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: GWHD18A1NK3EA (Applied to new Refrigerant R-410A) Prior to installation, this air-conditioning unit must be submitted for approval by the utility service which provides electricity (EN 61000-3 Norm).
Air Conditioner Service Manual TABLE OF CONTENTS Safety Precautions ...........................................................................................................................1 Dimensions .......................................................................................................................................6 Product Specifications ....................................................................................................................8 Installation.................
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.
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. 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. Do not install the product on a defective installation stand. • It may cause injury, accident, or damage to the product.
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. 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 allow water to run into electrical parts. Use a dedicated outlet for this appliance. • There is risk of fire or electrical shock. Do not place a heater or other appliances near the power cable.
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. Keep level even when installing the product. • To avoid vibration or water leakage.
Safety Precautions ■ Operation Use a soft cloth to clean. Do not use harsh detergents, solvents, etc. Do not touch the metal parts of the product when removing the air filter. They are very sharp! • There is risk of fire, electric shock, or damage to the • There is risk of personal injury. plastic parts of the product. x Wa Do not step on or put anyting on the product. (outdoor units) • There is risk of personal injury and failure of product.
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.
Dimensions Outdoor Unit L2 D L1 W H L3 L5 Liquid side (2-way valve) Gas side (3-way valve) DIM MODEL unit 18k Btu Series W mm 845 H mm 680 D mm 304 L1 mm 378 L2 mm 68 L3 mm 530 L4 mm 14 L5 mm 100 7 Room Air Conditioner
Product Specifications Product Specifications Table-1 Model Name Item Unit MIN Cooling Capacity Type Max MIN Heating Capacity Type Max Power Input Running Current COP Power Supply Power Factor Air Circulation IN:20°C,Out: -10°C(Heater ON) IN:20°C,Out: -10°C(Heater OFF) Cooling Heating Heating(-10°C,Heater ON) Heating(-10°C,Heater OFF) Cooling Heating Heating(-10°C,Heater ON) Heating(-10°C,Heater OFF) Cooling Heating Indoor,Max Outdoor,Max Moisture Removal Noise Level Indoor,High (Sound Med.
Installation Installation Selection of the Best Location Indoor unit Rooftop Installations: • 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.
Installation The wall you select should be strong and solid enough to prevent vibration 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. 1. 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.
Flaring work and connection of piping Flaring work and connection of piping Flaring work • Carry out flaring work using flaring tool as shown below. 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.
Flaring work and connection of piping Connecting the pipings to the indoor unit and drain hose to drain pipe. For right rear piping Route the indoor tubing and the drain hose in the direction of rear right. Drain hose • Align the center of the pipes and sufficiently tighten the flare nut by hand. 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.
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. 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. Pipe Vinyl tape(wide) Indoor unit tubing Drain hose For left rear piping Flare nut Pipes • Tighten the flare nut with a wrench.
Flaring work and connection of piping • Wrap the area which accommodates the rear piping housing section with vinyl tape. Indoor unit piping Connection pipe Vinyl tape (wide) Wrap with vinyl tape Indoor unit installation • Remove the spacer. • Ensure that the hooks are properly seated on the installation plate by moving it left and right.
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. 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 mm inch Ø6.35 1/4 Ø12.7 1/2 Torque kg.m 1.8 5.
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. 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.
Connecting the cable between indoor unit and outdoor unit Outdoor Unit Connect the cable to the outdoor unit Remove the control cover from the unit by loosening the screw. Terminal block Connect the wires to the terminals on the control board individually. Secure the cable onto the control board with the cord clamp. Over 5mm Connecting cable Cover control Refix the control cover to the original position with the screw. Use a recognized circuit breaker "A" between the power source and the unit.
Checking the drainage and forming the pipings Checking the drainage and forming the pipings Checking the drainage Form the piping To remove the front panel from the indoor unit. • Set the air direction louvers up-and-down to the position(horizontally) by hand. Form the piping by wrapping the connecting portion of the indoor unit with insulation material and secure it with two kinds of vinyl tapes. • Remove the securing screws that retain the front panel.
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. • 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.
Air purging Soap water method (1) Remove the caps from the 2-way and 3-way valves. Gas side (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.
Test running Test Running 1. Check that all tubing and wiring have been properly connected. 2. Check that the gas and liquid side service valves are fully open. 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.
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.
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.
Operation Operation Function of Controls • DISPLAY 1) 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.
Operation Cooling mode operation • Operating frequency of compressor depend on the difference of the temperature. (= intake air Temp.- Compressor off Temp. • Compressor off temp.= setting temp. -0.5°C on temp. = setting temp. +0.5°C • Condition of compressor turned off - When intake air temperature stay at the temperature between setting temp. -0.5°C and setting temp. -1.0°C for 3 minutes continuously. - When intake air temperature reaches below the temperature of setting temp. -1.0°C.
Operation Heating mode operation • Operating frequency of compressor depend on the difference of the temperature (= compressor off temp. - intake air temp.) • Compressor off temp. = setting temp.+3.0°C on temp. = setting temp. • Condition of compressor turned off - 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.
Operation Sleep timer operation • When the sleep time is reached after [1,2,3,4,5,6,7hr] 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. 1. 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 1°C. After another 30min. elapse, it increases by 1°C again. Setting temp. (˚C) 1.0˚C up 1.
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.
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. 120 °C ∆T = (T off - T on) T1 = T on + ∆T T2 = T on + 2 * ∆T Heat Sink Temp.
Operation Remote Control Operations The remote control sends signals to the appliance. 1. Liquid crystal display Displays all the operating modes. 2. MODE button Used to select the operating mode. 3. FAN button Used to set the fan speed, in sequence, to automatic, low, medium, high. 4. SLEEP button Used to set or cancel SLEEP mode. 5. SWING button Used to start or stop the movement of the vertical louvers. 6.
Disassembly Disassembly Indoor Unit Disconnect the unit from power supply before making any checks. Be sure the power switch is set to “OFF”. 1.Disassemble the front panel • Open the front panel, loosen the clasp which fix on the front panel, then lift it up can disassemble the front panel. 2.Disassemble the filter and electric box cover • Push up the filter, to loosen the clasp, then two filters could be taken out.
Disassembly ３． Disassemble the guide louver and body case • To bend the guide louver, to make the rotating shaft slide from the groove, then can take down the guide louver. • Open 3pcs screw cover, and screw off 6pcs screw which fix the body case, then lift it up loosen the clasp, then can take down the body case. Screw cover Screw Tube sensor Earth screw ４． Disassemble the electric box • Screw off 2pcs screw which fix the light board, then disassemble the light board.
Disassembly ６． Disassemble the evaporator • Screw off the fixing screws of evaporator left side and right side (2 pcs for each side), then lift the evaporator left side up, and remove it backward, can take down the evaporator. • When repair, do not damage the Caution label. Screws ７． Disassemble the motor and cross flow fan • Screw off 4pcs screw from the motor clamp, then take down the motor clamp.
Disassembly outdoor Unit 1.Take down the top cover • Screw off the 6pcs screw around the top cover, lift the unit up can take down the top cover. Top cover Screws 2.Disassemble the rear grill • Screw off 4pcs tapping screw of rear grill, then take down the rear grill. Rear grill Screws 3.Disassemble the front grill • Screw off 4pcs tapping screw on the front grill, then take down the front grill.
Disassembly 4. Disassemble the front panel • Screw off the tapping screws of front panel, motor supporter, chassis condenser side plate, then can take down the front panel. Screws Earth screw 5.Disassemble the right side plate • Screw off 9pcs screw of the right side plate, then take down the right side plate. Right side plate Screws 6.Disassemble the electric box • Screw off 2pcs screw of electric box cover, then take down the electric box cover.
Disassembly 7. Disassemble the axial flow fan • Srew off the nut which fixing the axial flow fan by the spanner, then take out the nut, spring washer, flat washer in turn. Axial flow fan Nut 8. Disassemble the motor and motor supporter • Screw off 4pcs screw which fixing the motor, then take down the motor. • Screw off 2pcs screw which fixing the motor supporter, then can take down the motor supporter. Screws Motor Screws 8.
Disassembly Four-way valve Soldered point 9. Disassemble the capillaries and valves • Unsolder each soldered point of main capillary and auxiliary, then take down the capillary. • To screw off the screws which fixing the gas valve and liquid valve (2pcs for each), unsolder the connection pipe and take down the valves. Capillary Bolt Valves 10. Disassemble the compressor • Loosen the 3pcs bottom nut of compressor, unsolder the air in pipe, and carefully remove the pipelines, take out the compressor.
Schematic Diagram Schematic Diagram Wiring Diagram Indoor Unit Models: ROOM TEM.SENSOR DISPLAY FAN MOTOR POWER:220/230/240V~50/60HZ M1 牟 牟 RT2 RT1 ROOM TUBE RX FAN N1 X111 AP1 SWING YEGN BN BL AC-L TR-IN TR-OUT XT BL N(1) BK 2 BN 3 X100 L N BL BK BN YEGN TO OUTDOOR UNIT TUBE TEM.
Schematic Diagram Outdoor Unit Models: FAN MOTOR M4 E YEGN E COMPRESSOR OUTTUBE OUTROOM EXHAUST TEM.SENSOR TEM.SENSOR TEM.
Schematic Diagram Models: • TOP VIEW • TOP VIEW Service Manual 40
Schematic Diagram Outdoor Unit Models: • TOP VIEW • BOTTOM VIEW 41 Room Air Conditioner
Troubleshooting Guide Troubleshooting Guide Refrigeration Cycle Diagram Cooling & Heating Models INDOOR UNIT OUTDOOR UNIT LIQUID SIDE EER 3-WAY VALVE HEAT EXCHANGE (EVAPORATOR) HEAT EXCHANGE (CONDENSER) GAS SIDE 3-WAY VALVE REVERSING VALVE ACCUMU LATOR COMPRESSOR COOLING HEATING Room Air Conditioner 42
Troubleshooting Guide 2-way, 3-way Valve 2-way Valve (Liquid Side) Hexagonal wrench (4mm) Flare nut 3-way Valve (Gas Side) Valve cap Open position Flare nut Closed position Open position Closed position To piping connection To piping connection To outdoor unit Works Shipping 1.
Troubleshooting Guide Air purging 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. 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.
Troubleshooting Guide Pumping Down Liquid side Indoor unit 2-Way valve Open Outdoor unit Gas side Closed 3-Way valve Lo CLOSE CLOSE Purge the air • Procedure (1) 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. (6) Operate the air conditioner at the cooling cycle and stop it when the gauge indicates 1kg/cm2g.
Troubleshooting Guide Re-air Purging (Re-installation) Liquid side Indoor unit 3-Way valve Closed Outdoor unit Gas side Closed 3-Way valve Gas cylinder Lo R410A OPEN CLOSE • Procedure (1) 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.
Troubleshooting Guide Balance Refrigerant of the 3-way Valve (Gas leakage) Liquid side Indoor unit Outdoor unit 3-Way valve Open Gas side 3-Way valve Open Lo OPEN CLOSE • Procedure (1) 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.
Troubleshooting Guide Evacuation (All amount of refrigerant leaked) Liquid side Indoor unit Outdoor unit 3-Way valve Open Gas side 3-Way valve Open Vacuum pump Lo OPEN CLOSE • Procedure (1) 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).
Troubleshooting Guide Gas Charging (After Evacuation) Liquid side Indoor unit 3-Way valve Open Outdoor unit Gas side Open 3-Way valve Check valve Charging cylinder Lo (1) OPEN CLOSE • Procedure \ (1) 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.
Troubleshooting Guide Cycle Parts Trouble analysis Breaker tripped or fuse burnt out When set the breaker to ON, it will trip off at once. Test the insulative resistance for earthing, to confirm whether unit is current leakage or not When turn on the unit, the breaker will trip in a few minutes Check the breaker and test the resistance. Check the circuit Air conditioner can not start up No power supply The power plug is not connected well or poor connected.
Troubleshooting Guide Air circulation is insufficient Poor cooling (heating) effect When unit is cooling or heating, both compressor and outdoor fan don't run Air filters are blocked Clean the filter Fan speed was set too slow Set the fan speed to high or medium speed Filters of indoor unit are blocked Clean the filters regularly Heat exchanger of outdoor unit is blocked Clean the dust accumulated on the surface of the heat exchanger Leakage occurs between high and low pressure inside compressor
Troubleshooting Guide When cooling or heating, outdoor fan runs, but compressor doesn't run.
Troubleshooting Guide Malfunction display Blink 1 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) Blink 5 times SIPM module protection stop Blink 6 times Overcurrent protection stop Blink 7 times Cooling overload stop Blink 8 times Heating anti-high-temperature stop Blink 9 times Cooling antifreezing stop Blink 10 times Sensor malfunct
Troubleshooting Guide Blink 1 time Communication malfunction of unit B (not receiving correct data for 3 minutes) Blink 2 times 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 Indoor environmental sensor malfunction of unit B Blink 6 times Communication malfunction signal sent by indoor unit B Blink 7 times Antifreezing protection of unit B Blink 8 times Anti-high-tempera
Troubleshooting Guide Blink 5 times Blink 6 times Blink 7 times Blink 8 times Heating anti-high-temperature frequency limitation of unit B Oil return Keep 8A-current frequency for 3 minutes Keep 9A-current frequency for 3 minutes Blink 1 time Outdoor environmental sensor malfunction Blink 2 times Outdoor tube sensor malfunction Blink 3 times Outdoor discharge sensor malfunction Blink 4 times Compressor overload sensor malfunction Blink 5 times SIPM communication malfunction (not receiving
Troubleshooting Guide Blink 10 times Volts D.C. too low Blink 11 times FIN temperature too high Blink 12 times Abnormal high speed Blink 13 times EEPROM data exception Blink 14 times Volts D.C.
Troubleshooting Guide Voltage table of 15K sensor resistance value Value of Voltage resistance （V） *15K （℃） （KΩ） Temp. -20 -19 -18 -17 -16 -15 -14 -13 -12 -11 -10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 147.69 139.298 131.436 124.067 117.158 110.677 104.594 98.8834 93.5199 88.4804 83.7433 79.2888 75.0984 71.1548 67.4422 63.9457 60.6514 57.5465 54.6191 51.858 49.2528 46.7926 44.47 42.2765 40.2043 38.246 36.3946 34.6438 32.9875 31.
Troubleshooting Guide Voltage table of 20K sensor resistance value Temp. （℃） -20 -19 -18 -17 -16 -15 -14 -13 -12 -11 -10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Value of resistance （KΩ） 192 181.4 171.4 162.1 153.3 145 137.2 129.9 123 116.5 110.3 104.6 99.13 94 89.17 84.61 80.31 76.24 72.41 68.79 65.37 62.13 59.08 56.19 53.46 50.87 48.42 46.11 43.92 41.84 39.87 38.01 36.24 34.57 32.98 31.47 30.04 28.68 27.39 26.17 25.01 23.9 22.
Troubleshooting Guide Voltage table of 50K sensor resistance value Temp. （℃） -20 -19 -18 -17 -16 -15 -14 -13 -12 -11 -10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 （KΩ） Voltage （V） *15K 484.5536 457.3636 431.8647 407.9418 385.4885 364.4061 344.6029 325.9941 308.5007 292.0497 276.573 262.0074 248.2941 235.3787 223.2101 211.741 200.9274 190.7282 181.1052 172.0225 163.447 155.3267 147.6573 140.4114 133.5631 127.0885 120.9652 115.172 109.
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