Nortek Global HVAC, LLC - Flex Match Series System-Outdoor Unit

Preface

The Flex Match System utilizes advanced manufacturing. Please read this manual carefully before installation and operation. Key points include:

• Unit complies with UL1995 standards.
• Flex Match System conforms to ARI 210-240-2008 design standards.
• Strict adherence to all instructions in this manual is required.
• The total capacity of simultaneously operating indoor units must not exceed the outdoor unit's capacity to ensure sufficient cooling/heating effects.

Additional operational notes:

• Switch the main power on 8 hours before starting the unit.
• The indoor unit fan may continue to run for 20-70 seconds after receiving a "stop" signal to utilize residual heat.
• Conflicts between indoor and outdoor unit modes will be indicated on the wired controller, and the units will harmonize modes. Cooling mode is compatible with dehumidifying mode; fan mode can run with any mode. If power fails during operation, the unit will restart automatically 3 minutes after power recovery.
• Cautions for Debugging and Maintenance Personnel: The compressor heating belt must be energized for at least eight hours before startup. Once started, the compressor must run continuously for at least 30 minutes to prevent damage.

User Notice

Individuals with reduced mental, sensory, or physical capabilities should not operate or maintain this equipment. Children should not play with the appliance.

If the power cord is damaged, it must be replaced with an equivalent cord by a qualified professional to prevent damage or fire hazards.

Installation should be performed by expert or trained users.

DISPOSAL: Do not dispose of this product as unsorted household waste. Please dispose or recycle responsibly.

Contents

1. Safety Precautions
2. Product Introduction
3. Preparation before Installation
4. Installation Instruction
5. Troubleshooting
6. Common malfunctions and troubleshooting
7. Troubleshooting
8. Maintenance
9. After-sales Service

1 Safety Precautions

WARNING: Failure to comply with warning notices may result in property damage, serious personal injury, or death.

CAUTION: Failure to comply with caution notices may result in property damage or personal injury.

NOTICE: Failure to comply with notices may result in property damage.

WARNING

1. Installation and use instructions are provided by the manufacturer and should be kept for future reference.
2. Installation must comply with NEC and CEC requirements and be performed by authorized personnel only.
3. Verify power supply requirements against the unit's nameplate before installation. Ensure power safety.
4. Ensure the unit is properly and securely grounded to prevent electric shock. Do not connect the ground wire to gas pipes, water pipes, lightning rods, or telephone lines.
5. Use only approved accessories and parts to prevent water leakage, electric shock, or fire.
6. In case of refrigerant leakage during installation, ventilate immediately. Refrigerant gas can produce toxic fumes when exposed to flame.
7. Ensure the power cord is adequately sized. Replace damaged cords with approved cable.
8. Secure the electric box cover after connecting the power cord to prevent accidents.
9. Always comply with nitrogen charge requirements. Charge with nitrogen during pipe welding.
10. Never short-circuit or bypass the pressure switch, as this can damage the unit.
11. Connect the wired controller before turning on the power to avoid damage to the controller.
12. Before use, verify correct piping and wiring to prevent water leakage, refrigerant leakage, electric shock, or fire.
13. Do not insert fingers or objects into the air outlet/inlet grille.
14. If using a gas or petroleum heater in the same room, open a door or window for adequate ventilation.
15. Never start or stop the air conditioner by plugging or unplugging the power cord.
16. Do not turn off the unit immediately after it has run for at least five minutes; this can damage the compressor oil return system.
17. Do not allow children to operate this unit.
18. Do not operate the unit with wet hands.
19. Turn off the unit or cut off the power supply before cleaning to prevent electric shock or injury.
20. Never spray or flush water directly at the unit, as this may cause malfunction or electric shock.
21. Do not expose the unit to wet or corrosive environments.
22. Turn power on to the unit 8 hours before startup. If the unit will be turned off for a short period (e.g., overnight), do not turn off the power. If power is turned off, it must be turned back on 8 hours before the next startup to allow the compressor to warm up.
23. Volatile liquids like paint thinner or gasoline can damage the unit's appearance. Clean the outer casing with a soft cloth and mild detergent only.
24. In cooling mode, avoid setting the room temperature too low. Maintain a temperature difference of no more than 5°C (9°F) between indoor and outdoor units.
25. If abnormal conditions occur (e.g., burning smell), immediately power off the unit and cut off the main power supply. Contact a qualified service technician. Continued operation of a malfunctioning unit can lead to further damage, electric shock, or fire.
26. Users are not permitted to repair the unit. Faulty repairs can cause electric shock or fire. Contact a qualified service center for assistance.

Nortek Global HVAC is not responsible for personal injury or equipment damage resulting from improper installation, commissioning, unauthorized service, or failure to follow the instructions in this manual.

2 Product Introduction

The Flex Match System employs inverter compressor technology, enabling stepless capacity regulation within a 15%-120% range by adjusting compressor displacement. Multiple product combinations are available, offering a capacity range from 30K Btu to 42K Btu.

2.1 Parts List

The outdoor unit components are labeled as follows:

• 1: Motor
• 2: Fan
• 3: Electric Box
• 4: Gas valve assembly
• 5: Liquid valve assembly

Models include: GXH30(8.8)FMK4DH, GXH36(10.6)FMK4DH, GXH42(12.3)FMK4DH.

Figure 1 illustrates the outdoor unit with labeled parts.

2.2 Combinations of outdoor and indoor units

The Flex Match Series air conditioning system allows one outdoor unit to operate with up to five indoor units, which can be cassette type, duct type, wall-mounted, or floor ceiling type. The outdoor unit operates when any indoor unit receives a running command, and all indoor units stop when the outdoor unit is turned off.

Figure 2 shows various indoor unit types compatible with the outdoor unit.

2.3 Rated working condition

NOTICE:

• Cooling/heating capacity and sound levels are tested before shipment.
• Parameters are tested under rated working conditions. Refer to the nameplate for any changes.
• Heating capacity parameters exclude auxiliary electric heating power.
• Performance parameters are tested according to ANSI/AHRI 1230-2010.

2.4 The range of production working temperature

3 Preparation before Installation

3.1 Standard parts

The following standard parts are supplied by GREE:

3.2 Selecting installation site

WARNING

• Verify that the support structure has sufficient load-carrying capacity and can be securely mounted.
• Protect the unit from direct sunlight, rainfall, dust, strong wind, and earthquakes.
• Keep the unit away from combustible, inflammable, corrosive materials, or exhaust gases.
• Ensure adequate clearance around the unit for service and maintenance.
• Position indoor and outdoor units as close as possible to minimize pipe length and bends.
• Keep children away from the unit during installation and operation.

When the outdoor unit is surrounded by walls, maintain appropriate clearances as shown in Figure 3.

Figure 3 illustrates recommended clearances around the outdoor unit.

3.3 Piping Connection

The maximum pipe length is detailed in the following table. Deviating from these ranges may affect normal unit operation.

NOTICE:

• Use water-proof insulating pipe.
• Pipe wall thickness: 0.019-0.039 inch; bearing pressure: 3.0MPa.
• Longer connection pipes may reduce cooling and heating capacity.

4 Installation Instruction

4.1 Outline and dimension of the outdoor unit

GXH30(8.8)FMK4DH

Figure 4 shows the outline dimensions and mounting holes for the GXH30(8.8)FMK4DH model.

GXH36(10.6)FMK4DH & GXH42(12.3)FMK4DH

Figure 5 shows the outline dimensions and mounting holes for the GXH36(10.6)FMK4DH and GXH42(12.3)FMK4DH models.

4.2 Installation of the Connection Pipe

Connecting piping for indoor and outdoor units is done in a manifold mode, as illustrated in Figure 6.

4.2.1 Piping between the Indoor and Outdoor Units

• If liquid and gas stop valves (A, B, C, D, or E) are not connected to indoor units, remove the caps with a wrench.
• Refer to Figure 7 for torque requirements.
• Align the flare end of the copper pipe with the screw and tighten by hand.
• Subsequently, tighten the screw with a torque wrench until it clicks (as shown in Figure 7).
• Use a pipe bender to bend the pipe. Bending the pipe too sharply may cause it to break.
• Wrap exposed refrigerant pipes and joints with sponge and secure with plastic tape.

Figure 7 illustrates the process of connecting pipes and the required tools.

CAUTION:

• When installing pipe lines, avoid pulling forcefully on pipes or connections, as this can cause damage and refrigerant leaks.
• Support refrigerant pipes with brackets; the units should not bear the weight of the pipes.
• If the outdoor unit's piping connection size differs from the indoor unit's, use an adapter joint.
• Label each pipe for easier and more accurate connections in the Flex Match system.

4.2.2 Allowable pipe length and drop height between indoor and outdoor units

No additional refrigerant is needed if the total refrigerant pipe length (liquid pipe) is less than the value in Table 6.

Table 8 provides allowable lengths and height differences for the refrigerant pipe. Figure 8 illustrates the pipe length and height difference measurements.

4.2.3 Installation of the Protection Layer for Refrigerant Pipe

• The refrigerant pipe should be insulated with insulating material and plastic tape to prevent condensation.
• Joints of the indoor unit should be wrapped with insulating material without gaps, as shown in Figure 9.

Figure 9 shows the thermal insulating layer required for the joints.

CAUTION: After protection, do not bend the pipe sharply, as it may break.

• Wrap the pipe with tape:
• Bundle refrigerant pipes and electric wires together with tape, separating them from the drain pipe to prevent condensate overflow.
• Wrap the pipe from the bottom of the outdoor unit upwards, overlapping each layer of tape by half its width.
• Secure the wrapped pipe to the wall with clamps.

CAUTION: Do not wrap the pipe too tightly, as this weakens the insulation effect. Ensure the drain hose is separated from the pipe.

• Seal wall openings to prevent wind and rain entry.

4.2.4 Support and protection for pipeline

Support hanging connection pipes. The distance between supports should not exceed 1m (3 ft).

4.3 Air Purging and Refrigerant Charge

4.3.1 Air purging

• Refrigerant is pre-charged into the outdoor unit before shipment. Additional refrigerant may be needed during installation.
• Ensure the liquid and gas valves of the outdoor unit are fully closed.
• Use a vacuum pump to remove refrigerant from the indoor unit and refrigerant pipe, as shown in Figure 10.
• When the compressor is not running, charge R410A refrigerant into the pipe via the liquid valve of the outdoor unit (not the gas valve).

Figure 10 illustrates the vacuum pump connection for refrigerant removal.

4.3.2 Additional refrigerant charging

The GXH30, 36, and 42 models are factory charged for a minimum of 130 feet. For longer runs, calculate additional refrigerant at 0.2 ounces per foot. The maximum lineset length is 225 feet for GXH30 and 250 feet for GXH 36 and 42. The total additional refrigerant charge should not exceed 28 ounces.

4.4 Electric Wiring

4.4.1 Wiring precautions

• Installation must comply with national wiring regulations.
• Use only a power cord with the correct voltage rating and a dedicated circuit for the air conditioning.
• Do not pull the unit by its power cord.
• Electrical installation must follow local laws, regulations, and this manual.
• Ensure the power cord diameter is sufficiently sized. Replace damaged cords with appropriate ones.
• Grounding must be secure and performed by a qualified technician. The circuit breaker must have adequate capacity and include both magnetic and thermal tripping functions for short circuit and overload protection.

4.4.2 Grounding Requirements

• The air conditioner is a Class I appliance and requires reliable grounding.
• The yellow-green wire is the ground line and must not be cut, removed, or tampered with, as this could cause electric shock.
• A reliable ground terminal must be provided. Do not connect the ground wire to water pipes, coal gas pipes, sewage pipes, or other unreliable objects.

4.4.3 Electrical Cable Connection

CAUTION:

• Faulty connections can lead to malfunction. Ensure wires are not taut after connection.
• Connect piping and wiring as described in this manual.
• Electrical installation must be performed by a technician following local laws, regulations, and this manual.
• Install the unit in a dry location, protected from direct sunlight and strong winds.
• A circuit breaker must be installed to shut off the main power supply for the entire system.

4.4.4 Wiring of the Power Cord

• Open the side plate.
• Connect the power cord to terminals “L1”, “L2”, and the grounding bolt. Connect wiring terminals “N(1),2,3” of the indoor unit to the outdoor unit accordingly. Use the green bonding screw for the grounding cord, as shown in Figure 13.
• Secure the power cord with wire clips.
• Lead the power cord through the rubber ring.

CAUTION: If the supply cord is damaged, it must be replaced by a qualified person to avoid hazards.

Figure 13 shows the power cord connection points.

5 Troubleshooting

WARNING:

• In case of abnormal conditions (e.g., strong or burning smell), immediately shut off the main power supply and contact qualified service personnel. Continued use of a malfunctioning unit can damage the air conditioner and cause electric shock or fire hazards.
• Users should not attempt to repair the air conditioner. Contact professionally skilled personnel, as faulty repairs can lead to electric shock or fire hazards.

Check before Contacting Service Center

NOTICE! If the air conditioner continues to run abnormally after performing these checks, contact the maintenance serviceman at the local appointed service center and provide a description of the error and the model number.

6 Common malfunctions and troubleshooting.

Please check the following before calling for service.

NOTICE! If problems cannot be solved after checking the above items, please contact a qualified service technician. The following circumstances are not malfunctions:

7 Troubleshooting

Error codes will be displayed on the wired controller and the outdoor unit's main board. Refer to Table 13 for error code meanings.

8 Maintenance

Regular checks, maintenance, and care by professional personnel will prolong the unit's lifespan.

8.1 Outdoor heat exchanger

Clean the outdoor heat exchanger every two months using a vacuum cleaner with a nylon brush to remove dust and debris. Compressed air can be used if available. Do not use water to wash the heat exchanger.

8.2 Drain Pipe

Regularly check the drain pipe for clogs to ensure proper condensate drainage.

8.3 Preseason Checklist

• Check if the indoor/outdoor unit inlet/outlet is blocked.
• Check the ground wire.
• Check if the remote wireless controller battery needs replacement.
• Verify the filter screen is properly set.
• After prolonged shutdown, turn on the main power switch 8 hours before re-operation to preheat the compressor crankcase.
• Check if the outdoor unit is securely mounted. Contact an appointed qualified service center if any abnormalities are found.

8.4 Post-Season Checklist

• Turn off the main power supply to the unit.
• Clean the filter screen and both indoor and outdoor units.
• Remove dust and debris from the indoor and outdoor units.
• In case of rust, apply anti-rust paint to prevent its spread.

8.5 Parts Replacement

Purchase parts from an authorized service center or dealer.

NOTICE! During airtight and leakage tests, do not mix oxygen, ethane, or other dangerous gases into the refrigeration circuit. Use nitrogen for leak testing.

9 After-sales Service

For any quality issues or inquiries regarding the air-conditioning unit, please contact the installer or authorized distributor.

Warranty claims must meet the following requirements:

• Installation and startup must be performed by professional personnel.
• Only approved accessories should be used on the machine.
• All instructions in this manual must be followed.
• Warranty will be void if any of the above conditions are not met.

Specifications and illustrations are subject to change without notice or incurring obligations.

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