Room Air Conditioner SERVICE MANUAL

Transcription

1 Room Air Conditioner SERVICE MANUAL SPLIT TYPE ROOM AIR CONDITIONER CAUTION -BEFORE SERVICING THE UNIT, READ THE SAFETY PRECAUTIONS IN THIS MANUAL. -ONLY FOR AUTHORIZED SERVICE PERSONNEL. MODEL: GWHD8B5NK3EA GWHD8B5NK3EB GWHD8B5NK3EC GWHD8B5NK3ED (Applied to new Refrigerant R-40A) Prior to installation, this air-conditioning unit must be submitted for approval by the utility service which provides electricity (EN Norm).

2 Air Conditioner Service Manual TABLE OF CONTENTS Safety Precautions... Dimensions...6 Product Specifications...9 Installation...0 Flaring work and connection of piping...2 Connecting the cable between indoor unit and outdoor unit...8 Checking the drainage and forming the pipings...20 Air purging...2 Test running...23 Functions...24 Operation...26 Disassembly...3 Schematic Diagram...42 Troubleshooting Guide...47 Exploded View...65 Replacement Parts List...69

3 Safety Precautions Safety Precautions To prevent injury to the user or other people and property damage, the following instructions must be followed. Incorrect operation due to ignoring instruction will cause harm or damage. The seriousness is classified by the following indications. This symbol indicates the possibility of death or serious injury. This symbol indicates the possibility of injury or damage to properties only. Meanings of symbols used in this manual are as shown below. Be sure not to do. Be sure to follow the instruction. Installation Do not use damaged power cords, plugs, or a loose socket. There is risk of fire of electric shock. Always use the power plug and socket with the ground terminal. There is risk of electric shock. Install the panel and the cover of control box securely. Do not modify or extend the power cord. There is risk of fire of electric shock. No grounding may cause electric shock. Room Air Conditioner

4 Safety Precautions For re-installation of the installed product, always contact a dealer or an authorized service center. There is risk of fire, electric shock, explosion, or injury. Do not install, remove, or re-install the unit by yourself. There is risk of fire, electric shock, explosion, or injury. Be cautious when unpacking and installing the product. Sharp edges could cause injury. Be especially careful of the case edges and the fins on the condenser and evaporator. For installation, always contact the dealer or an Authorized service center There is risk of fire, electric shock, explosion, or injury. Do not install the product on a defective installation stand. It may cause injury, accident, or damage to the product. Be sure the installation area does not deteriorate with age. If the base collapses, the air conditioner could fall with it, causing property damage, product failure, and personal injury. Service Manual 2

5 Safety Precautions Operation Do not turn the air-conditioner ON or OFF by plugging or unplugging the power plug. There is risk of fire or electrical shock. Use a dedicated outlet for this appliance. There is risk of fire or electrical shock. Grasp the plug to remove the cord from the outlet. Do not touch it with wet hands. There is risk of fire or electrical shock. Do not place a heater or other appliances near the power cable. There is risk of fire and electric shock. Do not allow water to run into electrical parts. There is risk of fire, failure of the product, or electric shock. Do not store or use flammable gas or combustibles near the air conditioner. There is risk of fire or failure of product. 3 Room Air Conditioner

6 Safety Precautions Unplug the unit if strange sounds, odors, or smoke comes from it. There is risk of electric shock or fire. Be cautious that water could not enter the product. There is risk of fire, electric shock, or product damage. Installation Always check for gas (refrigerant) leakage after installation or repair of product. Low refrigerant levels may cause failure of product. Install the drain hose to ensure that water is drained away properly. A bad connection may cause water leakage. Keep level even when installing the product. To avoid vibration or water leakage. Use two or more people to lift and transport the air conditioner. Avoid personal injury. 90 Service Manual 4

7 Safety Precautions Operation Use a soft cloth to clean. Do not use harsh detergents, solvents, etc. There is risk of fire, electric shock, or damage to the plastic parts of the product. Do not touch the metal parts of the product when removing the air filter. They are very sharp! There is risk of personal injury. Wax Do not step on or put anyting on the product. (outdoor units) There is risk of personal injury and failure of product. Do not insert hands or other objects through the air inlet or outlet while the air conditioner is plugged in. There are sharp and moving parts that could cause personal injury. 5 Room Air Conditioner

8 Dimensions Dimensions Symbols Used in this Manual This symbol alerts you to the risk of electric shock. This symbol alerts you to hazards that could cause harm to the air conditioner. NOTICE This symbol indicates special notes. Indoor Unit H W D Installation plate Model 8k Btu Series Dimension W mm 907 H mm 290 D mm 23 Service Manual 6

9 Dimensions Outdoor Unit Model:GWHD8B5NK3EA/O,GWHD8B5NK3EB/O,GWHD8B5NK3ED/O W L2 L D L3 L5 H Liquid side (2-way valve) Gas side (3-way valve) MODEL DIM unit 8k Btu Series W mm 840 H mm 675 D mm 304 L mm 378 L2 mm 68 L3 mm 350 L4 mm 4 L5 mm 00 7 Room Air Conditioner

10 Dimensions Model:GWHD8B5NK3EC/O W L2 L D L3 L5 H Liquid side Gas side MODEL DIM unit 8k Btu Series W mm 840 H mm 675 D mm 304 L mm 378 L2 mm 68 L3 mm 350 L4 mm 4 L5 mm 00 Service Manual 8

11 Product Specifications Product Specifications Table- Item Model Name Unit W MIN kcal/h.(w) Btu/h. W Cooling Capacity Type kcal/h.(w) Btu/h. W Max kcal/h.(w) Btu/h. W MIN kcal/h.(w) Btu/h. W Heating Capacity Type kcal/h.(w) Btu/h. W Max kcal/h.(w) Btu/h. IN:20 C,Out: -0 C(Heater ON) Btu/h. IN:20 C,Out: -0 C(Heater OFF) Btu/h. Power Input Cooling W Heating W Heating(-0 C,Heater ON) W Heating(-0 C,Heater OFF) W Running Current Cooling A Heating A Heating(-0 C,Heater ON) A Heating(-0 C,Heater OFF) A COP Cooling W/W Heating W/W Power Supply Ø,V,Hz Power Factor % Air Circulation Indoor,Max m 3 /min(cfm) Outdoor,Max m 3 /min(cfm) Moisture Removal l/h.(pts/h.) Noise Level Indoor,High db(a)±3 (Sound Med. db(a)±3 Pressure,m) Low db(a)±3 Outdoor,Max db(a)±3 Refrigerant(R40A)Charge Power Cord DXL Connecting Cable DXL Connecting Tube Liquid Side mm(in) (Ø. Socket Flare) Gas Side mm(in) Length,std m(in) Drain Hose (O.D, I.D) mm(in) Indoor mm Dimension inch (W*H*D) Outdoor mm inch Net Weight Indoor kg(lbs) Outdoor kg(lbs) GWHD8ANK3EA , , Φ4.0X.0 Φ4.0X (/4) 2(/2) 5(27) 2.5,6.0(0.85,0.63) 907X290X X.4X9. 840X675X X26.6X2.0 3(29) 52(5) GWHD8ANK3EB , , Φ4.0X.0 Φ4.0X (/4) 2(/2) 5(27) 2.5,6.0(0.85,0.63) 907X290X X.4X9. 840X675X X26.6X2.0 3(29) 52(5) GWHD8ANK3EC , , Φ4.0X.0 Φ4.0X (27) 2.5,6.0(0.85,0.63) 907X290X X.4X9. 840X675X X26.6X2.0 3(29) 52(5) GWHD8ANK3ED , , Φ4.0X.0 Φ4.0X (27) 2.5,6.0(0.85,0.63) 907X290X X.4X9. 840X675X X26.6X2.0 3(29) 52(5) 9 Room Air Conditioner

12 A Installation Installation Selection of the Best Location Indoor unit Do not have any heat or steam near the unit. Select a place where there are no obstacles in front of the unit. Make sure that condensation drainage can be conveniently routed away. Do not install near a doorway. Ensure that the space around the left and right of the unit is more than "A". The unit should be installed as high on the wall as possible, allowing a minimum of "B" from ceiling. Use a stud finder to locate studs to prevent unnecessary damage to the wall. Rooftop Installations: If the outdoor unit is installed on a roof structure, be sure to level the unit. Ensure the roof structure and anchoring method are adequate for the unit location. Consult local codes regarding rooftop mounting. Piping Length and Elevation Capacity Pipe Size (Btu/h) GAS LIQUID Standard Length (m) Max. Elevation B (m) Max. Length A (m) Additional Refrigerant (g/m) 8k /2"(Ø2.7) /4"(Ø6.35) More than 5cm More than 0cm Indoor unit Outdoor unit More than 2.3m More than 5cm B A Outdoor unit Indoor unit B Install the indoor unit on the wall where the height from the floors more than 2.3 meters. A B Maximam langth of the pipe 5m Hight less than 5m Outdoor unit If an awning is built over the unit to prevent direct sunlight or rain exposure, make sure that heat radiation from the condenser is not restricted. Ensure that the space around the back and sides is more than 0cm. The front of the unit should have more than 70cm of space. Do not place animals and plants in the path of the warm air. Take the air conditioner weight into account and select a place where noise and vibration are minimum. Select a place so that the warm air and noise from the air conditioner do not disturb neighbors. More than 60cm More than 0cm More than 0cm Capacity is based on standard length and maximum allowance length is on the basis of reliability. More than 70cm More than 60cm Service Manual 0

13 Installation How to Fix Installation Plate The wall you select should be strong and solid enough to prevent vibration. Mount the installation plate on the wall with four type A screws. If mounting the unit on a concrete wall, use anchor bolts. Mount the installation plate horizontally by aligning the centerline using a level. Installation Plate Chassis Hook Type "A" screw 2. Measure the wall and mark the centerline. It is also important to use caution concerning the location of the installation plate-routing of the wiring to power outlets is through the walls typically. Drilling the hole through the wall for piping connections must be done safely. Drill a Hole in the Wall Drill the piping hole with a ø65mm hole core drill. Drill the piping hole at either the right or the left with the hole slightly slanted to the outdoor side. Indoor WALL Open the Front Grille. Pass Telephone Control Cord Wire through the hole which the power cord goes through. Connect Telephone Control Cord Wire to the phone jack of telephone PCB of Control Box. Fix Telephone Control Cord Wire inside Control box so as not to disconnect. Close the Front Grille. Drain hose junction 5-7mm Outdoor (3/6"~5/6") D Ø70mm C Left rear piping Installation plate A Right rear piping B Ø70mm Remove the rubber stopple in the desired drain direction. Insert drain hose into the handle of drain pan, and join drain hose and connecting hose according to the figure by. CHASSIS (Grade) Distance (mm) A B C D 8k Adhesive Connecting part Drain hose Room Air Conditioner

14 Flaring work and connection of piping Note:This section is mainly for the units without quick connectors. Flaring work Flaring work Main cause for refrigerant leakage is due to defect in the flaring work. Carry out correct flaring work using the following procedure. Cut the pipes and the cable. Use the piping kit accessory or pipes purchased locally. Measure the distance between the indoor and the outdoor unit. Cut the pipes a little longer than the measured distance. Cut the cable.5m longer than the pipe length. Copper pipe 90 Slanted Uneven Rough Burr removal Completely remove all burrs from the cut cross section of pipe/tube. Put the end of the copper tube/pipe in a downward direction as you remove burrs in order to avoid dropping burrs into the tubing. Point down Putting nut on Pipe Reamer Remove flare nuts attached to indoor and outdoor unit, then put them on pipe/tube having completed burr removal. (not possible to put them on after flaring work) Flare nut Check Bar Flaring work and connection of piping "A" Copper pipe Bar Handle Yoke Cone Clamp handle Red arrow mark Carry out flaring work using flaring tool as shown below. Outside diameter A mm inch mm Ø6.35 /4 0~0.5 Ø2.7 /2 0~0.5 Compare the flared work with figure below. If flare is noted to be defective, cut off the flared section and re-flare it. Smooth all round Even length all round Inside is shiny without scratches Inclined = Improper flaring = Surface Cracked Uneven damaged thickness Connection of piping -- Indoor Preparing the indoor unit's piping and drain hose for installation through the wall. Remove the plastic tubing retainer(see illustration below) and pull the tubing and drain hose away from chassis. Replace the plastic tubing holder in the original position.(optional) Copper tube Drain hose Flaring work Firmly hold copper pipe in a die in the dimension shown in the table above. When install, make sure that the remaining parts must be removed clearly so as not to damage the piping and drain hose, especially power cord and connecting cable. Service Manual 2

15 Flaring work and connection of piping For right rear piping Route the indoor tubing and the drain hose in the direction of rear right. Connecting the pipings to the indoor unit and drain hose to drain pipe. Align the center of the pipes and sufficiently tighten the flare nut by hand. Drain hose Indoor unit tubing Flare nut Pipes Tighten the flare nut with a wrench. Insert the connecting cable into the indoor unit from the outdoor unit through the piping hole. Do not connect the cable to the indoor unit. Make a small loop with the cable for easy connection later. Wrench Indoor unit tubing Open-end wrench (fixed) Flare nut Connection pipe Tape the tubing, drain hose, and the connecting cable. Be sure that the drain hose is located at the lowest side of the bundle. Locating at the upper side can cause drain pan to overflow inside the unit. Outside diameter Torque mm inch kg.m Ø6.35 /4.8 Ø2.7 /2 5.5 Tape Connecting pipe Drain hose Connecting cable NOTE: If the drain hose is routed inside the room, insulate the hose with an insulation material* so that dripping from "sweating"(condensation) will not damage furniture or floors. *Foamed polyethylene or equivalent is recommended. Indoor unit installation Hook the indoor unit onto the upper portion of the installation plate.(engage the two hooks of the rear top of the indoor unit with the upper edge of the installation plate.) Ensure that the hooks are properly seated on the installation plate by moving it left and right. Connecting cable Drain hose Press the lower left and right sides of the unit against the installation plate until the hooks engage into their slots(clicking sound). When extending the drain hose at the indoor unit, install the drain pipe. Drain pipe Connection pipe Adhesive Plastic bands Indoor unit drain hose Vinyl tape(narrow) Wrap the insulation material around the connecting portion. Overlap the connection pipe insulation material and the indoor unit pipe insulation material. Bind them together with vinyl tape so that there is no gap. Insulation material Wrap the area which accommodates the rear piping housing section with vinyl tape. Vinyl tape Wrap with vinyl tape (wide) Connecting cable Indoor unit pipe Pipe Vinyl tape(narrow) 3 Room Air Conditioner

16 Flaring work and connection of piping Bundle the piping and drain hose together by wrapping them with vinyl tape for enough to cover where they fit into the rear piping housing section. Pipe Wrap with vinyl tape Connecting the pipings to the indoor unit and the drain hose to drain pipe. Align the center of the pipes and sufficiently tighten the flare nut by hand. Drain hose For left rear piping Vinyl tape(wide) Indoor unit tubing Flare nut Pipes Tighten the flare nut with a wrench. Route the indoor tubing and the drain hose to the required piping hole position. Open-end wrench (fixed) Flare nut Wrench Connection pipe Indoor unit tubing Insert the piping, drain hose, and the connecting cable into the piping hole. Connecting cable Outside diameter Torque mm inch kg.m Ø6.35 /4.8 Ø2.7 /2 5.5 Drain pipe Insert the connecting cable into the indoor unit. Don't connect the cable to the indoor unit. Make a small loop with the cable for easy connection later. Tape the drain hose and the connecting cable. Connecting cable Indoor unit installation Hang the indoor unit from the hooks at the top of the installation plate. When extending the drain hose at the indoor unit, install the drain pipe. Drain hose Vinyl tape Adhesive Wrap the insulation material around the connecting portion. Overlap the connection pipe heat insulation and the indoor unit pipe heat insulation material. Bind them together with vinyl tape so that there is no gap. Plastic bands Indoor unit drain hose (narrow) Insulation material Insert the spacer etc. between the indoor unit and the installation plate and separate the bottom of the indoor unit from the wall. Indoor unit Spacer Installation plate 8cm Service Manual 4

17 Flaring work and connection of piping Wrap the area which accommodates the rear piping housing section with vinyl tape. Connection pipe Vinyl tape (wide) Connecting cable Wrap with vinyl tape Pipe Vinyl tape(narrow) Indoor unit piping Indoor unit installation Remove the spacer. Ensure that the hooks are properly seated on the installation plate by moving it left and right. Connecting cable Drain hose Bundle the piping and drain hose together by wrapping them with cloth tape over the range within which they fit into the rear piping housing section. Press the lower left and right sides of the unit against the installation plate until the hooks engage into their slots(clicking sound). Drain hose Pipe Vinyl tape(narrow) Wrap with vinyl tape(wide) Installation Information (For left piping) Good case For left piping. Follow the instruction below. Press on the upper side of clamp. ( ) Reroute the pipings and the drain hose across the back of the chassis. Unfold the tubing to downward slowly. ( ) Piping for passage through piping hole Set the pipings and the drain hose to the back of the chassis with the tubing holder. Hook the edge of tubing holder to tap on chassis and push the bottom of tubing holder to be engaged at the bottom of chassis. Bend the tubing to the left side of chassis.( C ) Tubing holder 5 Room Air Conditioner

18 Flaring work and connection of piping Connection of the pipes-outdoor Bad case Following bending type from right to left could cause problem of pipe damage..gwhd8b5nk3ea/o.gwhd8b5nk3eb/o. GWHD8B5NK3ED/O Align the center of the pipings and sufficiently tighten the flare nut by hand. Finally, tighten the flare nut with torque wrench until the wrench clicks. When tightening the flare nut with torque wrench, ensure the direction for tightening follows the arrow on the wrench. Outside diameter Torque mm inch kg.m Ø6.35 /4.8 Ø2.7 /2 5.5 Outdoor unit Liquid side piping (Smaller diameter) Gas side piping (Bigger diameter) Service Manual 6

19 Flaring work and connection of piping 2.GWHD8B5NK3EC\O Press big handle downward and take it off. Undo the tighten plate on quick connector (male). Position-setting pin Tighten plate Pull the tighten noose inward by the arrow direction. Tighten noose Insert quick connector (male) into root of the female one, and reposit tightening noose at the same time. Note: Make orientating pin downward. Rotate tighten plate and press it to bottom. Note: It is hard to press tighten plate to bottom if tighten noose doesn't reposited thoroughly. Tighten plate 7 Room Air Conditioner

20 Connect the cable to the Indoor unit. Connecting the cable between indoor unit and outdoor unit Connecting the cable between indoor unit and outdoor unit Connect the cable to the indoor unit by connecting the wires to the terminals on the control board individually according to the outdoor unit connection. (Ensure that the color of the wires of the outdoor unit and the terminal No. are the same as those of the indoor unit.) The above circuit diagram is subject to change without notice. The earth wire should be longer than the common wires. When installing, refer to the circuit diagram behind the panel front of the indoor unit. Connect the wires firmly so that they may not be pulled out easily. Connect the wires according to color codes, referring to the wiring diagram. Main power source If a power plug is not used, provide a circuit breaker between power source and the unit as shown by. Air Conditioner Circuit Breaker Use a circuit breaker or time delay fuse. The power cord connected to the indoor unit and the power connecting cable connecting the indoor and outdoor unit should be selected according to the following specifications (Type "B" approved by HAR or SAA). (mm 2 ) Power cord Connecting cable.5.5 H05W-F H07RN-F Service Manual 8

21 Connecting the cable between indoor unit and outdoor unit Connect the cable to the outdoor unit Remove the control cover from the unit by loosening the screw. Connect the wires to the terminals on the control board individually. Outdoor Unit Terminal block Over 5mm Secure the cable onto the control board with the cord clamp. Connecting cable Refix the control cover to the original position with the screw. Cover control Use a recognized circuit breaker "A" between the power source and the unit. A disconnecting device to adequately disconnect all supply lines must be fitted. This Air-conditioner use 20A. Blue Black Brown YE/GN Wire clamp Power connection cord Wire clamp Power connection cord After the confirmation of the above conditions, prepare the wiring as follows: ) Never fail to have an individual power circuit specifically for the air conditioner. As for the method of 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 loose from vibrations to which the unit is subjected during the course of transportation. Check them and 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 voltage marked 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. (Refer to page 9)) 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 normal function of the overload. 9) The means for disconnection from a power supply shall be incorporated in the fixed wiring and have an air gap contact separation of at least 3mm in each active(phase) conductors. 9 Room Air Conditioner

22 Checking the drainage and forming the pipings Checking the drainage and forming the pipings Checking the drainage To remove the front panel from the indoor unit. Set the air direction louvers up-and-down to the position(horizontally) by hand. Remove the securing screws that retain the front panel. Pull the lower left and right sides of the grille toward you and lift it off. Pull the right and the left side. To check the drainage. Pour a glass of water on the evaporator. Ensure the water flows through the drain hose of the indoor unit without any leakage and goes out the drain exit. Form the piping Form the piping by wrapping the connecting portion of the indoor unit with insulation material and secure it 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. In cases where the outdoor unit is installed below the indoor unit perform the following. Tape the piping, drain hose and connecting cable from down to up. Secure the tapped piping along the exterior wall using saddle or equivalent. Seal small openings around pipings with a gum type sealer. Taping Drain hose Pipings Connecting cable Drain piping The drain hose should point downward for easy drain flow. Downward slope Trap is required to prevent water from entering into electrical parts. In cases where the Outdoor unit is installed above the Indoor unit perform the following. Tape the piping and connecting cable from down to up. Secure the taped piping along the exterior wall. Form a trap to prevent water entering the room. Fix the piping onto the wall by saddle or equivalent. Seal a small opening around the pipings with gum type sealer. Trap Do not make drain piping. Do not raise Accumulated drain water Air Tip of drain hose dipped in water Less than 50mm gap Trap Water leakage Water leakage Waving Water leakage Ditch Service Manual 20

23 Air purging Air Purging Air purging Air and moisture remaining in the refrigerant system have undesirable effects as indicated 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 refrigeration system. Therefore, the indoor unit and tubing between the indoor and outdoor unit must be leak tested and evacuated to remove any noncondensables and moisture from the system. Air purging with vacuum pump Preparation Check that each tube(both liquid and gas side tubes) between the indoor and outdoor units have been properly connected and all wiring for the test run has been completed. Remove the service valve caps from both the gas and the liquid side on the outdoor unit. Note that both the liquid and the gas side service valves on the outdoor unit are kept closed at this stage. Leak test Connect the manifold valve(with pressure gauges) and dry nitrogen gas cylinder to this service port with charge hoses. Be sure to use a manifold valve for air purging. If it is not available, use a stop valve for this purpose. The "Hi" knob of the manifold valve must always be kept close. Pressurize the system to no more than 50 P.S.I.G. with dry nitrogen gas and close the cylinder valve when the gauge reading reached 50 P.S.I.G. Next, test for leaks with liquid soap. Do a leak test of all joints of the tubing(both indoor and outdoor) and both gas and liquid side service valves. Bubbles indicate a leak. Be sure to wipe off the soap with a clean cloth. After the system is found to be free of leaks, relieve the nitrogen pressure by loosening the charge hose connector at the nitrogen cylinder. When the system pressure is reduced to normal, disconnect the hose from the cylinder. Pressure gauge Manifold valve Lo Indoor unit Outdoor unit Hi Charge hose To avoid nitrogen entering the refrigerant system in a liquid state, the top of the cylinder must be higher than its bottom when you pressurize the system. Usually, the cylinder is used in a vertical standing position. Nitrogen gas cylinder(in vertical standing position) 2 Room Air Conditioner

24 Air purging Soap water method () 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 counterclockwise approximately 90, wait for about 2~3 sec, and close it. (4) Apply a soap water or a liquid neutral detergent on the indoor unit connection or outdoor unit connections by a soft brush to check for leakage of the connecting points of the piping. (5) If bubbles come out, the pipes have leakage. 3-way valve (Close) 2-way valve (Open) Gas side Liquid side Evacuation Connect the charge hose end described in the preceding steps to the vacuum pump to evacuate the tubing and indoor unit. Confirm the "Lo" knob of the manifold valve is open. Then, run the vacuum pump. The operation time for evacuation varies with tubing length and capacity of the pump. The following table shows the time required for evacuation. Required time for evacuation when 30 gal/h vacuum pump is used If tubing length is less than 0m (33 ft) IIf tubing length is longer than 0m (33 ft) 0 min. or more 5 min. or more Outdoor unit Hexagonal wrench Indoor unit Cap When the desired vacuum is reached, close the "Lo" knob of the manifold valve and stop the vacuum pump. Finishing the job With a service valve wrench, turn the valve stem of liquid side valve counter-clockwise to fully open the valve. Turn the valve stem of gas side valve counter-clockwise to fully open the valve. Loosen the charge hose connected to the gas side service port slightly to release the pressure, then remove the hose. Replace the flare nut and its bonnet on the gas side service port and fasten the flare nut securely with an adjustable wrench. This process is very important to prevent leakage from the system. Replace the valve caps at both gas and liquid side service valves and fasten them tight. This completes air purging with a vacuum pump. The air conditioner is now ready to test run. Pressure gauge Open Manifold valve Lo Hi Vacuum pump Close Service Manual 22

25 Test running Test Running. Check that all tubing and wiring have been properly connected. 2. Check that the gas and liquid side service valves are fully open. Settlement of outdoor unit Anchor the outdoor unit with a bolt and nut(ø0mm) tightly and horizontally on a concrete or rigid mount. When installing on the wall, roof or rooftop, anchor the mounting base securely with a nail or wire assuming the influence of wind and earthquake. In the case when the vibration of the unit is conveyed to the hose, secure the unit with an anti-vibration bushing. Bolt Evaluation of the performance Tubing connection Operate unit for 5~20 minutes, then check the system refrigerant charge:. Measure the pressure of the gas side service valve. 2. Measure the temperature of the intake and discharge of air. 3. Ensure the difference between the intake temperature and the discharge is more than 8 C(46 F) (Cooling) or (Heating). Discharge air Intake temperature NOTE: If the actual pressure is higher than shown, the system is most likely over-charged, and charge should be removed. If the actual pressure are lower than shown, the system is most likely undercharged, and charge should be added. The air conditioner is now ready for use. PUMP DOWN This is performed when the unit is to be relocated or the refrigerant circuit is serviced. Pump Down means collecting all refrigerant in the outdoor unit without loss in refrigerant gas. CAUTION: Be sure to perform Pump Down procedure with the unit cooling mode. Pump Down Procedure. 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 to 0.5kg/cm2 G(4.2 to 7. P.S.I.G.), fully close the gas side valve stem and then quickly turn off the unit. At that time, Pump Down has been completed and all refrigerant gas will have been collected in the outdoor unit. Some running failure appear 6 times consecutively,please select ON/OFF operation sequence. Press the forced switch until BUZZER sounds times (beep~beep~). Release the forced switch if BUZZER sounds. Check the function selection ON/OFF with the operation LED. Discharge temperature 4. For reference; the gas side pressure of optimum condition is as below.(cooling) Refrigerant Outside ambient TEMP. The pressure of the gas side service valve. R-40A 35 C (95 F) 8.5~9.5kg/cm 2 G(20~35 P.S.I.G.) 23 Room Air Conditioner

26 Functions Functions Indoor Unit Cooling Mode Operation Healty dehumidification Mode Operation Heating Mode Operation Operation ON/OFF by Remote controller Sensing the Room Temperature Room temperature control Maintain the room temperature in accordance with the Setting Temp. Time Delay Safety Control Restarting is for approx. 3 minutes. Indoor Fan Speed Control Super High, High, Med, Low Operation indication Lamps (LED) Sleep Mode Auto Control The fan is switched to low(cooling), low(heating) speed. The unit will be stopped after, 2, 3, 4, 5, 6, 7 hours. Natural Air Control by CHAOS Logic The fan is switched to intermittent or irregular operation The fan speed is automatically switched from high to low speed. Airflow Direction Control The louver can be set at the desired position or swing up and down automatically. Auto Changeover Defrost(Deice) Control (Heating) Both the indoor and outdoor fan stops during defrosting. Hot-start Control (Heating) The indoor fan stops until the evaporator pipe temperature will be reached at 34 C. Service Manual 24

27 Functions Outdoor Unit Power Relay Control If power is on, it will operate to chage capacitor on controller and power relay will operate after about 2~5sec. Active Power Filter Control(PSC) The active power filter is designed to correct power factor(cos θ) and to regulate DC link voltage. It will be operated PFC circuit when the compressor freq. is over 30Hz and wattage is over 450 watt. Comp. Freq. Control The final operating freq. of comp. is set the lowest freq. that limited outdoor temp., discharge pipe temp., heat-sink temp., target freq., owing to CT. OverheatIng. Protection(Power Module) When the temp. of power module increases to 85 C, controller decreases Freq. of Comp. Freq. Speed Control(Up/Down Speed) It will be changed the drive freq. of comp. according to temp. of indoor and outdoor. Total Current Control (Over Current Protection) DC Peak Current Control 4 way Valve Control It is only operated in the heating operation mode except defrosting operation. Outdoor Fan Motor Control High speed - Although fan motor speed is middle, it will change high speed in case of below AC93V, over 45 C of outdoor temp., and over fc, fh of comp. Freq. Low speed - Although fan motor speed is middle, it will change Low speed in case of over AC 270V, over 2 C (Heating Mode) of outdoor temp. below 24 C (Cooling Mode) of outdoor temp. Discharge Pipe Temp. Control Low Ambient Comp. Torque Control Over Heating Protection (Comp.) Electrical Heating Control (NOT SUIT FOR ALL) When outdoor temperature less than -3 C,the electrical heating will start working so as to make sure the compressor starting and condenser disfrosting. 25 Room Air Conditioner

28 Operation Operation Function of Controls DISPLAY ) C/O Model Operation Indicator ON while in appliance operation, OFF while in appliance pause. Flashing while in disconnection or short in Thermistor. (3 sec off / 0.5 sec on) Timer Indicator ON while in timer mode (on/off), OFF when timer mode is completed or canceled. Comp. Running Incidator While in appliance operation, ON while in outdoor unit compressor running, OFF while in compressor off. 2) H/P Model Operation Indicator ON while in appliance operation, OFF while in appliance pause. Flashing while in disconnection or short in Thermistor. (3 sec off / 0.5 sec on) Timer Indicator ON while in timer mode (on/off), OFF when timer mode is completed or canceled. Defrost Indicator OFF except when hot start during heating mode operation or while in defrost control. Protection of the evaporator pipe from frosting If the indoor pipe temperaure is below - C in 3 min. after the compressor operates without pause while in cooling cycle operation mode, compressor, outdoor fan are turned off. When indoor pipe temp. is 0 C or higher after 3 min pause of compressor Cooling mode operation Operating frequency of compressor depend on the difference of the temperature. (indoor temp,outdoor temp,setting temp) Compressor off temp.= setting temp C on temp. = setting temp C Condition of compressor turned off - When intake air temperature stay at the temperature between setting temp C and setting temp. -.0 C for 3 minutes continuously. - When intake air temperature reaches below the temperature of setting temp. -.0 C. Compressor 3 minutes delay - The compressor can restart minimum 3 minutes later after compressor off. Heating mode operation Operating frequency of compressor depend on the difference of the temperature (indoor temp,outdoor temp,setting temp) Compressor off temp. = setting temp.+3.0 C on temp. = setting temp. Condition of compressor turned off Service Manual 26

29 Operation - When intake air temperature reaches +3 C above the setting temperature. Condition of indoor fan turned off - While in compressor on:indoor pipe temp. < 30 C While in defrost control, between the indoor and outdoor fans are turned off. Compressor 3 minutes delay - After compressor off, the compressor can restart minimum 3 minutes later. Sleep timer operation When the sleep time is reached after [,2,3,4,5,6,7hr] is input by the remote control during the operation, the operation of the appliance stops. When the appliance is on pause, the sleep timer mode cannot be input.. Sleep timer operation for cooling cycle While in cooling mode operation, 60 min. later since the start of the sleep timer, the setting temperature increase by C. After another 30min. elapse, it increases by C again. Setting temp. ( C).0 C up.0 C up Cooling ON temp. (Setting temp C) Cooling OFF temp. (Setting temp C) 0.5 Sleep time (hr) 2. Sleep timer operation for heating cycle While in heating mode operation, 60 min. later since the start of the sleep timer, the setting temperature decrease by C. After another 60min. elapse, it decreases by C again. Setting temp. ( C) Heating ON temp. (Setting temp).0 C down Heating OFF temp. (Setting temp C).0 C down 2 Sleep time (hr) 27 Room Air Conditioner

30 Operation Auto restarting operation When the power is restarted after a sudden power failure while in appliance operation, the mode before the power failure is kept on the memory and the appliance automatically operates in the mode on the memory. Operation mode that is kept on the memory - State of operation ON/OFF - Operation mode/setting temp./selected airflow speed - Sleep timer mode/remaining time of sleep timer - Chaos Swing Forced operation To operate the appliance by force in case that the remote control is lost, the forced operation selection switch is on the main unit of the appliance to operate the appliance in the standard conditions. The operation condition is set according to the outdoor temp. and intake air temperature as follows. Indoor temp. Operating Mode Setting temp. Setting speed of indoor fan over 24 C Cooling 25 C 2~24 C FAN High speed below 2 C Heating The unit select before operating mode in 3 hours. 8 C Protection from total current control CT control If the operating current reaches 3A, the operating frequency of the compressor stop insteally. After stoping 3min, the compressor will operate again. CT2 control If the operating current of the appliance reaches I2A, the compressor will keep the frequence. If the operating current of the appliance reaches 2.5A, the compressor's frequence will dearease, until the current less than 2A. Protection from DC Peak Current DC Peak Current Error by a fault signal of IPM If the operating current of IPM reaches 27A, the compressor stop instantly. If DC PEAK occurs 5 times within hour, the appliance turns off and display ERROR CODE H5. DC Peak Current Error by the compressor lock If the DC LINK voltage below DC 40V occurs 5 times within hour while the compressor is operating, the appliance turns off and display ERROR CODE H5. DC Peak Current Error by the Outdoor Fan Lock If it s 5 times within hour in case of the temperature of outdoor pipe TH is over 65 C while the compressor is operating, the appliance turns off and display ERROR CODE E4. Service Manual 28

31 Operation Portection from overheating of power module If the temperature of the heat sink TH. reaches over Toff, the Compressor stop instantly. It will be limited the compressor operating frequency according to the heat sink TH.(refer to below FIG.) It will be blink 4 times, when the thermistor is open or short, also the temperature is over Toff. 20 C T = (T off - T on) T = T on + T T2 = T on + 2 * T Heat Sink Temp. T2 C T C T on C Compress Frequency Protection from overheating of compressor If the temperature of the discharge pipe of compressor reaches over 30 C or below -30 C the compressor stop instantly. It will be limited the compressor operating frequency according to the compressor dome TH.(Refer to below Fig.) Temperature range by COMP SPEC varies by 0 C. 0 C T3 C D-Pipe Temp. T = (T off - T2)/2 T = T2-2 * T T3 = T2 + T T2 C T C -3 C Compress Frequency 29 Room Air Conditioner

32 Operation Remote Control Operations The remote control sends signals to the appliance. Signal transmitter. Liquid crystal display Displays all the operating modes. 2. ON/OFF button Used to switch appliance on or off. 3. TEMP. button Used to set the room temperature. 4. TIMER button Used to select the time MODE button Used to select the operating mode. 6. SWING button Used to start or stop the movement of the vertical louvers. 7. FAN button Used to set the fan speed, in sequence, to automatic, low, medium, high. 8. SLEEP button Used to set or cancel SLEEP mode. Meaning of the symbols shown on the liquid crystal display: Automatic fan speed Low fan speed Medium fan speed High fan speed Cooling indicator Dehumidification indicator Fan only operation indicator Heating indicator Automatic mode indicator SLEEP indicator Louver swing indicator 9. TIMER ON button When the appliance is off, this button is used to switch the air-conditioner on automatically. 0.. TIMER OFF button When the appliance is on, this button is used to switch the air-conditioner off automatically. CLOCK button Comes into time setting mode. 2. CANCEL button Used to cancel all the timing settings. 3. RESET button The control system comes into default settings. Service Manual 30

33 Disassembly Disassembly Indoor Unit Disconnect the unit from power supply before making any checks. Be sure the power switch is set to OFF..Disassembling filter and electric box cover Push the filter upwards to unloose the clasp,and then. pull out the two filters Screw off the screws fixing the electric box cover and then open the cover,next unscrew the screws fixing the toggle switch on the cover,at last remove the cover out. filter front panel electric box cover controller terminal 2.Disassembling front panel O pen the front panel and unloose the slipknot fixing it,then pull out the controller terminal to remove the panel upwards. 3.Disassembling guide louver and panel body Bend the guide louver to back the rotating shaft from. the groove and take off the guide louver. Pry the 3 screw caps to unscrew the 6 srews fixing the panel body,then unloose the clasps upwards to remove the panel body. srews 3 Room Air Conditioner

34 Disassembly 4.Disassembling electric box Press the 3 clasps inby till they loose,then lift upwards the electric cover.. R emove the ground line connecting the evaporator and t ake out the piping temp. sensor,then pull out the interinserting connector for stepping motor and indoor motor, at last unscrew the screws fixing the electric box to remove it. clasps ground screw pipe temp. sensor motor terminal screws 5.Disassembling water tray Break off the clasp under the water tray and turn the water tray till it falls from the clasp,then remove it. Service Manual 32

35 Disassembly 6.Disassembling the evaporator Unscrew the 5 screws fixing the left and right side of the evaporator,then elevate left side the evaporator to remove it backward. When repair, do not damage the Caution label. screws 7.Disassembling motor and cross flow fan U nscrew the 4 screws fixing the motor cover and then take the motor cover out. screw motor cover screws motor U nscrew the screw connecting the cross flow fan a nd motor,then pull out the motor and remove the cross flow fan. cross flow fan 33 Room Air Conditioner

36 Disassembly outdoor Unit Model:GWHD8B5NK3EA/O, GWHD8B5NK3EB/O,GWHD8B5NK3ED/O.Disassembling top cover Unscrew the 6 screws around the top cover to remove it upwards. top cover screws 2.Disassembling rear grill Unscrew the four tapping screws around the rear grill to remove it. rear grill screws 3.Disassembling cabinet Unscrew the four tapping screws fixing the cabinet to remove it. screws cabinet Service Manual 34

37 Disassembly 4.Disassembling front panel Unscrew the tapping screws fixing the front panel, motor support,and side plate of condenser of chassis to take out the front panel. screw 5.Disassembling right side plate U nscrew the 9 screws fixing the right side plate to remove it. right side plate screws 6.Disassemble electric box Unscrew the 4 screws fixing the electric box cover. to remove it. U nscrew the 2 screws fixing the electric box and pull out the compressor,reactor,4-way valve and inset block of fan motor leading-out line to remove the electric box. electric box cover screws 35 Room Air Conditioner

38 Disassembly 7.Disassembling axial flow fan Loosen the tight nuts fixing the axial flow fan with a spanner,then take out nuts,spring washer, flat washer in turn. axial flow fan nuts 8.Disassembling motor and motor support Unscrew the 4 screws fixing the motor to remove it. Unscrew the 2 screws fixing the motor support to remove it. screws motor screws 8.Disassemble 4-way valve Unscrew the tight nuts fixing the 4-way valve coil to remove the coil,then wrap the 4-way valve with wet cotton,next unsolder the 4 welding spots to remove the 4-way valve.. The refrigerant must be discharged before disassembling. Make the soldering process as quick as possible and keep the cotton wet to prevent the soldering flame from burning out the leading wire of compressor. Service Manual 36

39 Disassembly 4-way valve welding spots 9.Disassemble capillary and valve Unsolder the welding spots in primary capillary and. auxiliary capillary to remove the capillary. Unscrew the 2 bolts fixing the gas valve and liquid valve, then unsolder the connecting pipe to remove the valve. capillary bolt valve 0.Disassembling compressor Loosen the 3 nuts with at the foot of the compressor. Unsolder the suction and discharge pipe,and then remove them carefully to take the compressor out. compressor foot nut 37 Room Air Conditioner

40 Disassembly Model:GWHD8B5NK3EC/O.Disassembling top cover Unscrew the 6 screws around the top cover to remove it upwards. top cover screws 2.Disassembling rear grill Unscrew the four tapping screws around the rear grill to remove it. rear grill screws 3.Disassembling cabinet Unscrew the four tapping screws fixing the cabinet to remove it. screws cabinet Service Manual 38

41 Disassembly 4.Disassembling front panel Unscrew the tapping screws fixing the front panel, motor support,and side plate of condenser of chassis to take out the front panel. screws 5.Disassembling right side plate Unscrew the 9 screws fixing the right side plate to remove it. right side plate screws 6.Disassemble electric box Unscrew the 4 screws fixing the electric box cover to remove it.. Unscrew the 2 screws fixing the electric box and pull out the compressor,reactor,4-way valve and inset block of fan motor leading-out line to remove the electric box. electric box cover screws 39 Room Air Conditioner

42 Disassembly 7.Disassembling axial flow fan Loosen the tight nuts fixing the axial flow fan with a spanner,then take out nuts,spring washer, flat washer in turn. axial flow fan nuts. 8.Disassembling motor and motor support Unscrew the 4 screws fixing the motor to remove it. Unscrew the 2 screws fixing the motor support to remove it. screws motor screws. 8.Disassemble 4-way valve Unscrew the tight nuts fixing the 4-way valve coil to remove the coil,then wrap the 4-way valve with wet cotton,next unsolder the 4 welding spots to remove the 4-way valve. 4-way valve. The refrigerant must be discharged before disassembling. Make the soldering process as quick as possible and keep the cotton wet to prevent the soldering flame from burning out the leading wire of compressor. welding spots Service Manual 40

43 Disassembly 9.Disassemble capillary and quick connector Unsolder the welding spots in primary capillary and auxiliary capillary to remove the capillary. Unscrew the 2 screws fixing the quick connector,then. unsolder the connecting pipe to remove the quick connector. screws quick connector capillary 0.Disassembling compressor Loosen the 3 nuts with at the foot of the compressor. Unsolder the suction and discharge pipe,and then remove them carefully to take the compressor out. compressor foot nut 4 Room Air Conditione

44 Schematic Diagram Schematic Diagram Wiring Diagram Indoor Unit Service Manual 42

45 Schematic Diagram Outdoor Unit Models: GWHD8B5NK3EA/O T O INDOOR UNIT TO INDOOR UNIT E YEGN BL N() BK 2 BN 3 XT E YEGN BN OR Models: GWHD8B5NK3EB/O BL FAN MOTOR E M4 YEGN OUTTUBE OUTROOM EXHAUST E U TEM.SENSOR TEM.SENSOR TEM.SENSOR BN BN BL YE BK WH COMPRESSOR COMPRESSOR YEGN TEM.SENSOR M3 X V X E RT RT2 RT3 BN BN YE BK WH C RT4 YE BL RD X08 X204 X203 AC-L FILTERE OUTTUBE OUTROOM EXHAUST U V W 3 X2 BL X06 CN0 X5 IPM 2 4 BN X07 PCB X3 X COM-A P P2 N L L V (4-V) X202 X4 RLY NO COM BL LAC X0 BK BK WH OR + - C2 L BN OR BK + AC WH U AC - 43 Room Air Conditione

46 Schematic Diagram Models: GWHD8B5NK3EC/O T O INDOOR UNIT TO INDOOR UNI T Models: GWHD8B5NK3ED/O Service Manual 44

47 Schematic Diagram Indoor Unit TOP VIEW BOTTOM VIEW 45 Room Air Conditioner

48 Outdoor Unit Schematic Diagram TOP VIEW BOTTOM VIEW Service Manual 46

49 Troubleshooting Guide Troubleshooting Guide Refrigeration Cycle Diagram Cooling & Heating Models INDOOR UNIT OUTDOOR UNIT LIQUID SIDE 3-WAY VALVE EER HEAT EXCHANGE (EVAPORATOR) HEAT EXCHANGE (CONDENSER) GAS SIDE 3-WAY VALVE ACCUMU LATOR REVERSING VALVE COMPRESSOR COOLING HEATING 47 Room Air Conditioner

50 Troubleshooting Guide 2-way, 3-way Valve 2-way Valve (Liquid Side) 3-way Valve (Gas Side) Flare nut To piping connection To outdoor unit Hexagonal wrench (4mm) Open position Closed position Flare nut To piping connection Valve cap Open position Closed position Service port cap To outdoor unit Pin Service port Works Shipping Air purging (Installation) Operation Pumping down (Transfering) Evacuation (Servicing) Gas charging (Servicing) Pressure check (Servicing) Gas releasing (Servicing) Shaft position Shaft position Service port Closed Closed Closed (with valve cap) (with valve cap) (with cap) Open Closed Open (counter-clockwise) (clockwise) (push-pin or with vacumm pump) Open Open Closed (with valve cap) (with valve cap) (with cap) Closed Open Open (clockwise) (counter-clockwise) (connected manifold gauge) Open Open Open (with charging cylinder) Open Open Open (with charging cylinder) Open Open Open Open Open (with charging cylinder) Open (with charging cylinder) Service Manual 48

51 Troubleshooting Guide Air purging Required tools : hexagonal wrench, adjustable wrench, torque wrenches, wrench to hold the joints, and gas leak detector. The additional gas for air purging has been charged in the outdoor unit. However, if the flare connections have not be done correctly and there gas leaks, a gas cylinder and the charge set will be needed. The air in the indoor unit and in the piping must be purged. If air remains in the refrigeration pipes, it will affect the compressor, reduce to cooling capacity, and could lead to a malfunction. Indoor unit Liquid side Open 2-way valve Outdoor unit Gas side 3-way valve Clsed Service port nut: Be sure, using a torque wrench to tighten the service port nut (after using the service port), so that it prevents the gas leakage from the refrigeration cycle. CAUTION: Do not leak the gas in the air during Air purging. Procedure () Recheck the piping connections. (2) Open the valve stem of the 2-way valve counterclockwise approximately 90, wait 0 seconds, and then set it to closed position. Be sure to use a hexagonal wrench to operate the valve stem. (3) Check for gas leakage. Check the flare connections for gas leakage. (4) Purge the air from the system. Set the 2-way valve to the open position and remove the cap from the 3-way valve s service port. Using the hexagonal wrench to press the valve core pin, discharge for three seconds and then wait for one minute. Repeat this three times. (5) Use torque wrench to tighten the service port nut to a torque of.8kg.cm. (6) Set the 3-way valve to the back seat. (7) Mount the valve stem nuts to the 2-way and 3- way valves. (8) Check for gas leakage. At this time, especially check for gas leakage from the 2-way and 3-way valve s stem nuts, and from the service port nut. CAUTION: If gas leakage are discovered in step (3) above, take the following mesures : If the gas leaks stop when the piping connections are tightened further, continue working from step (4). If the gas leaks do not stop when the connections are retightened, repair the location of the leak, discharge all of the gas through the service port, and then recharge with the specified amount of gas from a gas cylinder. 49 Room Air Conditioner

52 Troubleshooting Guide Pumping Down Indoor unit Liquid side 2-Way valve Open Outdoor unit Gas side 3-Way valve Closed CLOSE Purge the air Lo CLOSE Procedure () Confirm that both the 2-way and 3-way valves are set to the open position. Remove the valve stem caps and confirm that the valve stems are in the raised position. Be sure to use a hexagonal wrench to operate the valve stems. (2) Operate the unit for 0 to 5 minutes. (3) Stop operation and wait for 3 minutes, then connect the charge set to the service port of the 3-way valve. Connect the charge hose with the push pin to the service port. (6) Operate the air conditioner at the cooling cycle and stop it when the gauge indicates kg/cm 2 g. (7) Immediately set the 3-way valve to the closed position. Do this quickly so that the gauge ends up indicating 3 to 5kg/cm 2 g. (8) Disconnect the charge set, and mount the 2- way and 3-way valve s stem nuts and the service port nut. Use torque wrench to tighten the service port nut to a torque of.8 kg.m. Be sure to check for gas leakage. (4) Air purging of the charge hose. Open the low-pressure valve on the charge set slightly to air purge from the charge hose. (5) Set the 2-way valve to the closed position. Service Manual 50

53 Troubleshooting Guide Re-air Purging (Re-installation) Indoor unit Liquid side 3-Way valve Closed Outdoor unit Gas cylinder Gas side 3-Way valve Closed R22 OPEN Lo CLOSE Procedure () Confirm that both the liquid side valve and the gas side valve are set to the closed position. (2) Connect the charge set and a gas cylinder to the service port of the Gas side valve. Leave the valve on the gas cylinder closed. (3) Air purging. Open the valves on the gas cylinder and the charge set. Purge the air by loosening the flare nut on the liquid side valve approximately 45 for 3 seconds then closing it for minute; repeat 3 times. After purging the air, use a torque wrench to tighten the flare nut on liquid side valve. (6) Disconnect the charge set and the gas cylinder, and set the Liquid side and Gas side valves to the open position. Be sure to use a hexagonal wrench to operate the valve stems. (7) Mount the valve stem nuts and the service port nut. Use torque wrench to tighten the service port nut to a torque of.8 kg.m. Be sure to check for gas leakage. CAUTION: Do not leak the gas in the air during Air Purging. (4) Check for gas leakage. Check the flare connections for gas leakage. (5) Discharge the refrigerant. Close the valve on the gas cylinder and discharge the refrigerant until the gauge indicates 3 to 5 kg/cm 2 g. 5 Room Air Conditioner

54 Troubleshooting Guide Balance Refrigerant of the 3-way Valve (Gas leakage) Indoor unit Liquid side 3-Way valve Open Outdoor unit Gas side 3-Way valve Open OPEN Lo CLOSE Procedure () Confirm that both the 2-way and 3-way valves are set to the back seat. (2) Connect the charge set to the 3-way valve s port. Leave the valve on the charge set closed. Connect the charge hose to the service port. (3) Open the valve (Lo side) on the charge set and discharge the refrigerant until the gauge indicates 0 kg/cm 2 G. If there is no air in the refrigerant cycle (the pressure when the air conditioner is not running is higher than kg/cm 2 G), discharge the refrigerant until the gauge indicates 0.5 to kg/cm 2 G. if this is the case, it will not be necessary to apply a evacuatin. Discharge the refrigerant gradually; if it is discharged too suddenly, the refrigeration oil will also be discharged. Service Manual 52

55 Troubleshooting Guide Evacuation (All amount of refrigerant leaked) Indoor unit Liquid side 3-Way valve Open Outdoor unit Gas side 3-Way valve Open Vacuum pump OPEN Lo CLOSE Procedure () Connect the vacuum pump to the center hose of charge set center hose (2) Evacuation for approximately one hour. Confirm that the gauge needle has moved toward -76 cmhg (vacuum of 4 mmhg or less). (3) Close the valve (Lo 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). (4) Disconnect the charge hose from the vacuum pump. Vacuum pump oil. If the vacuum pump oil becomes dirty or depleted, replenish as needed. 53 Room Air Conditioner

56 Troubleshooting Guide Gas Charging (After Evacuation) Indoor unit Liquid side 3-Way valve Open Outdoor unit Gas side Charging cylinder Check valve 3-Way valve Open Lo () OPEN CLOSE Procedure () Connect the charge hose to the charging cylinder. Connect the charge hose which you dis-connected from the vacuum pump to the valve at the bottom of the cylinder. If you are using a gas cylinder, also use a scale and reverse the cylinder so that the system can be charged with liquid. (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). The procedure is the same if using a gas cylinder. (3) Open the valve (Lo side on the charge set and charge the system with liquid refrigerant. If the system can not be charged with the specified amount of refrigerant, it can be charged with a little at a time (approximately 50g each time) while operating the air conditioner in the cooling cycle; however, one time is not sufficient, wait approximately minute and then repeat the procedure (pumping down-pin). \ This is different from previous procedures. Because you are charging with liquid refrigerant from the gas side, absolutely do not attempt to charge with larger amounts of liquid refrigerant while operating the air conditioner. (4) Immediately disconnect the charge hose from the 3-way valve s service port. Stopping partway will allow the gas to be discharged. If the system has been charged with liquid refrigerant while operating the air conditioner turn off the air conditioner before disconnecting the hose. (5) Mount the valve stem nuts and the service port nut. Use torque wrench to tighten the service port nut to a torque of.8 kg.m. Be sure to check for gas leakage. Service Manual 54

57 Troubleshooting Guide Cycle Parts Trouble analysis Breaker tripped or fuse burnt out When the breaker is set ON, it will trip at once. When the unit is turned on, the breaker will trip in a few minutes No power supply Measure the insulating resistance for grounding to confirm whether there is electrical leakage in the unit Check the breaker and measure the resistance. Check power supply circuit Air conditioner cannot start up The power plug is not or poorly connected Wrong wiring between indoor and outdoor unit Transmitting malfunction of wireless remote control Controller fuse is burnt out Check and insert the plug tightly Check the circuit according to the circuit diagram and correct wrong wiring Check wireless remote control Change controller fuse Both indoor and outdoor units cannot start up Whether connection between strong and weak current board of controller is firm Whether the output wire of transformer is firm, whether there is voltage output Make the connecting wire firm Make the connecting wire firm and check the output voltage Improper setting of temperature Adjust the set temperature Whether cooling (heating) load is proper Check the estimated load of cooling (heating) Poor cooling (heating) effect Malfunction of refrigerant flow Malfunction of four-way valve Insufficient refrigerant volume Malfunction of compressor Replace the four-way valve Charge refrigerant Replace the compressor Insufficient flow volume of valve Open the valve completely Improper installation location for outdoor unit Outdoor unit should be installed in a place with well ventilation, and awning should be installed. 55 Room Air Conditioner

58 Troubleshooting Guide Air circulation is insufficient Air filters are blocked Fan speed was set too slow Clean the filter Set the fan speed to high or medium speed Filters of indoor unit are blocked Clean the filters regularly Poor cooling (heating) effect Heat exchanger of outdoor unit is blocked Leakage occurs between high and low pressure inside compressor Partial blockage of capillary Clean the dust accumulated on the surface of the heat exchanger Replace the compressor Replace the capillary Leakage of refrigerant Find out the leakage and charge refrigerant Blockage in one-way valve of outdoor unit Replace one-way valve When unit is cooling or heating, both compressor and outdoor fan don't run Abnormal power supply of outdoor unit Abnormal transformer output Damage of main control board Check the circuit according to circuit diagram Replace the transformer Replace the main control board Damage of main control board Replace the main control board When unit is cooling or heating, the compressor runs but outdoor fan doesn't run Improper setting of temperature Breakage of outdoor fan Wrong wire connection Adjust the set temperature Replace the fan motor Wire according to the circuit diagram Breakage of outdoor fan motor capacitor Replace the fan motor capacitor When cooling or heating, outdoor fan runs, but compressor doesn't run. Malfunction of compressor Poor contact of connection between the main control board and module Abnormal input of power module Abnormal output of power module Replace the compressor Re-fasten the connection Check if input is 320V. If not, replace the rectifier Replace the power module Service Manual 56

59 Troubleshooting Guide When cooling or heating, outdoor fan runs, but compressor doesn't run. Compressor temperature is too high Wrong wiring Damage of main control board Cool the compressor for 30 min before running Wire according to the circuit diagram Replace the main control board Water leakage Blockage or breakage of drainage hose Wrap of refrigerant pipe connector is not tight enough Replace the drainage hose Re-wrap and make it tight Fan doesn't run when FAN mode is set Burn-out or broken wire of indoor fan motor Wrong wiring Circuit break or damage of fan motor capacitor Repair or change the fan motor Wire according to the circuit diagram Replace the main control board Fan of indoor unit contacts other parts Adjust fan location Abnormal sound and vibration There is foreign substance in indoor unit Compressor shakes too much Touch of pipeline of outdoor unit Touch of inner plates Take out the foreign substance Adjust support washer of the compressor and tighten loose bolts Separate the touched pipeline. Tighten connecting screws 2.Stick shock-absorbing clay between plates Touch of outdoor unit fan blade with outer case Abnormal sound inside compressor Abnormal electromagnetic sound inside four-way valve when heating Adjust louver position Replace compressor Short circuit inside electromagnetic valve. Replace the electromagnetic valve 57 Room Air Conditioner

60 Troubleshooting Guide Malfunction Display Malfunction and protection meaning Code Malfunction and protection meaning Code High-pressure protection to system Anti-high-temperature Inside antifreezing protection E2 Anti-cold-air protection Low-pressure protection to system E3 Indoor environmental sensor open or short circuit Compressor discharge protection E4 Indoor evaporator sensor open or short circuit Low voltage overcurrent protection E5 Outdoor environmental sensor open or short circuit F3 Communication malfunction E6 Outdoor condenser sensor open or short circuit F4 Mode conflict E7 Outdoor discharge sensor open or short circuit F5 Blink time Compressor is running Blink 2 times High-pressure protection stop of compressor Blink 3 times Exhaust protection stop Blink 4 times Communication malfunction stoop (including indoor unit and SIPM) LED Blink 5 times Blink 6 times SIPM module protection stop Overcurrent protection stop Blink 7 times Cooling overload stop Blink 8 times Heating anti-high-temperature stop Blink 9 times Cooling antifreezing stop Blink 0 times Sensor malfunction stop Service Manual 58

61 Troubleshooting Guide Blink time Communication malfunction of unit A (not receiving correct data for 3 minutes) Blink 2 times Blink 3 times Indoor middle sensor malfunction of unit A Indoor outlet sensor malfunction of unit A Blink 4 times Indoor inlet sensor malfunction of unit A Blink 5 times Blink 6 times Indoor environmental sensor malfunction of unit A Communication malfunction signal sent by indoor unit A Blink 7 times Antifreezing protection of unit A Blink 8 times Anti-high-temperature protection of unit A Blink time Blink 2 times Communication malfunction of unit B (not receiving correct data for 3 minutes) Indoor middle sensor malfunction of unit B Blink 3 times Indoor outlet sensor malfunction of unit B Blink 4 times Indoor inlet sensor malfunction of unit B Blink 5 times Blink 6 times Blink 7 times Indoor environmental sensor malfunction of unit B Communication malfunction signal sent by indoor unit B Antifreezing protection of unit B Blink 8 times Anti-high-temperature protection of unit B Blink time Discharge protection frequency limitation Blink 2 times Overcurrent protection frequency limitation Blink 3 times Cooling overload frequency limitation

62 Troubleshooting Guide Blink 4 times Blink 5 times Blink 6 times Heating anti-high-temperature frequency demultiplication of unit A Heating anti-high-temperature frequency demultiplication of unit B Defrosting Blink time Discharge protection frequency limitation Blink 2 times Overcurrent protection frequency limitation Blink 3 times Cooling overload frequency limitation Blink 4 times Blink 5 times Heating anti-high-temperature frequency limitation of unit A Heating anti-high-temperature frequency limitation of unit B Blink 6 times Oil return Blink 7 times Keep 8A-current frequency for 3 minutes Blink 8 times Keep 9A-current frequency for 3 minutes Blink time Outdoor environmental sensor malfunction Blink 2 times Outdoor tube sensor malfunction Blink 3 times Outdoor discharge sensor malfunction Blink 4 times Blink 5 times Compressor overload sensor malfunction SIPM communication malfunction (not receiving correct data for 0 seconds) Service Manual 60

63 Troubleshooting Guide Blink time Blink 2 times Blink 3 times Reset stopping Surge current is too high or 7V voltage is too low Abnormal low speed Blink 4 times Switch failure Blink 5 times Overload stop Blink 6 times Over heat LED7 SIPM message Blink 7 times OH or FIN sensor malfunction Blink 8 times Poor speed up Blink 9 times Poor communication Blink 0 times Volts D.C. too low Blink times FIN temperature too high Blink 2 times Abnormal high speed Blink 3 times EEPROM data exception Blink 4 times Volts D.C. too high On Receiving indoor data Off Indoor data received 6 Room Air Conditioner

64 Troubleshooting Guide Resistance value and voltage list for 5K temp. sensor Temp. Resistance Voltage(v) Voltage(v) Temp. Resistance Voltage(v) Voltage(v) Resistance Voltage(v) Voltage(v) ( ) (KΩ) *5K *8.K ( ) (KΩ) *5K *8.K ( ) (KΩ) *5K *8.K Temp. N ote:the above voltage values are in the conditions that power voltage is 5V and partial pressure resistance is 5k or 8.k.

65 Troubleshooting Guide Resistance value and voltage list for 20K temp. sensor Temp. Resistance Voltage(v) Temp. Resistance Voltage(v) Voltage(v) ( ) (KΩ) *5K ( ) (KΩ) *8.K ( ) (KΩ) *8.K Temp. Resistance N ote:the above voltage values are in the conditions that power voltage is 5V and partial pressure resistance is 20k. 63 Room Air Conditioner

66 Troubleshooting Guide Resistance value and voltage list for 50K temp. sensor Temp. Resistance Voltage(v) Temp. Resistance Voltage(v) Resistance Voltage(v) ( ) (KΩ) *5K ( ) (KΩ) *8.K ( ) (KΩ) *8.K N ote:the above voltage values are in the conditions that power voltage is 5V and partial pressure resistance is 4.3k. Temp. Service Manual 64

67 Exploded View Exploded View Indoor Unit Models:GWHD8B5NK3EA/I 65 Room Air Conditioner

68 Exploded View Models:GWHD8B5NK3EC/I Service Manual 66

69 Exploded View Outdoor Unit 67 Room Air Conditioner

70 Exploded View Service Manual 68

71 Replacement Parts List Replacement Parts List Parts List (Indoor) No Description Part Code GWHD8B5NK3EA/I Qty Wall-Mounting Frame Rear Case Helicoid tongue Cross Flow Fan Evaporator Assy Front Case Big Panel Case Small Panel Case Water Tray Guide Louver(up) Guide Louver(down) Room Sensor 5k Electric Box Cover Electric Box Cover Main PCB Wire Clamp Terminal Board T4B3A Lower Shield of Electric Box Transformer 57X25C Receiver Board 5H53EA Tube Sensor 20k Sensor Insert Upper Shield of Electric Box Electric Box Filter Evaporator Support Drainage Pipe Pipe Clamp Screw Cover Fan Bearing Motor FN2A Swing Link Swing Link Swing Louver Power Cord Motor Clamp Connecting Cable Remote Controller YBB Stepping Motor MP28EA NOTE) * Please ensure GCSC since these parts may be changed depending upon the buyer's request. 69 Room Air Conditioner

72 Replacement Parts List No Description Part Code GWHD8B5NK3EC/I Wall-Mounting Frame Rear Case Helicoid tongue Cross Flow Fan Evaporator Assy Front Case Big Panel Case Small Panel Case Water Tray Guide Louver(up) Guide Louver(down) Room Sensor 5k Electric Box Cover Electric Box Cover Main PCB Wire Clamp Terminal Board T4B3A Lower Shield of Electric Box Transformer 57X25C Receiver Board 5H53EA Tube Sensor 20k Sensor Insert Upper Shield of Electric Box Electric Box Filter Evaporator Support Drainage Pipe Pipe Clamp Screw Cover Fan Bearing Motor FN2A Swing Link Swing Link Soft Pipe Assy Connecting Cable Power Cord Swing Louver Motor Clamp Remote Controller YBB Stepping Motor MP28EA Qty NOTE) * Please ensure GCSC since these parts may be changed depending upon the buyer's request. Service Manual 70

73 Replacement Parts List Parts List (Outdoor) No Description Part Code GWHD8B5NK3EA/O GWHD8B5NK3EB/O GWHD8B5NK3ED/O Qty Front Grill Handle Front Plate Assy Axial Flow Fan Metal Base Valve Support Motor FW60F Motor Support Condenser Assy Ambient Sensor 5K Top Cover Valve /2" Valve /4" Rear Grill Isolation Sheet Tube Sensor 20K Rear Side Plate Handle Assy Electric Box Assy Electric Box Cover Main PCB WB9M25A Main PCB WB9M35A Main PCB WB9M35B Radiator Power Module SIPM30A/600V Rectifler S25VB Capacitor 000uF/450V Radiator Support Capacitor CBB6 3uF/450V Filter 250VAC/20A Way Valve Coil Wiring Terminal Way Valve Reactor L0.35mH/30A/4/ Reactor Support Rubber foot of compressor NONE NONE NONE 36 Compressor EU03DD Discharge Sensor 50K OH Thermistor NONE NONE NONE NOTE) * Please ensure GCSC since these parts may be changed depending upon the buyer's request. 7 Room Air Conditioner

74 Replacement Parts List No Description Part Code GWHD8B5NK3EC/O Front Grill Handle Front Plate Assy Axial Flow Fan Metal Base Valve Support Motor FW60T Motor Support Condenser Assy Ambient Sensor 5K Top Cover Quick Connector (Female) Wiring Bracket Rear Grill Isolation Sheet Tube Sensor 20K Rear Side Plate Handle Assy Electric Box Assy Electric Box Cover Main PCB WB9M35c Radiator Power Module SIPM30A/600V Rectifler S25VB60 Capacitor 000uF/450V Radiator Support Capacitor CBB6 3uF/450V Filter 250VAC/20A Wiring Terminal Way Valve Coil 4-Way Valve Reactor L0.35mH/30A/4/300 Reactor Support Rubber foot of compressor Compressor EU03DD NONE Discharge Sensor 50K OH Thermistor NONE NOTE) * Please ensure GCSC since these parts may be changed depending upon the buyer's request. Qty Service Manual 72

75 P/No.: 3828A20833B GREE ELECTRIC APPLIANCES,INC.OF ZHUHAI