on one person perfloor area 3.3m2.

(1) For other electric appliances, input (W) by coefficient. Fluorescentlight : coefficient 1. (2) Gas appliance iscalculated by gas heat * gas consumption.


23

10.3 Aircon selection

1) Calorie required per 1m 2

100 ~ 130 Kcal/h/m2

2) Considerations in capacity selection

• A place of good insulation, an apartment ¡ 90~105 kcal/h/m2

• A place of poor insulation, a slate building ¡ 135~150 kcal/h/m2

• A place of poor insulation and many windows ¡ 150 kcal/h/m2 or over

• A place of poor insulation, many windows, much sunshine ¡ 160 kcal/h/m2 or over

• Western or southern room (+)

• Many persons in a room (+)

• Heater in a room (+)

3) Rough selection of capacityConsidering the above 2), add the clearance rate by 10% each except for lecture room, kitchen, or specialarea, and select the capacity.

The nominal area is selected on the basis of outdoor 35°C and indoor 27°C, but actually the temperature in condenser is higher than standard condition according to summer hottest temperature and condenser installa-tion condition, so the capacity selection by the rough method does not matter.


24

1900180017001600150014001300120011001000

900800700600500400300200100

Daytime

Are

a to

coo

led-

squa

re fe

et

Cooling

Primarily

4000~6000

4000 60005000

6000~8500

24000~27000

8500~ 15000~19000 19000~24000 27000~3200011000

11000~15000

1900180017001600150014001300120011001000

900800700600500400300200100

Band A

- Occ

upied sp

ace a

bove ce

iling

Band B - lnsulated ceilin

g under attic

Band C - Non lnsulated ceilin

g under attic

NighttimeCooling

Cooling capacity required-BTU/Hr.

If area to be cooled includes a kitchen, add 1,000 BTU/Hr.If more than two people occupy area, add 600 BTU/Hr. per person.If only one person, subtract 600 BTU/HR.

How to read the cooling Selection Guide1. Determine area to be cooled in sqare feet.

Locate that point on the left side of the Cooling Selection Guide.

2. Move horizontally across to Band A, B or C, according to ceiling condition in the area to be cooled as follows:- Band A: Occupied space above ceiling- Band B: Insulated ceiling under attic- Band C: Non-insulated ceiling unter attic

This "band" on the Selection Guide indicates a range of BTU/Hr. capacity normally required to cool such an area.

11. The coordination coefficient of cooling capacityYou can use the cooling selection guide chart to determine the size unit best suited for the consumer's application.


25

ANNEX 3 TROUBLE SHOOTING

INDEX

1. Electric parts

2. Refrigerant system

3. Troubleshooting

4. Installation Fundamentals


1. Electric partsIt is compressor and motor fan that finally drives after power is supplied. And it is necessary to check the inter-nal factors like switches, protectors, or lead wires that are needed to reach the compressor and motor fan tosee if their connections are normal and the external factors to see if voltage is normally supplied.

1.1 External factors check1) Working power and voltage drop

The rated voltage for airconditioner is specified in a workable range.

In order to operate airconditioner normally, it is desirable for the working voltage and minimum. starting voltageto be within the following chart range.

Especially, just the fact that the voltage when airconditioner is not at work is within the working voltage range isinsufficient, and the voltage is sure to be within the working voltage range by measuring in a operating condi-tion.

* Usable voltage = Product rating ±10%

2) Electric wire capacity

The electric wire for airconditioner should have an allowable current more than the load current of the circuitand be able to control the voltage drop by the load current within 2%.

And it should be a thickness capable of keeping the voltage drop by a starting current within -10%, and espe-cially for an airconditioner of single phase, the voltage drop (Flicker voltage) by the starting currnet be withinabout 5%.

A = V1 - V2 : Voltage drop by the starting current of airconditioner (Flicker voltage)

B = V1 - V3 : Voltage drop by the normal running current of airconditioner

In case of using an airconditioner in a low voltage area where power supply voltage is low, especially, the Flickervoltage due to inadequate wires may cause the fluorescent light to be off or may affect the other electric products.So, care should be taken to the wiring work.

lnput voltage (V1)

Voltage drop

Vol

tage

Time

Starting voltage(V2) Running voltage(V3)

V1 - V3X 100 ≤ 2%(B case)

V1

V1 - V2X 100 ≤ 5%(A case)

V1


2

3) Wire thickness required

Rated current appliance(A) Nominal cross-sectional area(mm2)

Up to and including 6 0.75

Over 6 up to and including 10 1.0






For rated currents up to 3A, a nominal cross-sectional area of 0.5mm2 is only allowed if the length of the corddoes not exceed 2m.

1.2 Internal factors check

1.2.1 Insulation resistance

Measure the insulation resistance between live part and dead metal part by 500V insulation resistor tocheck if the insulation resistance is more than 10MΩ.

1.2.2 Insulation resistance measurement of compressor

Measure the insulation resistance of compressor between compressor terminal and dead metal part by insu-lation resistor, and the insulation resistance should be above 10MΩ.

Compressor may change the insulation resistance while running. Accordingly, measure the insulation resistance just after running as needed.

• Note: For R-22 used in airconditioner, the dielectric rate on liquid state is high. If a contaminant is mixedinto R-22, the electric resistance is extremely low and the poor insulation is occurred. Accordingly,be sure to prevent contaminants from mixing into refrigerant system.

Powersupply

• Operation switch• Rotary switch• Remocon

• Operation indicator lamp• Relay• reversing coil• Conductor• Thermistor

• Pressure switch• O.L.P• Fuse

Switches Function parts Protector CompressorMotor Fan


3

1.2.3 Running capacitor

1) Earth inspection between terminal and bodyAs shown in Figure 1, connect a resistor between one side terminal and body of condenser to check forcontinuity.

2) Capacity inspection

(1) Remove the lead wire from both terminals of condenser to be checked.

(2) Contact both terminals of lead wire for 2-3 sec., and discharge.(Be sure to perform to prevent the tester damage before measuring.)

(3) After discharging, contact both terminals of tester with the terminal of condenser to see the dial vibratingdirection of resistor. (See Figure 2.)There are three kinds of dial vibrating direction in tester, and each vibrating direction and symptom is asfollows.

A: Normal : Dial shakes instantaneously and returns to the original state immediately.

B: Short : Dial remains moved.

C: Capacity consumed up : Dial does not move at all.

1.2.4 Motor fan

1) Power off, remove motor fan, and test independently.

2) Measure the resistance of main coil, sub coil and control coil in motor.

3) Use a good quality of capacitor in testing.

4) Diagnose the following troubles by the independent test, and replace motor.

a) Motor is not started.

b) Motor rotation rises very slowly.

c) Bearing failure : The shaft does not move.

d) Arc occurs in the motor inside.

e) Smoke emits from motor inside.

f) Excessive noise

Figure 1. Figure 2.


4

Measuring main coil resistance : White ↔ Black

Measuring sub coil resistance : Brown ↔ Black

Measuring control coil resistance : Red ↔ Black

1.2.5 Thermostat

There are 3 kinds of thermostat malfunction.

1) Leak of gas charged in sensor part

2) Short of contact point

3) Wrong wiring

Switch off at room temperature 18-30°C, turn carefully the knob of thermostat from 1 to 10 (the number maybe different or a figure be used according to model) or reversely, and click sounds.

After the sound is heard, turn reversely to check again the click sounds.

If click sounds, the thermostat is in normal. If room temperature exceeds 30°C, test should be done aftercooling by putting the sensor part of thermostat into a cold water container because the contact point is notopened.

If knob is turned but click does not sound, remove the thermostat cover and examine the contact point.

The fused contact point should be replaced with a new thermostat.

If contact point is not closed despite of the sensor temperature being sufficiently high, the gas at the sensorpart may be leaked. In this case, replace the thermostat.

When replacing thermostat, be sure to conduct after performing carefully as the above content.

1.2.6 Thermistor

Pull out the lead wire of thermistor terminal to test continuity.

Connect a tester to the terminal of thermistor and measure the resistance. The resistance value variesaccording to the measuring condition and temperature, so in order to vary temperature forcibly, put water ina cup, cool the sensor part of thermistor, and then measure the resistance, and also measure in a conditionthat the sensor part of thermistor becomes warm by hands.

MC

SO.L.P

Black

Red

Brown

White


5

1.3 Compressor trouble diagnosis1.3.1 Electrical troubles

1) Ground test

Test single phase and three phase in the samemanner.

(1) Shut off the power supply to product.

(2) Remove the wires connected to the compres-sor terminal.

(3) Clean the compressor terminal and discharge(suction) pipe.

(4) Measure the resistance of discharge (suction)pipe and each terminal by using a R x 1Kscale of Ohm meter.

(5) If dial moves remarkably, the terminal is inground state. So, replace the compressor.

2) Wrong wiring check of compressor terminal

Examine the wiring diagram of compressor terminal or the electric circuit diagram of product on the coverof compressor terminal to check if there is wrong wiring.

3) Checking of wire disconnection or overload protector (O.L.P) operating condition

This check is to see the wire terminal condition of motor inside, and for a single phase compressor withO.L.P built-in, it identifies the O.L.P operating condition and wire disconnection.

(1) Shut off the power supply to product.

(2) Remove the wires connected to the compres-sor terminal.

(3) After checking the ground state, cool thecompressor sufficiently.(at room temperature)<For single-phase compressor>

(4) Measure the resistance of each terminal byOhm meter R x 1K scale, and if dial does notmove, compressor is in opened condition.<For three-phase compressor>

(5) Measure the resistance of each terminal byOhm meter R x 1K scale, and if dial does notmove, the wire between two terminals is disconnected.-> Action: Replace the compressor.

* OLP may be operated by the following causes, so be sure to find and remove the cause.(1) Operation at low voltage(2) Defects of operation or starting device(3) Overheat of compressor motor due to the condensing coil closing, condensing motor defects,

liquid line close, or injection capillary close.

Ohm MeterR x 1K


6

1.3.2 Mechanical troubles

1) Not starting

(1) Phenomenon : Compressor is not started but the starting current continues to flow.

(2) Checking

a) Check capacitor. (for a type where a capacitor for compressor starting or operating is used)

b) If there is no trouble, it is judged as lock due to the wear of compressor inside or the damage of lubricatingdevice. Replace the compressor.

2) Poor compression

(1) Phenomenon : Compressor is at work, but the cooling capacity is weak, the pressure of high pressure sideis low and the pressure of low pressure side is high.

(2) Cause : Damage of valve in compressor inside, damage of connecting rod or crank shaft, or other internalleak

(3) Checking

a) Stop and then start the condenser fan, and if the pressure of high pressure side does not increase, thecompressor is bad.

b) Measure the temperature of discharge pipe in compressor, and if it is abnormally low temperature (50°C orless), the compressor is bad.

c) Conduct the pump down test of system to check the compression capacity. - Power off the product.- Close the service valve of liquid line. (Rotate the valve rod clockwise to close the valve rod.)- Start product and observe the suction pressure.- If compressor is normal by pumping down the system, pressure is kept 0-5 psiG (0-0.35kg/cm2.G), and if

the suction pressure increases, the compressor is bad due to the internal leak or valve damage.

(4) The compressor to be assumed as bad compression should be replaced.If running for a long time in a bad compression condition, abnormal superheat may occur and the compressor motor is burnt.- Clean the cycle.

3) Overcurrent flowing while running

Check the working pressure, and if there is no trouble, it is assumed as the compressor bearing damage.Replace the compressor.

(Excessive refrigerant charging may cause the overcurrent.)


7

2. Refrigerant system2.1 Refrigerant system troubleshooting

Check the following items when troubleshooting the refrigerant system.

1) The thermostat setting or remocon temperature setting is not wrong?

2) Air filter is not cleaned?

3) Blower fan control switch is not at "low"?

4) Ventilation lever is not opened?

5) There is no obstacle in suction or discharge side of outdoor unit?

6) Dirty heat exchanger causes the heat exchanging efficiency to be down?(Thorough cleaning)

7) Cooling/heating load is not increased?

8) Too many persons are in room? (Cooling)

9) The insulation of window gap is not wrong?

If there is no trouble from the above checks and also if there is no trouble on the electric appliances ofairconditioner body, it is assumed as refrigerant system failure.

a) Set aircon to High cool, run cooling for 15 min. or more, and measure the temperature difference of suc-tion/discharge air in indoor unit. (Adjust the wind direction so that wind is discharged to the front direction inthe installed condition.)

b) Measure the voltage and current in running condition.

c) Measure the pressure of low pressure side in cooling condition.(If the temperature is low, convert into the test switch.)

2.1.1 Temperature difference and current of suction/discharge air in evaporator

Temperature differenceof suction/discharge air

No temperature difference.80% or less of rated current.

Temperature diff.: Under 8°C.80% or less of rated current.

Temperature diff.: Under 8°C.Rated current or over.

Temperature diff.: 8°C or over.

Gas leak (almost) Refrigerantcycle closed

Gas leak, refrigerant cycleclosed, bad compressor

Excessive refrigerant charging

No refrigerant cycle trouble

--

--

--

--

Running current measurement

• Temperature difference of suction-discharge air

Normally, the temperature difference is based at 10°C. Actually, the judgemnt criteria is 8°C, because when theroom humidity is high, the temperature difference is small and when humidity is low, it becomes large.


8

2.1.2 Pressure and temperature of refrigerant

The pressure in normal condition shows the figure in the right sidetable, but the pressure (P1) of high pressure side tube is affectedgreatly by the temperature change and about 16kg/cm2.G in a lowtemperature condition (indoor/outdoor 21°C).

The pressure fluctuation is affected by the tube length or insulationas well as temperature change, so measure the pressure (P2) of lowpressure side for the trouble shooting of refrigerant system.

<Trouble finding by pressure/temperature>

Note) The high/low temperature is a figure converted into pressure.The low pressure is normally 4.5-6.0kg/cm2G.(Temperature is normally 3°C-10°C.)

Indo

or S

ide

Out

door

Sid

e

Eva

pora

tor

Com

pres

sor

Capillary Tube

High pressure (Liquid side)tube

Low pressure(Gas side) tube

Accumulator

Compressor

P1

P2

Measuring place Pressure(kg/cm2 G)

P1 About19.5

P2 About 5.0

Pressure TemperatureCause Explanation

(than normal) (than normal)

Higher

HigherBad compression: Compressor failure, Bad revers-ing Valve

Current flows weakly.

Cooling load is small. Current flows weakly.

Liquid refrigerant suction: Excessive refrigerant charging

Gas short : Gas leak

Closed : Pipe internal

Current is low.

Current is low.

High pressure is notincreased rapidly in earlyrunning stage.

Higher

Normal

Lower


9

• Pressure measurement of low pressure side

As shown in Figure above, connect the manifold gauge to the low pressure (gas side) tube of condenser and mea-sure the pressure.

2.1.3 Symptoms and actions

1) Short of refrigerant

The short of refrigerant appears in a slightly different symptom as (1) no refrigerant or (2) short of refrigerant.

(1) Symptoms : The temperature difference of suction-discharge air is 8°C or less, the runningcurrent is less than the rated current, and the pressure of low pressure side islow. (These are symtoms changed by short of refrigerant.)

(2) Judgement method : Frost is formed from the capillary tube outlet to the evaporator inlet.The suction pipe of compressor is not cold. (The temperature of suction pipe issimilar to the outdoor temperature.)The pressure of low pressure side in cooling is 4kg/cm2.G or less. (Surrounding

temperature : 30°C or over)Refrigerant oil comes out from the evaporator-condenser connections and each

welded portion. (Finding the gas leak place)

(3) Actions: ➀ Find the gas leak area. (Check at balance pressure of 5kg/cm2.G or over.)➁ Charge refrigerant to the specified level.➂ Check for gas leak.

2) Closing of refrigerant system

(1) Symptoms : If the refrigerant system of strainer or capillary tube is closed, pressure drops atthe outlet of closed area, and refrigerant evaporates to form and attach dew orfrost.The running current is less than the rated current, and the pressure of low pres-sure side is lower than the normal. If completely closed, the pressure of lowpressure side is to be 0kg/cm2.G as time goes by.

(2) Judgement method : The same symptoms as the short of refrigerant appears, and the same phenome-non occurs even if refrigerant is sealed.It takes 3 min. or more for refrigerant to balance.If running in the condition, the temperature of discharge gas becomes higher, therefrigerant oil is deteriorated, and the life time may be affected.(Compressor motor may be burnt.)

Closed Closed


10

Low High

Gas side tube

Liquid side tube

IndoorUnit

OutdoorUnit

Com

pressor

3) Overcharge

(1) Symptoms : • The temperature difference of suction-discharge air is 8°C or less, the running currentis higher than the specified current, the pressure of low pressure side is high, andthe compressor and suction pipe are cold.If running in the condition, pressure switch activates at overload operation to makecontinuous operation impossible, compressor is difficult to start, and fuse or breaker iseasy to be disconnected.

(2) Actions : ➀ Dischage the refrigerant. (By 3-5kg/cm2G)➁ Charge refrigerant to the specified level.➂ Check for gas leak.

4) Bad compression

(1) Symptoms : • The temperature difference of suction-discharge air is little, the running current is lessthan the specified current, the pressure of high pressure side is low, and the pressureof low pressure is high.

(2) Judgement method :• Close service valve of high pressure side in condenser (front seat) and connect themanifold gauge to the service valve of low pressure side.(Close the valve.)

• If the dial of pressure gauge does not indicate 0kg/cm2G or less by cooling in the con-dition, the compressor is judged as bad.

Note) If pressure gauge is near 0kg/cm2G, immediately stop the cooling.Otherwise, air flows into the refrigerating cycle or the compressor motor coating is taken off to cause thepoor insulation. So, care should be taken.


11

2.1.4 Summary of check items by cause

Check item Suction/discharge airtemp.diff. of evaporator

Short of refrigerant ¢ ¢ ¢ ¢ ¢ ¢ ¢ ¢

Capillary closing (a part) ¢ ¢ ¢ ¢ ¢ ¢ ¢ ¢

¢ ¢ ¢ ¢ ¢ ¢ ¢ ¢

¢ ¢ ¢ ¢ ¢ ¢ ¢ ¢

Bad compressor ¢ ¢ ¢ ¢ ¢ ¢ ¢ ¢

Rated current

Cooling HeatingCooling 8°C Heating 14°C Cooling Heating Cooling Heating

Low pressure High pressure

Cause

Outdoor heat exchangercontaminated

Indoor heat exchangercontaminated

2.2 Precautions on repair1) When discharging refrigerant (from pipe or body), the discharge outlet should direct the direction where

nobody exists.

2) Do not work near fire or flame.

3) Work in a large space if possible and arrange the scaffold.

4) Especially for working on rooftop, prepare a place to keep tools and take care to prevent from falling.

5) While running (pump down work, test run), do not insert hands into fan.

6) Clean the Indoor-outdoor connecting pipes and the manifold gauge edges to be free from dust or moisture.

7) Be sure to fill refrigerant to the specified level. (If refrigerant is too much or short, the capacity is down andtrouble may occur.)

8) Keep tools well, and check the measuring machine periodically.


12

3. Troubleshooting3.1 Product does not operate at all.

Power supply voltage check

Power input voltage Driving load terminal Display PCB connector

Power receptable voltageProduct input voltageEvaportor-condenserconnecting pipePCB assy(fuse, varistor, pattern)

AC about 14±3V (General model)

Connector contact check

Power trans output voltage

PCB assy check


13

3.2 Room fan does not operate at all.

Connector contact check

Motor bearing insertedstateFan(Blower) fixed stateFan(Blower) contact state

Motor output connectorMotor capacitor

Communication efforBlower lock sensing

In dehumidifying, heating,or artificial intelligence operation, room fan maybe off.

Coil resistance (TP)Motor capacitorMotor insulation resistance

Motor-related parts check

Motor detail check

Error code check

PCB ass'y check

Operation mode check

Motor driving circuitRelay output


14

3.3 Compressor or outdoor fan does not operate at all.

Re-input after power off

Insulation resistanceCoil resistanceCapacitor capacityCompressor OLP

Set the desired temperature of remocon to be lower by 2°C or over than roomtemperature, and start the cooling operation.

Does not operate at all.

Temperature sensoropen/close check

Connector check(Contact & power)

Disconnection/short circuitcheck of connecting wire

Electric wire connectioncheck for outdoor side

Compressor & motor detailcheck

Repeat running/stopping ata short time period.

Thermistor and evaporatorsurface contact check.- Clearance is needed (5mm).

Connector check(Contact & power)

OLP/High pressure switch/Low pressure switch check

Operation mode (dehumidifying) check

PCB assy check

Temperature sensing circuitRelay output


15

3.4 Up/down vane does not operate at all.

Vane bending, structuresinterferance check

If a constant torque is felt when rotating vane by hands,the assembled condition is normal.

At the moment the blower is stopped, up/down vane autoswitch is stopped, and if blower is started, auto switch isre-operated.- Especially, it occurs while dehumidifying or heating.

Motor shaft assembly check

Connector check(Disconnection/shortcircuit/malconnection)

Blower operating conditioncheck

PCB ass'y check

Step motor driving circuit


16

3.5 Left/right louver does not operate at all.

Louver/link/cam assemblycheck

If a constant torque is felt when rotating louver by hands,the assembled condition is normal.

At the moment the room fan is stopped, louver autoswing is stopped, and if room fan is started, auto swing isre-operated.- Especially, it occurs while dehumidifying or heating.

Motor shaft assembly check

Connector check(Disconnection/shortcircuit/malconnection)

Blower operating conditioncheck

PCB ass'y check

Step motor driving circuitSynchronous motor driving circuit


17

3.6 Function setting by remocon is disable.

Power input after power off

• UCheck the transmission signal of remocon - Liquid crystal remocon: signal blinked- Button remocon: LED blinked• UCheck the product receiving- Buzzer sounds.

- If there is no remocon transmission signal, check the battery or remocon operation.- If product receiving is not checked, check the display PCB.

- In cooling mode, if compressor is stopped, blower is operated at low fan.- In dehumidifying mode, to enhance the dehumidifying effect, blower is operated at low fan.- In heating mode, blower is stopped or operated at low fan according to the situations (defrosting, hot start, compressor off).- In Sleep operation mode, blower is operated without switched-over (low or middle fan).- In artificial intelligence mode, room fan switching-over is not possible by remocon.

Operation ON by remocon

Switchover the air flow by remocon.

PCB ass'y check

Display PCB assy check- Connector/damage


18

3.7 Cooling/heating conversion is disable.

Heating operation ON by remocon

4-way valve connection checkoutdoor unit connecting wirecheck

Switchover into cooling operation by remocon,and after about 30 sec., check the 4-way valverelay output = 4-way valve OFF

If 4-way valve is OFF, the refrigerant flowing sounds(pee....) due to cycle switchover occurs.

If the reversing valve (4-way valve) is ON, "tick" sounds.

Connector check

PCB ass'y check

4-way valve coil resistance check

4-way valve relay output = ON


19

4. Installation FundamentalsLeakage /Freon - 1/4 Case-1

90˚

Key Factor Pipe cutting

Gas leaks due to the mal-flared copper pipes with non-rectangular section.Troubles &Causes

Defect Details

Guidelines

Pipe cutter

Pipe cutter

Make pipe straight beforecutting, and it makes arectangular section.

Cu. pipe

Cu. pipe

Cutting curved pipe leadsmal-rectangular section.And it makes gas leakage.


20

Leakage /Freon - 2/4 Case-2

Key Factor Removing burrs of pipes.

Gas Leaks due to the burrs caused by cutting and not removing properly.Troubles &Causes

Defect Details

Guidelines

Reamer

• Burrs should be removed clearly with REAMER.

• Only clean surfaces prevent gas leakages.

Burrs not removed properlyafter cutting.

• Flaring the pipe with burrs(not removed after cutting)can make freon gas leakages.

• Burrs won't make smooth contacting surfaces.


21


b

ab

c

Factor Flaring works

Gas leaks and connecting troubles on tubings caused by the inaccurate sizing during flaringworks.

Troubles &Causes

Defect Details

Guidelines

Recommending sizes for several pipes whichmake proper connectings.

(a) Pipe dia. (b) Hight (c) Flared dia.

Pipe worked with largesized b won't be

assemsled into the nut.

Pipe worked with small sized b will make small contact

with nut and gas leak againsteven a weak shock.

ø6.35

ø9.52

ø12.70

ø15.8

ø19.05

1.0~1.3

0.8~1.0

0.5~0.8

0.5~0.8

0~0.5

8.3~8.7

12.0~12.4

15.4~15.8

18.6~19.0

23.3~22.9

unit:mm


22


Factor Flare nut's fastening.

Damaged flares by over-fastening make gas leakages. And incompletely fastened nuts too.

Troubles &Causes

Defect Details

Guidelines Fastening Torques of Flare Nuts Torque-wrench is required for proper fastenings.

Check gas leakages of 4 fastened points and weldedpoints with soap bubbles ctc.-High pressure points: amid compressor's running. -Low pressure points: amid compressor's not running.

Tube Dia.(mm) Torques (Kg-Cm)6.35 160~2009.52 350~45015.88 450~55019.05 550~650

Damaged Flares byover-fastening

Incompletely fastened nuts

Indoor Side

Outdoor Side


23

Leakage / Drainage - 1/5 Case-5

Factor

Water leaks caused by the inclined indoor unit and the drain hose's bad connecting.

1. Indoors leveling 2. Drain hose connecting.

Troubles &Causes

Defect Details

Guidelines

Indoors need to be leveled.(For a better drain the install-plate may betilted 2~3° to drain-pan's drain side)

Install-plate

Weight

Confirm the water draining is good or not byporing water into the drain pan.

Connecting parts of drain pan and hose shouldbe well fixed with bond for waterproofing.

2. Mal-linked drain hose1. Non-leveled indoor

Horizon

Evaporator

Drain pan

Connect hoses with drain pandrainageleaks

Slanted


24


Factor

Water leaks came from the extending or laying work of drain hose.

1. Drain hose extend(adding another hose).2. Drain hose laying.

Troubles &Causes

Defect Details

Guidelines

Connect the extending hose outside and sealwith bond and finish by taping.

Install the drain hose straightened anddownward.

2. Curved or upward drain hose.1. Improperly extended drain hose.

Extending hose

Extending hose

Downward

Drain hose

(Water leaks through theinside-connected drain

hose.)

Drain hose


25


Factor

Water leaks caused by upwarded drain hose along the wall-through hole and clogged drainhose with water.

Drain piping and ending.

Troubles &Causes

Defect Details

Guidelines

The wall-through hole should be downward. Don't make drain hose clogged with water.

2. Clogged drain hose with water.1. Upwarded drain hose along the wall-throughhole.

Downward

Arrange gap

Drainage can't flow downacross the wall.

Drainage can't flowdown along thehose.


26

Leakage / Drainage- 4/5 Case-8

Factor

Water leaks caused by wrong insulation works on tubing lines.

Insulation work on connecting parts and hidden parts of tubings.

Troubles &Causes

Defect Details

Guidelines

Completely insulate weak points likepipe-connection and hidden parts.

Ceiling

Hidden parts like behindthe ceiling is a weak point,too.

2. Un insulated hidden parts.1. Incomplete insulation works on tubeconnecting parts.

Use designatedinsulations on pipeconnecting parts.

Drainage flows downfrom incompletelyinsulated parts.

Drainage flowsdown from thehidden parts.

Ceiling


27

Leakage / Drainage -5/5 Case-9

Factor

Water leaks by the waterdrops led by wrong tubing and taping works.

Tubing and taping works against the waterdrops.

Troubles &Causes

Defect Details

Guidelines

Make U-trap against the waterdrop inflow.

tapings should be upward form downside.

Outdoor unit

Indoor unitU-trap

1. Pipe from upside lead waterdrops(rain, drainageetc.) into the room.

2. Wrong taping direction lead waterdrops into theroom too.

Taping directionUpward

Downward

Waterdrops

outdoor unit

Outdoor unit


28

Freon shortage Case-10

R-22

Lo Hi

Factor

Cooling capacity downs by the freon shortage.

Tube Extending and freon adding.

Troubles &Causes

Defect Details

Guidelines

Ensure to add freon after extending tubings.(Fora simple check of proper freon quantity, compare the in-and-out air temperature after 15 m infrom com pressor's running.)

Air in

Detect the gas leakages before insulationtubing(confirm new welded points).

1. Not adding freon for extended tubings. 2. Gas leakage on welded points for extendingtubings.

< Temp. diff. >-Cooling: 8deg

-Heating: 14deg

Air out


29

Cooling capacity - 1/5 Case-11

Factor

Cooling capacity downs by bad air flows.

Spacing for the air flows in split type air conditioners.

Troubles &Causes

Defect Details

Guidelines

Ensure the distance needed for air flows.

Bad air flows lead cooling capacity's drop.(The product may not run normally as the accumulated heat make compressor stop by protectingdevice's work like PTC)

1. The space for air intake is too narrow. 2. The space for air discharge is too narrow.

10cm50cm

Wall

Wall Wall

Wall


30


Factor

Cooling capacity downs by bad air flows.

Spacing for the air flows in window type air conditioners.

Troubles &Causes

Defect Details

Guidelines

Ensure not to disturb the air intake flows. Ensure not to disturb the air discharge flows. Theawning is recommended for a optimum cooling.

1. The space for air intake is too narrow.

Closed air intake flowClosed airdischarge flow

2. The space for air discharge is too narrow.

Air intake holes

30cm

Wall

Wall Wall

Wall


31


Factor

Cooling capacity downs by improper air flows and awning.

Improper installation and awning for outdoor unit.

Troubles &Causes

Defect Details

Guidelines

Discharged air should be outward and notdisturbed.

Establish a proper awning.

1. The outdoor shut in a verandah does not work normally.(The air around the outdoor unit arise too high)

Living

2. Improper awning

Living room30cm

Verandah

Verandah

Wall


32


Factor

Cooling capacity downs by the crushed tubes and changed tubes.

Using crushed tubes and changed tubes.

Troubles &Causes

Defect Details

Guidelines

To get a good shaped tube after bending,use specified spring or bending tools.

In changing air conditioning unit, the tubes tooshould be changed with proper ones.

1. Crushed tube by improper bendingworks.

2. Changed tubing from specified tubes.(Not using proper tubes designed for eachproduct.)

Crushed area

(Spring for bending) (Bending tool)


33


Factor

Cooling capacity downs by long distance tubings.

Long distance tubings.

Troubles &Causes

Defect Details

Guidelines

Installed too high beyond recommended height difference between indoor and outdoor unit.

Higher than recommended

Nth.....

3rd.

2rd.

1st. floor

Recommending maximum distances between indoor and outdoor unit:

-RAC (Split): vertical=5m, horizontal =10m-PAC (3.0 HP¡¡ØØ): vertical=5m, horizontal=10m -PAC (3.5 Hp¡¡ŁŁ): vertical=5m, horizontal=20m


34

Noise - 1/2 Case-16

Factor

Noise from the unstably installed parts and units.

Unstable installing units.

Troubles &Causes

Defect Details

Guidelines

1. Unstable installed outdoor unit. 2. Released fittings and fasteners.

Slanted

Parallel

Duct

Indoorunit

Install the unit balanced stably using specified legs etc.

To prevent vibrations and noises, fasten tightly all the connecting parts for electric heater, steam line, air duct line etc.


35

Noise - 2/2 Case-17

Factor

Noise and vibration form the tubings.

Unstably fixed tubings.

Troubles &Causes

Defect Details

Guidelines

Unstable fixing of surplus tubings will make vibrations and noises during the compressor'srunning.

Fixing band

Cut away the surplus tubings.But if there are any surplus tubings left for some reasons, be sure to fix them stably with fixing bands.


36

Wiring mistake -1/2 Case-18

S R T

R S T

R S T

R S T

Factor

Major electrical problems(not operating properly) by bad wirings.

Wiring in 3 phase electric power lines.

Troubles &Causes

Defect Details

Guidelines

1. Not firmly fixed screws of electric powerlines.(It can be led to critical accidents)

2. Wiring mistake of fan's electric power linesfor outdoor.(Fan rotates reversely and theunit will be shutdown with overload.)

Air discharge(Reversed flow)

Circu it breaker(Exclusive)

Circuit breaker(Exclusive)

Fixing screw

Each phase should be matchedone by one.

Fix screws firmly. Confirm the R-S-T phase lines respectively.


37

Wiring mistake -2/2 Case-19

Factor

Major electrical problems(not operating properly) by bad insulations of connecting cables.

Poor electric insulation.

Troubles &Causes

Defect Details

Guidelines

Poor electric insulations of connecting cables between indoor and outdoor.

Insulation break(Badly insulated or damaged cables)

From outdoor Cupper pipes

Black WhiteRed

To indoor

How to confirm the correct insulations of connecting cables.(for the troubles be insulation break)1. Outdoor runs on main electric power's supply.

Short between white and red cables.

2. Fuse melts on compressor's running. Short between red cable and copper pipe.

3. Fuse melts on main electric power's supply. Short between black (or white) cable and copper pipe.

4. Main electric braker operates on electric power's supply. Short between black or white cables.

5. Main electric braker operates after 10~20 min from electric power's supply. Short between black or white cables.

(Occurs after drainage break into badly insulated parts)

TCL Air Conditioner Service ManualTCL Air Conditioner Service Manual

38

Bad smells & Gases Case-20

Factor

Bad smells and gases from outside(Ex. ditch) are discharged from the system.(Be careful not to be confused as if it's from the system).

Bad smells and gases delivered by drain line.

Troubles &Causes

Defect Details

Guidelines

Discharging bad smells & gases

Bad smells & gases can bedischarged through the drain hose.

Bad smells & gases(from ditch etc.)

Add trap on the drain line.

Bad smells & gases areprotected by the trap.

Trap against gas smells etc.


39

1 General

R-407c is a blend of three basic constituents: R32, R125,R-134a with respectively weight composition 23%, 25%, 52%.

R-407c is an HFC refrigerant that does not destroy Ozonelayer.General behaviour of R-407c systems is very similar tostandard R22 one; system differences linked to R-407c arebelow:

• Since R-407c is a zeotropic blend, during phase change,liquid composition is different from vapour one; for thisreason in case of leakage in zones with biphase, residualrefrigerant composition could be changed.

• R-407c phase changes are not at constant temperatureas in R22 case, but with increasing temperature duringevaporation and with decreasing temperature duringcondensation (Glide effect).

In case of refrigerant recharge, in order to assure correctcomposition two following steps will have to be followed:

1) Residual refrigerant in the system will have to be pulled

out and stored in a disposal cylinder (do not ventilate inambient).

2) Refrigerant charge will have to be done only with liquidphase in order to guarantee proper refrigerant compositioninside the system; this can be done or using dedicatedcylinders with two valves (one for liquid, the other forvapour), or, in case of one valve cylinder, put cylinder inup side down position.

3) In case of too much refrigerant charged, it is dangerous toremove partially the charge; this could change refrigerantcomposition inside the system; in such case it is suggestedto remove completely the refrigerant charge, pull vacuumagain and recharge the system with proper amount ofrefrigerant.

Leak detection will have to be carryed-out only with HFCsensitive leak detector.Even if R-407c refrigerant is ozone friendly, do not ventilate itin the ambient because its warming effect is not zero.

For all other technical details see standard for R22.


1

ANNEX 4 R407C REFRIGERANT

R-407c R-22

1. Refrigerant charging procedure

2. Refrigerant composition

3. Partial refrigerant charge

4. Leak detector

5. Temperature trend in evaporate

6. Temperature trend in condenser

NOT PERMITTED!Only complete refrigerant charge

YES!Possible partial refrigerant charge

Use only HFC detector Use only HCFC detector

2 Main differences between R-407c and R22 refrigerant

R-407c R32 23%R125 25%R-134a 52%

2


ANNEX 5 INSTALLATION INSTRUCTION


Part 1 Wall-mounted Split Type

1. Characteristics of refrigerant1.1 Temperature-pressure relationships in saturated condition

1.2 Strong/weak points of freon1.2.1 Strong points

1) Chemical stability2) No toxicity3) By little corrosive action on metals, it is applicable to almost all metals.4) The ratio of Cp/Cv is lower than ammonia and the discharge gas temperature is low, so air cooling type is available.

1.2.2 Weak points1) A little amount of evaporation heat should circulate a great deal of liquid at the same refrigerating capacity.2) When using for iron steels, scale occurs more rapidly than ammonia use due to hydrolysis .3) Generally it is fused in lubricant.4) Since it is not melted in water, water is separated and water closing occurs in capillary tube.5) High price

-10 0 10 20 30 40 50 60 70 800

5

10

15

20

25

30

35

Saturation curve

Temperature(°C)

Pre

ssu

re (

kg/c

m2

G)

R-22

R-12

INSTALLATION


2

2. Tools required 2.1 Tools

Screw driver Hand drill Ruler, knife Gas leak detector& soup water

Thermometer Hex. wrench(Large side: 4mm, 5mm)

Assembly,disassmbly

Indoor installationplate fixing

Ruler: Length &distance measurement.Knife: Tape cutting

Leak inspection

Temperature measurement atIndoor suctioninlet/discharge outlet.

Service valve operating

Core drill (diameter 70mm)

Monkey spanner(300mm): 2EA

Torque wrench Hook meter(for current measurement)

Insulationresistance meter

Flare tool set

Connnection cable Winter cover Anti-vibration rubber

Band Adhesive Drain hose

Refrigerant pipe(for high/low pressure)

Putty Vinyl tape Remocon fixture Fixture clampingscrew

Remocon

Refrigerant circuitconnection to

Indoor/Outdoor.Chaging of wall-

through holeWire & pipe

finishingRemocon hanger Remocon fixture

fixing

Indoor-Outdoorwire connnection

Outdoor protectionin a unusedseason

like winterVibration absorption

of outdoorWire & pipe

finishingFinishing Drainage

Wall through Indoor/Outdoorpipe connection

Indoor/outdoorpipe connection

Current, voltage,resistance

measurement

Insulation resistancemeasurement

(Electric shock prevention)Pipe cutting,Burr removal

Level

Clamp meter

Thermometer

Drive torch Mega tester

2.2 Accessory


3

Remark: Some of the above parts are provided by the installer and not included in the standard air-conditioner.

7K, 9K 3/8" 1/4" 4 or 5 5 12K 1/2" 1/4" 4 or 5

18K 1/2" 1/4" 5

24K 5/8" 3/8" 5

3. Split type installation3.1 Select the best location 3.1.1 Indoor unit

1) Do not have any heat or steam near the unit.2) Select a place where there are no obstacles in front of

the unit.3) Make sure that condensation drainage can be conve-

niently routed away.4) Do not install near a doorway.5) Ensure that the space around the left and right of the

unit is more than 5cm. The unit should be installed ashigh on the wall as possible, allowing a minimum of5cm from ceiling.

6) Use a stud finder to locate studs to prevent unneces-sary damage to the wall.

3.1.2 Outdoor unit1) If an awning is built over the unit to prevent direct sun-

light or rain exposure, make sure that heat radiationfrom the condenser is not restricted.

2) Ensure that the space around the back and sides ismore than 10cm. The front of the unit should havemore than 70cm of space.

3) Do not place animals and plants in the path of thewarm air.

4) Take the air conditioner weight into account and selecta place where noise and vibration are minimum.

5) Select a place so that the warm air and noise from theair conditioner do not disturb neighbors.

6) Rooftop Installations:If the outdoor unit is installed on a roof structure, besure to level the unit. Ensure the roof structure andanchoring method are adequate for the unit location.Consult local codes regarding rooftop mounting.

3.2 Piping length and elevation

More than 5cmMore than 5cm

More than 2.3m More than 5cm

More than 10cm

More than 60cm

More than 10cm

More than 60cm

More than 70cm

Pipe SizeCapacity(Btu/h) GAS LIQUID

Max. lengthA (m)

AdditionalRefrigerant

(g/m)

Max.Elevation

B (m)

StandardLength

(m)

* Both gas and liquid interconnecting pipes must beinsulated as a pair, but it is not necessary to indi-vidually insulate them.

In case more than 5m

• Capacity is based on standard length and maximum allowancelength is on the basis of reliability.

• Oil trap should be installed every 5~7 meters.

AOil trap

Outdoor unit

Indoor unitB

Outdoor unit

Indoor unit

A

B

Install the indoor unit on the wall where the height from thefloors more than 2.3 meters.

CAUTION

CAUTION


4

10155

5

5

2020

15

15

20

30

3.3 How to fix installation plateThe wall you select should be strong and solid enough toprevent vibration

3.3.1 Mount the installation plate on the wall withfour type A screws. If mounting the unit on aconcrete wall, use anchor bolts.

• Mount the installation plate horizontally by aligning the center-line using a level.

3.3.2 Measure the wall and mark the centerline. Itis also important to use caution concerningthe location of the installation plate-routingof the wiring to power outlets is through thewalls typically. Drilling the hole through thewall for piping connections must be donesafely.

• For right rear piping and left rear piping, draw aline in the direction of the arrow marked "D". Themeeting point of the two lines is the center of thehole.

5-7m

m(0

.2~

0.3"

)

Indoor

WALL

Outdoor

Installation Plate

Marking-off line

Thread

Weight

Type "A" screw

A,B

A,B,CC

D

D

A,B,DC

A

B,DC

ø70mm

Left rear piping Right rear piping

Hole Center Installation plate

• Drill the piping hole with a ø70mm hole core drill.Drill the piping hole at either the right or the left withthe hole slightly slanted to the outdoor side.

3.4 Drill a hole in the wall

• The position of the center of the hole.

D

D

D

D

Left holecore position Right holecore position


5

3.5.1 Flaring workMain cause for gas leakage is due to defect in flaringwork. Carry out correct flaring work in the followingprocedure.

A. Cut the pipes and the cable.1) Use the piping kit accessory or the pipes pur-

chased locally.2) Measure the distance between the indoor and the

outdoor unit.3) Cut the pipes a little longer than measured dis-

tance.4) Cut the cable 1.5m longer than the pipe length.

B. Burrs removal1) Completely remove all burrs from the cut cross

section of pipe/tube.2) Put the end of the copper tube/pipe in a downward

direction as you remove burrs in order to avoiddropping burrs into the tubing.

C Putting nut on• Remove flare nuts attached to indoor and outdoor

unit, then put them on pipe/tube having completedburr removal.(not possible to put them on after flaring work)

Copperpipe 90° Slanted Uneven Rough

Bar

Copper pipe

Clamp handleRed arrow mark

Cone

Yoke

Handle

Bar"A"

Pipe

Reamer

Point down

Flare nut

Copper tube

D. Flaring work• Carry out flaring work using flaring tool as shown

below.

Firmly hold copper pipe in a die in the dimension shown inthe table above.

E. Check1) Compare the flared work with figure below.2) If flare is noted to be defective, cut off the flared sec-

tion and do flaring work again.

Outside diameter A

mmmm inch

1/4

3/8

1/2

5/8

ø6.35

ø9.52

ø12.7

ø15.88

1.0~1.3

0.8~1.0

0.5~0.8

0.5~0.8

Inclined

Inside is shiny without scratches

Smooth all round

Even lengthall round

Surfacedamaged

Cracked Uneventhickness

= Improper flaring =

3.5 Flaring work and connection of piping


6

3.5.2 Connection of piping--Indoor1) Preparing the indoor unit's piping and drain hose for

installation through the wall.2) Remove the plastic tubing retainer(see illustration

below) and pull the tubing and drain hose away fromchassis.

3) Replace the plastic tubing holder in the original posi-tion.

A. Route the indoortubing and thedrain hose in thedirection of rearright.

B. Insert the connecting cable into the indoor unit fromthe outdoor unit through the piping hole.1) Do not connect the cable to the indoor unit.2) Make a small loop with the cable for easy connection

later.3) Connecting cable

D. Indoor unit installation• Hook the indoor unit onto the upper portion of the

installation plate.(Engage the two hooks of the reartop of the indoor unit with the upper edge of theinstallation plate.) Ensure that the hooks are properlyseated on the installation plate by moving it left andright.

Press the lower left and right sides of the unit against theinstallation plate until the hooks engage into their slots(click-ing sound).

C. Tape the tubing, drain hose and the connectingcable. Be sure that the drain hose is located at thelowest side of the bundle. Locating at the upperside can cause drain pan to overflow inside theunit.

E. Connecting the pipings to the indoor unit anddrain hose to drain pipe.• Align the center of the pipings and sufficiently tighten

the flare nut by hand.

NOTE: If the drain hose is routed inside the room, insulate thehose with an insulation material* so that dripping from "sweat-ing"(condensation) will not damage furniture or floors.*Foamed polyethylene or equivalent is recommended.

Cooling ModelCapacity (Btu/h) Heat Pump Model

Drain hose

Indoor tubing

Connecting cable

Gas sidepiping

Liquid sidepipingDrain hose

Indoor tubing

Connecting cable

Drain hose

74cm

Cable

Gas side piping

Liquid side pipingLength of con -necting cable

Drain hose

Connectingcable

Indoor unit tubing Flare nut Pipings

For right rear piping

CAUTIONWhen install, make surethat the remaining partsmust be removed clearly soas not to damage the pipingand drain hose, especiallypower cord and connectingcable.


7

7K,9K,12K,18K

24K

F. Wrap the insulation material around the connectingportion.

• Overlap the connection pipe insulation material and theindoor unit pipe insulation material. Bind them togetherwith vinyl tape so that there is no gap.

A. Route the indoor tubing with the drain hose to therequired piping hole position.

B. Insert the piping, drain hose and the connecting cableinto the piping hole.

Plastic bands Insulation material

Drain pipe

Connecting cable

Pipe

Vinyl tape(narrow)

Connectionpipe

Connecting cable

Vinyl tape(wide)

Wrap with vinyl tape

Indoor unit pipe

Pipe

Torque wrench

Indoor unit tubing

Spanner (fixed)

Connection pipe

Flare nut

Vinyl tape(narrow)Adhesive

Drain pipe

Indoor unit drain hose

• When extending the drain hose at the indoor unit, installthe drain pipe.

• Tighten the flare nut with a wrench.

3/8"[4.2kg.m] 1/4"[1.8kg.m] 1/2"[5.5kg.m] 1/4"[1.8kg.m]

24K 5/8"[6.6kg.m] 3/8"[4.2kg.m]

Pipe Size[Torque]Capacity(Btu/h) GAS LIQUID

• Wrap the area which accommodates the rear pipinghousing section with vinyl tape.

• Bundle the piping and drain hose together by wrappingthem with vinyl tape over the range within which they fitinto the rear piping housing section.

For left rear piping


Drain hose

Pipe

Vinyl tape(wide)


8

12K,18K7K,9K

C. Insert the connecting cable into the indoor unit.1) Don't connect the cable to the indoor unit.2) Make a small loop with the cable for easy connection

later.

D. Tape the tubing, drain hose and the connectingcable.• Connecting cable

E. Indoor unit installation1) Hang the indoor unit from the hooks at the top of the

installation plate.2) Insert the spacer etc. between the indoor unit and the

installation plate and separate the bottom of the indoorunit from the wall.

Cooling ModelCapacity (Btu/h) Heat Pump Model

Installation plate

Spacer

Indoor unit

8cmF. Connecting the pipings to the indoor unit and the

drain hose to drain pipe.• Align the center of the pipings and sufficiently tighten


• Tighten the flare nut with a wrench.

G. Wrap the insulation material around the connect -ing portion.• Overlap the connection pipe heat insulation and the

indoor unit pipe heat insulation material. Bind themtogether with vinyl tape so that there is no gap.

Plastic bands Insulation material

Vinyl tape(narrow)

Connectionpipe

Connecting cable

Indoor unit piping

Pipe

Vinyl tape Wrap with vinyl tape

Indoor unit tubing Flare nut Pipings

Torque wrench

Indoor unit tubing

Spanner (fixed)

Connection pipe

Flare nut

Vinyl tapeAdhesive

Drain hose

Indoor unit drain hose

(narrow)

• When extending the drain hose at the indoor unit,install the drain pipe.

• Wrap the area which accommodates the rear pipinghousing section with vinly tape.

Loop

3/8"[4.2kg.m] 1/4"[1.8kg.m] 1/2"[5.5kg.m] 1/4"[1.8kg.m]

24K 5/8"[6.6kg.m] 3/8"[4.2kg.m]



9

7K,9K,12K,18K

24K

12K,18K 7K,9K

3.5.3 Connection of the pipes-OutdoorA. Align the center of the pipings and sufficiently tighten


B. Finally, tighten the flare nut with torque wrench untilthe wrench clicks.• When tightening the flare nut with torque wrench,

ensure the direction for tightening follows the arrow onthe wrench.

Liquid side piping(Smaller diameter)

Gas side piping(Bigger diameter)

Torque wrench

Outdoor unit

H. Reroute the pipings and the drain hose across theback of the chassis.

I. Set the pipings and the drain hose to the back of thechassis with the tubing holder.

• Hook the edge of tubing holder to tap on chassis andpush the bottom of tubing holder to be engaged at thebottom of chassis.

J. Indoor unit installation 1) Remove the spacer.2) Ensure that the hooks are properly seated on the

installation plate by moving it left and right.

Drain hose

Connectingcable

Piping forpassage throughpiping hole

Taping


Vinyl tapeDrain hose

Pipe

• Bundle the piping and drain hose together by wrappingthem with cloth tape over the range within which they fitinto the rear piping housing section.

Press the lower left and right sides of the unit againstthe installation plate until the hooks engage into theirslots(clicking sound).

3/8"[4.2kg.m] 1/4"[1.8kg.m] 1/2"[5.5kg.m] 1/4"[1.8kg.m]

24K 5/8"[6.6kg.m] 3/8"[4.2kg.m]



10

12K,18K7K,9K

CAUTIONThe power cord connected to the indoor unit should becomplied with the following specifications(Type H05VV-F(Indoor), H07RN-F(Outdoor) approvedby HAR or SAA).

1

1

1

N

N

N

2

2

3

3

1 N L L N

1 N L

1 N

BROWN BLUE GREEN/YELLOW

BROWN BLUE

BROWN REDBLUE

BROWN

BROWNWHITE

Power supply

BLUE

BROWNWHITE BLUE

GREEN/YELLOW

GREEN/YELLOW

RED

YELLOW

YELLOWBLUE GREEN/YELLOW

The power connecting cable connected to the indoorand outdoor unit should be complied with the followingspecifications(Type H07RN-F approved by HAR or SAA).

The connecting cable connected to the indoor and out-door unit should be complied with the following specifi-cations(Type H07RN-F approved by HAR or SAA).

• 7K~18K cooling model

Terminal on the indoor unit


Terminal on the outdoor unit


• 7K~18K heat pump model



• 24K cooling model

.

3.6 Connecting the cable between indoorunit and outdoor unit

3.6.1 Connect the cable to the Indoor unit.• Connect the cable to the indoor unit by connecting

the wires to the terminals on the control board indi-vidually according to the outdoor unit connection .(Ensure that the color of the wires of the outdoor unitand the terminal No. are the same as those of theindoor unit.)

NORMALCROSS-SECTIONALAREA 2.5mm2

(18K: 1.5mm2, 7K~14K: 1.0mm2)


(18K: 1.5mm2, 7K~14K: 1.0mm2)



11

GREEN/YELLOW

Air Conditioner

Main power source

Circuit BreakerUse a circuitbreaker or timedelay fuse.

Circuit BreakerUse a 25A circuitbreaker or timedelay fuse.

Air Conditioner

Main power source

~18K ModelIf a power plug is not to be used, provide a circuit breakerbetween power source and the unit as shown below.

CAUTION 24K~ Model

If a power plug is not to be used, provide a circuit breakerbetween power source and the unit as shown below.

. 24K heat pump model

L N

1 2 3

YELLOWWHITE

Power supply

RED

L N

L N



GREEN/YELLOW

BROWN BLUE

BLUE BROWN

GREEN/YELLOW

YELLOW WHITE RED

1 2 3

Meccan Zhao

Meccan Zhao

Meccan Zhao

Meccan Zhao

3.6.2 Connect the cable to the outdoor unitA. Remove the control cover from the unit by loosen -

ing the screw.Connect the wires to the terminals on the controlboard individually.

B. Secure the cable onto the control board with thecord clamp.

C. Refix the control cover to the original position withthe screw.

D. Use a recognized circuit breaker 20A(18K) ,25A(24K) between the power source andthe unit. A disconnecting device to adequately dis -connect all supply lines must be fitted.

Terminal block

Over 5mm

Control cover

Power cord(power connectingcable)

Connecting cable

Outdoor unit

After the confirmation of the above conditions, prepare the wiring as follows:

1) Never fail to have an individual power circuit specifically for the air conditioner. As for the methodof wiring, be guided by the circuit diagram posted on the inside of control cover.

2) The screw which fasten the wiring in the casing of electrical fittings are liable to come loosefrom vibrations to which the unit is subjected during the course of transportation. Check themand make sure that they are all tightly fastened. (If they are loose, it could cause burn-out of the wires.)

3) Specification of power source.

4) Confirm that electrical capacity is sufficient.

5) See to that the starting voltage is maintained at more than 90 percent of the rated voltagemarked on the name plate.

6) Confirm that the cable thickness is as specified in the power source specification.(Particularly note the relation between cable length and thickness.

7) Always install an earth leakage circuit breaker in a wet or moist area.

8) The following would be caused by voltage drop.

• Vibration of a magnetic switch, which will damage the contact point, fuse breaking, disturbance of the normalfunction of the overload.

9) The means for disconnection from a power supply shall be incorporated in the fixed wiring andhave an air gap contact separation of at least 3mm in each active(phase) conductors.

CAUTION


12

3.7.2 Form the piping

A. Form the piping by wrapping the connecting portionof the indoor unit with insulation material and secureit with two kinds of vinyl tapes.• If you want to connect an additional drain hose, the end

of the drain outlet should be routed above the ground.Secure the drain hose appropriately.

B In cases where the outdoor unit is installed below theindoor unit perform the following.1) Tape the piping, drain hose and connecting cable from

down to up.2) Secure the tapped piping along the exterior wall using

saddle or equivalent.

Taping

Pipings

Connectingcable

Drainhose

Seal small openingsaround pipings with agum type sealer.

Trap is required to prevent waterfrom entering into electrical parts.

C. In cases where the Outdoor unit is installed abovethe Indoor unit perform the following.1) Tape the piping and connecting cable from down to

up.2) Secure the taped piping along the exterior wall. Form

a trap, to prevent water entering the room.3) Fix the piping onto the wall by saddle or equivalent.

Trap

Seal small openingsaround pipings with agum type sealer.

Trap

Trap is required to prevent waterfrom entering into electrical parts.

3.7 Checking the Drainage and formingthe pipings

3.7.1 Checking the drainageA. To remove the front panel from the indoor unit,

remove the front panel from the indoor unit cabinet.1) Set the air direction louvers up-and-down to the posi-

tion(horizontally) by hand.2) Remove 3 screws that retain the front panel.

Pull the lower left and right sides of the grille towardyou and lift it off.

Grille

Remove screws (3places)

Chassis

B. To check the drainage.1) Pour a glass of water on the evaporator.2) Ensure the water flows through the drain hose of the

indoor unit without any leakage and goes out the drainexit.

C. Drain piping• The drain hose should point downward for easy drain

flow.

• Do not make drain piping.

Downward slope

Do not raiseAccumulateddrain water

Tip of drain hose dipped in water

Air

WavingWaterleakage

Waterleakage Ditch

Less than 50mm gap

Waterleakage


13

3.8 Air purging3.8.1 Air purging

Air and moisture remaining in the refrigerant systemhave undesirable effects as indicated below.1) Pressure in the system rises.2) Operating current rises.3) Cooling(or heating) efficiency drops.4) Moisture in the refrigerant circuit may freeze and

block capillary tubing.5) Water may lead to corrosion of parts in the refrigera-

tion system.Therefore, the indoor unit and tubing between the indoorand outdoor unit must be leak tested and evacuated toremove any noncondensables and moisture from thesystem.

3.8.2 Air purging with vacuum pump

A. Preparation• Check that each tube(both liquid and gas side tubes)

between the indoor and outdoor units have been prop-erly connected and all wiring for the test run has beencompleted. Remove the service valve caps from boththe gas and the liquid side on the outdoor unit. Notethat both the liquid and the gas side service valves onthe outdoor unit are kept closed at this stage.

B. Leak test• Connect the manifold valve(with pressure gauges) and

dry nitrogen gas cylinder to this service port withcharge hoses.

• Pressurize the system to no more than 150 P.S.I.G.with dry nitrogen gas and close the cylinder valve whenthe gauge reading reached 150 P.S.I.G. Next, test forleaks with liquid soap.

• Do a leak test of all joints of the tubing(both indoor andoutdoor) and both gas and liquid side service valves.Bubbles indicate a leak. Be sure to wipe off the soapwith a clean cloth.

• After the system is found to be free of leaks, relieve thenitrogen pressure by loosening the charge hose con-nector at the nitrogen cylinder. When the system pres-sure is reduced to normal, disconnect the hose from thecylinder.

Be sure to use a manifold valve for air purging. If it isnot available, use a stop valve for this purpose. The "Hi"knob of the manifold valve must always be kept close.

To avoid nitrogen entering the refrigerant system in a liquid state, thetop of the cylinder must be higher than its bottom when you pressurizethe system. Usually, the cylinder is used in a vertical standing position.

CAUTION

CAUTION


14

C. Evacuation• Connect the charge hose end described in the preced-

ing steps to the vacuum pump to evacuate the tubingand indoor unit.Confirm the "Lo" knob of the manifold valve is open.Then, run the vacuum pump.The operation time for evacuation varies with tubinglength and capacity of the pump. The following tableshows the time required for evacuation.

• When the desired vacuum is reached, close the "Lo"knob of the manifold valve and stop the vacuum pump.

D. Finishing the job

1) With a service valve wrench, turn the valve stem of liq-uid side valve counter-clockwise to fully open thevalve.

2) Turn the valve stem of gas side valve counter-clock-wise to fully open the valve.

3) Loosen the charge hose connected to the gas sideservice port slightly to release the pressure, thenremove the hose.

4) Replace the flare nut and its bonnet on the gas sideservice port and fasten the flare nut securely with anadjustable wrench. This process is very important toprevent leakage from the system.

5) Replace the service valve caps at both the gas andthe liquid side and fasten them tight.

This completes air purging with a vacuum pump. The air conditioner is now ready to test run.

(1) Remove the caps from the 2-way and 3-way valves.(2) Remove the service-port cap from the 3-way valve.(3) To open the 2-way valve turn the valve stem counter-

clockwise approximately 90°, wait for about 2~3 sec, andclose it.

(4) Apply a soap water or a liquid neutral detergent on theindoor unit connection or outdoor unit connections by asoft brush to check for leakage of the connecting pointsof the piping.

(5) If bubbles come out, the pipes have leakage.

Soap water method

Cover controlOutdoor unit

Gas side(Bigger diameta)

Liquid side(Smaller diameta)

Hexagonalwrench

Service port cap

3-way valve(close)

2-way valve(open)

Cap

Required time for evacuation when 30 gal/hvacuum pump is used

10 min. or more 15 min. or more

If tubing length is lessthan 10m (33 ft)

if tubing length is longerthan 10m (33 ft)

Lo Hi

Indoor unit

Outdoor unit

Manifold valve

Vacuum pump

Pressure gauge

Open Close


15

B. Settlement of outdoor unit1) Anchor the outdoor unit with a bolt and nut

tightly and horizontally on a concrete or rigid mount.2) When installing on the wall, roof or rooftop, anchor

the mounting base securely with a nail or wire assum-ing the influence of wind and earthquake.

3) In the case when the vibration of the unit is conveyedto the hose, secure the unit with an anti-vibration rub-ber.

3.9 Test running1) Check that all tubing and wiring have been properly

connected.2) Check that the gas and liquid side service valves are

fully open.

A. Prepare remote control

1) Remove the battery cover bypulling it according to the arrowdirection.

2) Insert new batteries making surethat the (+) and (–) of batteryare installed correctly.

3) Reattach the cover by pushing itback into position.

NOTE:• Use 1.5volt batteries. Do not use rechargeable

batteries.• Remove the batteries from the remote control if the

system is not going to be used for a long time.

C. Evaluation of the performance

Operate unit for 15~20 minutes, then check the systemrefrigerant charge:1. Measure the pressure of the gas side service valve.2. Measure the temperature of the intake and discharge

of air.

NOTE: If the actual pressure are higher than shown, the systemis most likely over-charged, and charge should beremoved. If the actual pressure are lower than shown,the system is most likely undercharged, and chargeshould be added.

The air conditioner is now ready for use.

Bolt

Tubing connection

Outside ambient TEMP. The pressure of the gas side service valve

35°C(95°F) 4~6kg/cm2.G(56.8~85.2 P.S.I.G.)

This is performed when the unit is to be relocated orthe refrigerant circuit is serviced.Pump Down means collecting all refrigerant in the out-door unit without loss in refrigerant gas.

CAUTION:Be sure to perform Pump Down procedure with the unitcooling mode.

Pump Down Procedure1. Connect a low-pressure gauge manifold hose to the

charge port on the gas side service valve.2. Open the gas side service valve halfway and purge the air

from the manifold hose using the refrigerant gas.3. Close the liquid side service valve(all the way in).4. Turn on the unit's operating switch and start the cooling

operation.5. When the low-pressure gauge reading becomes 1 to

0.5kg/cm2.G(14.2 to 7.1 P.S.I.G.), fully close the gas sidevalve stem and then quickly turn off the unit. At that time,Pump Down has been completed and all refrigerant gaswill have been collected in the outdoor unit.

PUMP DOWN

3. Ensure the difference between the intake temperatureand the discharge is more than 8°C (Cooling) orreversely (Heating).

4. For reference; the gas side pressure of optimum condi-tion is as below.(Cooling)

Discharge air

Intake temperature

Discharge temperature


16

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