40GKX Cassette DX Old
40GKX Cassette DX Old
40GKX Cassette DX Old
INSTALLATION MANUAL
40 GKX
Split system “Global cassette” indoor unit
ENGLISH
IR Remote Control “Room Controller” “Group Controller” “Zone Manager”
The unit can be used with infrared Remote Control, with the Carrier “Room Controller” or “Group
Controller” remote control.
Some units can be used also with the Carrier “Zone Manager” remote control.
Infrared control installation instructions are contained in this manual.
Remote controls intallation instructions are contained in the relevant manuals.
The operation and maintenance instructions for the indoor unit and the installation instructions
for the indoor and the outdoor unit are given in the manuals for each unit.
Contents
Page
Dimensions and weight ........................................................................................ 2
Technical data ....................................................................................................... 3
General information .............................................................................................. 4
Avoid ..................................................................................................................... 5/6
Installation ............................................................................................................ 6/8
Refrigerant connections ....................................................................................... 9
Electrical connections ........................................................................................... 10/11
Wiring diagrams .................................................................................................... 12/13
Fresh air renewal and conditioned air supply to adjacent room ........................... 14/15
System configuration ............................................................................................ 16
Operating test ....................................................................................................... 16
Maintenance ......................................................................................................... 17
40GKX012---703-40 40GKX112W--703-40
40GKX018---703-40 40GKX118W--703-40
40GKX024---703-40 40GKX124W--703-40
40GKX028---703-40 40GKX128W--703-40 230V ~ 50Hz
40GKX036---703-40 40GKX136W--703-40
40GKX048---703-40 40GKX148W--703-40
40GKX060---703-40 40GKX160W--703-40
40GKX012W--703-40
40GKX018W--703-40
40GKX024W--703-40
40GKX028W--703-40 230V ~ 50Hz
40GKX036W--703-40
40GKX048W--703-40
40GKX060W--703-40
40GKX012W--303-40 40GKX112W--303-40
40GKX018W--303-40 40GKX118W--303-40
40GKX024W--303-40 40GKX124W--303-40
40GKX028W--303-40 40GKX128W--303-40 60Hz Special Export Market
40GKX036W--303-40 40GKX136W--303-40
40GKX048W--303-40 40GKX148W--303-40
40GKX060W--303-40 40GKX160W--303-40
AC Cooling only - HP Heat pump
GB - 1
40 GKX
Dimensions and weight
575 575
91
52
120
158
70
0
225
15
Ø
298
280
Ø 56
720
550
40GKX 012 - 018 - 024
515
30
50
825 825
126
298
237
ø156
168
813
GB - 2
40 GKX
Technical data ENGLISH
Table II: Connection wire size between indoor and outdoor units (mm2)
• The power supply cable to the electric heaters must be H07 RN-F type.
Model R C Y O(1) W2(1) S1(1) S2(1) • The connection cables between indoor and outdoor units must be:
- type A05 RN-F (3 x 1) (R - C -Y) for cooling only units (A/C)
from 12 to 60 1.0 1.0 1.0 1.0 1.0 0.75 0.75 - type A05 RN-F (2 x 1) (R - C) for heat pump units (H/P)
(1)
Heat pump unit only - type A05 RN-F (3 x 1) (Y - O - W2) for heat pump units (H/P)
- type A05 RN-F (2 x 0,75) (S1 - S2) for heat pump units (H/P)
GB - 3
40 GKX
General information
Unit installation
• Inspect equipment for damage during transport. In case of
Read this instruction manual thoroughly before starting damage file an immediate claim with the shipping company.
installation. Do not install or use damaged units.
• This unit complies with the low-voltage (EEC/73/23) and • In case of malfunction turn the unit off, disconnect the mains
electromagnetic compatibility (EEC/ 89/336) directives. power supply and contact a qualified service engineer.
• Follow all current national safety code requirements. • This equipment contains ozone depleting substances.
In particular ensure that a properly sized and connected ground Maintenance of the refrigerant circuit must only be carried out by
wire is in place. qualified personnel.
• Check that the voltage and frequency of the mains power supply • All of the manufacturing and packaging materials used for
are as required for the unit to be installed; the available power this appliance are biodegradable and recyclable.
source must be adequate to operate all other appliances
connected to the same line. • Dispose of the packaging material in accordance with local
Also ensure that national safety code requirements have been requiremements.
followed for the main supply circuit.
• This equipment contains refrigerant that must be disposed of
• Connect the main supply to the outdoor unit. correctly.
When disposing of the unit at the end of its operational life,
• Connect indoor and outdoor units with field-supplied copper pipes take the unit to an authorised waste disposal centre, or to the
with flare connections. original equipment dealer, for correct disposal.
Use insulated seamless refrigeration grade pipe only,
(Cu DHP type according to ISO 1337), degreased and deoxidised,
suitable for operating pressures of at least 3000 kPa.
Under no circumstances must sanitary type copper pipe be used.
• The manufacturer declines any liability for damage resulting • Consider using an area where installation is easy.
from modifications or errors in the electrical or refrigerant
connections. • Choose a position that allows for the clearances required.
Failure to observe the installation instructions, or use of the
unit under conditions other than those indicated in table • Look for a position in the room which ensures the best possible air
“Operating limits” of the outdoor unit installation manual, will distribution.
immediately invalidate the unit warranty.
• Install unit in a position where condensate can easily be piped to an
• Failure to observe electric safety codes may cause a fire hazard in appropriate drain.
the event of short circuits.
Table VI: Accessories A= mod. 012, 018, 024. B= mod. 028, 036, 048, 060.
Description Code A B Description Code A B
Outside condensate discharge pump, 40GK-900---003-40 X
head 2 m 230V ~ 50/60Hz 40GK-900---401-40 X X Air supply outlet obstruction kit (1)
40GK-900---013-40 X
40GK-900---001-40 X Group Controller 40QKX900---101-40 X X
Electrostatic filter 40GK-900---011-40 X Group Controller kit 40QKX900---103-40 X X
40GK-900---002-40 X Zone Manager kit 40QKX900---102-40 X X
Active carbon filter 40GK-900---012-40 X Zone Manager 40QKX900---100-40 X X
Room Controller 33DFS-RM X X Infrared control kit (2) 40QKX900---104-40 X X
(1)
Notes: Not to be used on units equipped with electric heater (mod. 40GKX1..W).
(2)
IMQ approved kit.
GB - 4
40 GKX
Avoid... ENGLISH
... any obstruction of the unit air intake or supply grilles. ... exposure to direct sunshine, when the unit is operating in the
cooling mode; always use shutters or shades.
... positions too close to heating sources which may damage the unit.
... exposure to oil vapours. ... connecting condensate piping to sewage system drain without
appropriate trap. Trap height must be calculated according to the
unit discharge head in order to allow sufficient and continuous
water evacuation.
... installation in areas with high frequency waves. ... only partial insulation of the piping.
Non-level installation which will cause condensate dripping.
MAX 200 mm
... ascending sections of condensate drain piping. ... flattening or kinking the refrigerant pipes or condensate pipes.
These may only be used near the unit with a maximum height
difference of 200 mm from the top of the unit.
... horizontal sections or curves of condensate drain piping with less ... excessive height difference between outdoor and indoor units
than 2% slope. (see installation manual of outdoor unit).
GB - 5
40 GKX
Avoid...
... slack on electrical connections. ... unnecessary turns and bends in connection pipes (see
... disconnecting refrigerant connections after installation: this will installation manual of outdoor unit).
cause refrigerant leaks. Excessive connection pipe length (see installation manual of
outdoor unit).
Installation
b
a a Heat pump: louvre position for correct air flow
b Cooling only: louvre position for correct air flow
• Install the unit as centrally as possible in the room, the air flow • In order to allow easy and rapid installation and maintenance,
direction can be controlled by means of the remote control (where make sure that in the selected position it is possible to remove
used) or automatically, according to the operating mode (cooling the ceiling panels or, if the ceiling is constructed using
or heating): this will ensure optimum distribution of the air in the masonry, that access to the unit is guaranteed.
room.
• During cooling mode operation the best position for the deflecting
ATTENTION:
louvres is one which allows air diffusion close to the ceiling
Only restrict the air outlets as indicated in the drawing.
(Coanda effect). In heating mode, the louvres should be
positioned so that the air is directed towards the floor, in order to
prevent layers of hot air forming in the upper part of the room (this
will happen automatically when the deflecting louvres are
positioned in the “AUTOMATIC” mode). WARNING:
Alternatively the louvres can be placed in intermediate positions To close one or two air outlets use the special kit.
(with infrared control only) or allowed to move continuously
(SWING).
GB - 6
40 GKX
Installation ENGLISH
Prior to installation
g Threaded
hangers
k "T" bar
g g (to be removed)
IMPORTANT:
Do not lift the unit by the condensate drain discharge pipe or
by the refrigerant connections; hold it by its four corners only.
g g
Unit installation will be facilitated using a stacker.
If plaster board ceiling panels are installed the maximum
dimensions of the unit housing must not exceed 660 x 660 mm (for k k l k
models 12-18-24) and 900 x 900 mm (for models 28-36-48-60).
In rooms with high humidity, brackets should be insulated using the l l
self adhesive insulation supplied. l
Installation
l Suspension brackets
Carefully lift the unit (without the frame) using the four
suspension brackets (or the four corners), inserting it into the
false ceiling.
If the “T” bar cannot be removed the unit may need to be tilted
(this operation may only be carried out with false ceilings with a
minimum height of 300 mm).
a
mm
d e
f
b g
h
c
d i
j m False ceiling
a n Spirit level
Align and level the unit by adjusting the nuts and locknuts on
a Nut f Washer the threaded hangers, maintaining a distance of 25 - 30 mm
b Wooden frame g Threaded hangers between the sheet metal body and the underside of the false
c Threaded hangers h Washer ceiling.
d Washers i Nut Reposition the “T” bar and align the unit in relation to the bar by
e Nut j Nut tightening the nuts and locknuts.
After connection of the condensate drain line and the refrigerant
Once the threaded hangers have been positioned, do not tighten lines, carry out a final check to make sure that the unit is level.
the nuts, and insert the washers as shown in the drawing.
GB - 7
40 GKX
Installation
a Indoors
b Outdoors
Making the hole for connection pipes in the external wall Installation of grille/frame assembly
• After positioning the units and determining the connection position, Carefully unpack the assembly and check for damage sustained in
make a 70 mm Ø hole in the wall. The same hole can be used as a transport. Attach the assembly to the unit by using the two hooks.
condensate drain pipe conduit.
Tighten the four screws, link the electrical connectors and insert the
wires in the cable clamp.
2%
Use the screws supplied to fix the frame in position.
50
A. Gasket "A"
B. Gasket "B"
GB - 8
40 GKX
Refrigerant connections ENGLISH
Tube diameter
Gas Liquid
Mod. (suction line) (discharge line)
mm (inches) mm (inches)
12 - 18 12 (1/2") 6 (1/4")
24 - 28 16 (5/8") 6 (1/4")
36 - 48 - 60 19 (3/4") 10 (3/8")
Tube diameter Torque
For refrigerant tubes use seamless, insulated refrigeration grade tube
mm (inches) Nm
(Cu DHP type according to ISO 1337), degreased and deoxidised,
suitable for operating pressures of at least 3000 kPa. 6 (1/4") 15 - 20
Under no circumstances use sanitary type copper pipe. 10 (3/8") 15 - 20
12 (1/2") 50 - 55
16 (5/8") 50 - 55
Flaring the end of pipes 19 (3/4") 50 - 55
b
a
a Pipe c
b Pipe insulation
c Adhesive tape
Remove the protection caps from the copper pipe ends. Once all connections have been completed, check for leaks using
Holding the tube downward, cut the extreme end off, removing any soapy water.
copper shavings with a deburring blade. Finally, wrap connections with anti-condensate insulation and
Remove the flare nuts from the “FLARE” connection body of the tighten with tape, without exerting excessive pressure on the
indoor unit and insert them into the pipes. insulation. Repair and cover any possible cracks in the insulation.
Make the flare to the pipe end with the proper flaring tool.
Lubricate the end of pipe and the thread of the flare connection Pour several litres of water into the condensate drain pan and
with anti-freeze oil. check that it flows freely to the drain.
Tighten by hand and then use two wrenches to tighten all Check pipe gradient and look for possible obstructions.
connections fully, applying the tightening torque shown in the table.
GB - 9
40 GKX
Electrical connections
CV
CLR
C
CA b h
C
c
CP CP
d a
CV
CG CP f
R
a C
W2 e CLR
O
Y
i f
S2
S1
i
CA
g
c
g
b
A A
B h
B
e d
CONTROL PANEL CONTROL PANEL
mod. 12 - 18 - 24 mod. 28 - 36 - 48 - 60
Control panel can be reached by opening the grille and removing its If errors are made during the operation previously described, switch
metal cover by 4 screws. off the main power supply, reposition switch A in the correct position
and then switch the power on.
Connect the power cables to terminal box connectors in accordance
with the wiring diagram and tighten firmly.
IMPORTANT:
• Main power supply comes from outdoor unit.
• Make ground connection prior to any other electrical
connections.
• If the indoor unit is fitted with an electric heater, this must have a
separate power supply.
Ensure that the mains supply connection is made through a switch
IMPORTANT for units equipped with electric heater: that disconnects all poles, with a contact gap of a least 3 mm.
The unit is equipped with two thermostats: one with automatic reset • Make the electrical connections between units prior to proceeding
and one with manual (electric) reset that can be reactivated by to the main supply unit connection.
switching the power supply off and then on. Ensure that the mains supply connection is made through a
switch that disconnects all poles, with a contact gap of a
least 3 mm.
SYSTEM CONFIGURATION • Fix the power cable of the electrical resistances under the single
cable clamp. (fig. “E”).
Make certain that the YELLOW/GREEN cable is stripped back
A
further than the others.
GB - 10
40 GKX
Electrical connections ENGLISH
Cooling only
mod. 12 - 18 - 24
E mod. 28 - 36 - 48 - 60
Heat pump
A B
mod. 12 - 18 - 24
mod. 12 - 18 - 24
mod. 28 - 36 - 48 - 60 mod. 28 - 36 - 48 - 60
Terminal box legend, all models a Interconnecting wire, indoor-outdoor units (field wiring).
GB - 11
40 GKX
Wiring diagram - Cooling only or heat pump units
R R R R R R A B
J4
BUTTON
J6
1
AIR SWG-LVR SEC PRIM
P3
TM COIL J5 J1 LED-BRD OD COIL
A COIL
BUTTON BRD J10
J3 P2
Y
Y J8 IDR/FAN
6 J9
C1 1
1
LED-I.R.
BOARD
ODRFAN
COMP
B W C G B
RVS
8 B
C4 MAIN
G J7 BOARD
LM J2 AUX BRD
9 1
* 1 G
W W
*
G
FS C C2
MSL G
P1
C3
J3 J1-PCB TRACE
Y/G
Y-G
W G C B
A
L1
IFM A
C C5
AUX
PS C BOARD FC
L2 R
J4
B
A
R R C O R B A
S1 S2 Y O W2 C C R R
SENSOR
HEAT PUMP SYSTEM ONLY
SENSOR
TO OUTDOOR UNIT
COMP.
RV
NEUTRAL
LINE
FIELD-CHANGED.
* IF PRESENT
GB - 12
40 GKX
Wiring diagram - Cooling only or heat pump units with electric heater ENGLISH
R R R R R R A B
J12
BUTTON
TM AIR J4 IR-CONN
BOARD
J6 1
AIR SWG-LVR SEC PRIM
P3
TM COIL J5 J1 LED-BRD OD COIL
A COIL
BUTTON BRD J10 P2
J3
Y
Y J8 IDR/FAN
C1 6 1 J9
1
BOARD
COMP
ODRFAN
RVS
LED-I.R.
B W C G B
8 B
C4
MAIN
G J7
LM J2 AUX BRD BOARD
* 1 9 1
G
G W W
*
FS C C2
MSL G
P1
C3
J2 J3 J1-PCB TRACE
Y/G
K2
Y-G
W G C B
A
L1 K1
TO "PCB"
TERMINAL "HR" HR IFM A
C5
TO "PCB"
C AUX
TERMINAL "C" FC
PS C BOARD R
L2
J4
B
A
Y/G
R R C O R B A
S1 S2 Y O W2 C C R R LEGEND
FACTORY WIRING
SENSOR
SENSOR HEAT PUMP SYSTEM ONLY FIELD WIRING
TO OUTDOOR UNIT
COMP CONNECTOR
RV
A/C COOLING ONLY HEAT PUMP SYSTEM ONLY TERMINAL ON COMPONENT
OMF
H/P HEAT PUMP
1 TAKEN FROM NEUTRAL TERMINAL ON STRIP
2 60Hz Special LINE
NORMALLY CLOSE CONTACT
Exsport Market
C2 FLOAT CONNECTOR
IMPORTANT
THE WARRANTY WILL BE INVALIDATED, C3 FAN MOTOR CONNECTOR
IF FACTORY WIRING AND SETTINGS ARE
FIELD-CHANGED. C4 LOUVRE MOTOR CONNECTOR
C5 PUMP CONNECTOR
* LM LOUVRE MOTOR
ST SAFETY THERMOSTAT
IF PRESENT
*
GB - 13
40 GKX
Fresh air renewal and conditioned air supply to an adjacent room
f
105 120
B
49
ØA
70 a
216
e
g
b
d
g h i
j j Wall
k Undercut door
l Wall-fitted grille
m Door-fitted grille
k l m
• Side knockouts allow connection of fresh air inlet ducts and ducts • Use locally purchased material, suitable for operating
to deliver conditioned air to an adjacent room. temperatures of 60 °C (continuous).
Conduits can be of flexible polyester (with spiral core) or
• Remove the external prepunched anti-condensate insulation and corrugated aluminium, externally covered with anti-condensate
take away the knockout panels using a punch. material (fibre glass from 12 to 25 mm thickness).
Remove the polystyrene partition. • The return and supply duct lengths can be calculated in
Introduce baffle supplied after frame has been hooked as per above accordance with the “air distribution to an adjacent room” and
figure (ref. h). “fresh air renewal” diagrams (also taking into account the
pressure drop through air diffusers, grilles and fresh air filters),
Following that screw the frame/grille assembly using the 4 screws. as well as the increase in noise caused by these ducts.
GB - 14
40 GKX
Fresh air renewal and conditioned air supply to an adjacent room ENGLISH
40
External static pressure - Pa
30
20
24/28
60
36
10
12 18
48
0
410
0 100 200 300 400 450
3
Air flow m /h
In case of two louvres closed, the fresh air flow towards the adjacent room is 50% higher compared with only one louvre
closed (with equal static external pressure).
• The supplementary fan motor for outside air intake has to be • Air supply to an adjacent room requires that the outlet
supplied separately and controlled by a bipolar ON-OFF switch corresponding with the duct is closed, using the air
with safety fuses (field-installed). supply outlet obstruction kit supplied.
To adjust the fan motor air flow to the required values it is The kit cannot be used in units equipped with electric
advisable to install a speed controller. heater (mod. 40GKX1..W).
Fresh air flow must be less than 10% of the total air flow, to An air inlet grille must be fitted (if possible near the floor)
avoid operating problems. between the air conditioned room (where the unit is situated)
For fresh air ventilation rates higher than 10%, a primary air and the adjacent room or, alternatively, the door must be
treatment system with separate deflectors is recommended. undercut, as shown in the drawing.
• Install an air inlet grille with filter inspection port to prevent • The duct lengths can be calculated in accordance with the “air
dust and dirt from entering and fouling the indoor unit heat distribution to an adjacent room” diagram, also taking into
exchanger. account the pressure drop through air diffusers and fresh air
Filter installation also makes the installation of a duct closing filters.
damper during shutdown periods unnecessary.
GB - 15
40 GKX
Control configuration and operating test
Remote control configuration
Once the electrical connections have been completed, enter
the system configuration.
Check the correct positioning of the switch (see “Electrical
connections”).
Incorrect switch positioning will cause serious damage to the
system.
Remote control configuration with cable connection has to be
made following the instructions contained in the respective
manuals.
• To send the message to the unit, press the start button for at
least two seconds, followed by the fan speed selection button .
Operating test
1) The air conditioner will start immediately (without the time delay
protection against frequent compressor cycling) in the cooling
mode without thermostatic control of the room temperature.
• Slide the switch under the unit panel from the “Test” to the
“Normal” position to exit from the test program.
• During the test program, any signal sent to the unit by the remote
control will stop the test.
GB - 16
40 GKX
Maintenance ENGLISH
• Remove the four fixing screws on the side of the drain pan and
carefully remove the condensate drain pan.
GB - 17