Monday, January 02, 2017

Carrier wall mounted air conditioner – 11M INVERTER - Installation procedure – How to fill the refrigerant

Installation for the first time
Air and moisture in the refrigerant system have undesirable effects as below:
# Pressure in the system rises.
# Operating current rises.
# Cooling or heating efficiency drops.
# Moisture in the refrigerant circuit may freeze and block capillary tubing.
# Water may lead to corrosion of parts in the refrigerant system.
Therefore, the indoor units and the pipes between indoor and outdoor units must be leak tested and evacuated to remove gas and moisture from the system.
Gas leak check (Soap water method):
Apply soap water or a liquid neutral detergent on the indoor unit connections or outdoor unit connections by a soft brush to check for leakage of the connecting points of the piping. If bubbles come out, the pipes have leakage.
Air purging with vacuum pump

1) Completely tighten the flare nuts of the indoor and outdoor units, confirm that both the 2-way and 3-way valves are set to the closed position.
2) Connect the charge hose with the push pin of handle lo to the 3-way valves gas service port..
3) Connect the charge hose of handle hi connection to the vacuum pump.
4) Fully open the handle Lo of the manifold valve.
5) Operate the vacuum pump to evacuate.
6) Make evacuation for 30 minutes and check whether the compound meter indicates -0.1Mpa. If the meter does not indicate -0.1Mpa after pumping 30 minutes, it should be pumped 20 minutes more. If the pressure can’t achieve -0.1Mpa after pumping 50 minutes, please check if there are some leakage points.
Fully close the handle Lo valve of the manifold valve and stop the operation of the vacuum pump. Confirm that the gauge needle does not move (approximately 5 minutes after turning off the vacuum pump).
7) Turn the flare nut of the 3-way valves about 45 Degree counterclockwise for 6 or 7 seconds after the gas coming out, then tighten the flare nut again. Make sure the pressure display in the pressure indicator is a little higher than the atmosphere pressure. Then remove the charge hose from the 3 way valve.
8) Fully open the 2 way valve and 3 way valve and securely tighten the cap of the 3 way valve.
Air purging by refrigerant

Procedure:
1). Confirm that both the 2-way and 3-way valves are set to the closed position.
2). Connect the charge set and a charging cylinder to the service port of the 3-way valve.
3). Air purging.
Open the valves on the charging cylinder and the charge set. Purge the air by loosening the flare nut on the 2-way valve approximately 45 
bar for 3 seconds then closing it for 1 minute; repeat 3 times. After purging the air, use a torque wrench to tighten the flare nut on the 2-way valve.
4). Check the gas leakage.
Check the flare connections for gas leakage.
5). Discharge the refrigerant.
Close the valve on the charging cylinder and discharge the refrigerant by loosening the flare nut on the 2-way valve approximately 45 bar until the gauge indicates 0.3 to 0.5 Mpa.
6). Disconnect the charge set and the charging cylinder, and set the 2-way and 3-way valves to the open position.
Be sure to use a hexagonal wrench to operate the valve stems.
7). Mount the valve stems nuts and the service port cap.
Be sure to use a torque wrench to tighten the service port cap to a torque 18N·m.
Be sure to check the gas leakage.
Adding the refrigerant if the pipe length >5m

Procedure:
1). Connect the charge hose to the charging cylinder, open the 2-way valve and the 3-way valve.
Connect the charge hose which you disconnected from the vacuum pump to the valve at the bottom of the cylinder. If the refrigerant is R410A, make the cylinder bottom up to ensure the liquid charge.
2). Purge the air from the charge hose.
Open the valve at the bottom of the cylinder and press the check valve on the charge set to purge the air (be careful of the liquid refrigerant).
3) Put the charging cylinder onto the electronic scale and record the weight.
4) Operate the air conditioner at the cooling mode.
5) Open the valves (Low side) on the charge set and charge the system with liquid refrigerant
6).When the electronic scale displays the proper weight , disconnect the charge hose from the 3-way valve’s service port immediately and turn off the air conditioner before disconnecting the hose.
7). Mount the valve stem caps and the service port.Use torque wrench to tighten the service port cap to a torque of 18N.m.
Be sure to check for gas leakage.
Adding the refrigerant after running the system for many years

Procedure:
1). Connect the charge hose to the 3-way service port, open the 2-way valve and the 3-way valve.
Connect the charge hose to the valve at the bottom of the cylinder. If the refrigerant is R410A, make the cylinder bottom up to ensure liquid charge.
2). Purge the air from the charge hose.
Open the valve at the bottom of the cylinder and press the check valve on the charge set to purge the air (be careful of the liquid refrigerant).
3) Put the charging cylinder onto the electronic scale and record the weight.
4) Operate the air conditioner at the cooling mode.
5) Open the valves (Low side) on the charge set and charge the system with liquid refrigerant.
6).When the electronic scale displays the proper weight (refer to the gauge and the pressure of the low side), disconnect the charge hose from the 3-way valve’s service port immediately and turn off the air conditioner before disconnecting the hose.
7). Mount the valve stem caps and the service port
Use torque wrench to tighten the service port cap to a torque of 18N.m.
Be sure to check for gas leakage.
Re-installation while the indoor unit need to be repaired
1. Collecting the refrigerant into the outdoor unit

Procedure
1). Confirm that both the 2-way and 3-way valves are set to the opened position
Remove the valve stem caps and confirm that the valve stems are in the opened position.
Be sure to use a hexagonal wrench to operate the valve stems.
2). Connect the charge hose with the push pin of handle lo to the 3-way valves gas service port.
3). Air purging of the charge hose.
Open the handle Lo valve of the manifold valve slightly to purge air from the charge hose for 5 seconds and then close it quickly.
4). Set the 2-way valve to the close position.
5). Operate the air conditioner at the cooling cycle and stop it when the gauge indicates 0.1MPa.
6). Set the 3-way valve to the closed position immediately
Do this quickly so that the gauge ends up indicating 0.3 to 0.5Mpa.
Disconnect the charge set, and tighten the 2-way and 3-way valve’s stem nuts.
Use a torque wrench to tighten the 3-way valves service port cap to a torque of 18N.m.
Be sure to check for gas leakage.
2. Air purging by the refrigerant

Procedure:
1). Confirm that both the 2-way and 3-way valves are set to the closed position.
2). Connect the charge set and a charging cylinder to the service port of the 3-way valve
Leave the valve on the charging cylinder closed.
3). Air purging.
Open the valves on the charging cylinder and the charge set. Purge the air by loosening the flare nut on the 2-way valve approximately 45 bar for 3 seconds then closing it for 1 minute; repeat 3 times.
After purging the air, use a torque wrench to tighten the flare nut on the 2-way valve.
4). Check the gas leakage
Check the flare connections for gas leakage.
5). Discharge the refrigerant
Close the valve on the charging cylinder and discharge the refrigerant by loosening the flare nut on the 2-way valve approximately 45 bar until the gauge indicates 0.3 to 0.5 Mpa.
6). Disconnect the charge set and the charging cylinder, and set the 2-way and 3-way valves to the open position
Be sure to use a hexagonal wrench to operate the valve stems.
7). Mount the valve stems nuts and the service port cap
Be sure to use a torque wrench to tighten the service port cap to a torque 18N.m.
Be sure to check the gas leakage.
Re-installation while the outdoor unit need to be repaired
1. Evacuation for the whole system

Procedure:
1). Confirm that both the 2-way and 3-way valves are set to the opened position.
2). Connect the vacuum pump to 3-way valve’s service port.
3). Evacuation for approximately one hour. Confirm that the compound meter indicates -0.1Mpa.
4). Close the valve (Low side) on the charge set, turn off the vacuum pump, and confirm that the gauge needle does not move (approximately 5 minutes after turning off the vacuum pump).
5). Disconnect the charge hose from the vacuum pump.
2. Refrigerant charging
Procedure:
1). Connect the charge hose to the charging cylinder, open the 2-way valve and the 3-way valve Connect the charge hose which you disconnected from the vacuum pump to the valve at the bottom of the cylinder. If the refrigerant is R410A, make the cylinder bottom up to ensure liquid charge.
2). Purge the air from the charge hose Open the valve at the bottom of the cylinder and press the check valve on the charge set to purge the air (be careful of the liquid refrigerant).
3) Put the charging cylinder onto the electronic scale and record the weight.
4). Open the valves (Low side) on the charge set and charge the system with liquid refrigerant.
If the system cannot be charge with the specified amount of refrigerant, or can be charged with a little at a time (approximately 150g each time) , operating the air conditioner in the cooling cycle; however, one time is not sufficient, wait approximately 1 minute and then repeat the procedure.
5).When the electronic scale displays the proper weight, disconnect the charge hose from the 3-way valve’s service port immediately
If the system has been charged with liquid refrigerant while operating the air conditioner, turn off the air conditioner before disconnecting the hose.
6). Mounted the valve stem caps and the service port Use torque wrench to tighten the service port cap to a torque of 18N.m.
Be sure to check for gas leakage
Indoor Unit Error Codes and Causes 
Operation lamp
Timer lamp
Display
LED STATUS
Blink 1 time
OFF
E0
Indoor unit EEPROM parameter error
Blink 2 times
OFF
E1
Indoor / outdoor units communication error
Blink 4 times
OFF
E3
Indoor fan speed has been out of control
Blink 5 times
OFF
E4
Indoor room temperature sensor T1 open circuit or short circuit
Blink 6 times
OFF
E5
Evaporator coil temperature sensor T2 open circuit or short circuit
Blink 7 times
OFF
EC
Refrigerant Leakage Detection
Blink 2 times
ON
F1
Outdoor ambient temperature sensor T4 open circuit or short circuit
Blink 3 times
ON
F2
Condenser coil temperature sensor T3 open circuit or short circuit
Blink 4 times
ON
F3
Compressor discharge temperature sensor T5 open circuit or short circuit
Blink 5 times
ON
F4
Outdoor unit EEPROM parameter error
Blink 6 times
ON
F5
Outdoor fan speed has been out of control
Blink 1 times
Blink
P0
IPM malfunction or IGBT over-strong current protection
Blink 2 times
Blink
P1
Over voltage or over low voltage protection
Blink 3 times
Blink
P2
High temperature protection of compressor top diagnosis and solution(only for 9k,12k models)
Blink 5 times
Blink
P4
Inverter compressor drive error