Gree GWH09KF-K3DN series Service Manual
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Gree GWH09KF-K3DN series Service Manual

Gree GWH09KF-K3DN series Service Manual

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  • Page 4 AUTO HEALTH X-FAN HUMIDITY FILTER TURBO HOUR ON/OFF ON/OFF MODE X-FAN TEMP TIMER TURBO SLEEP LIGHT...
  • Page 16 Condition Condition Indoor:DB 20°C Indoor:DB 27°C WB19°C Indoor air flow: Super High Indoor air flow: Super High Pipe length:7.5m Pipe length:7.5m Voltage:230V Voltage:230V Compressor Speed(rps) Compressor Speed(rps) 220V 220V Conditions Indoor : DB27°C/WB19°C Outdoor : DB35°C/WB24°C Indoor air flow : High Pipe length : 5m 230V 230V...
  • Page 17 Condition Condition Indoor:DB20°C Indoor:DB 27°C WB19°C Indoor air flow: Super High Indoor air flow: Super High Pipe length:7.5m Pipe length:7.5m 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 Outdoor temp. (°C) Outdoor temp. (°C) Conditions Conditions Indoor : DB27°C/WB19°C...
  • Page 18 Indoor side noise when blowing 18&24K Heating 18&24K Cooling 09&12K Heating 09&12K Cooling Middle Super High High Compressor frequency(Hz) Indoor fan motor rotating speed...
  • Page 19 120.5 548.5 Φ55 Φ55 41.3 41.3 54.5 Φ55 Φ55 Φ70 Φ70...
  • Page 21 1000...
  • Page 22 GAS SIDE 3-WAY VALVE 4-Way valve Muffler Di s charge HEAT EXCHANGE (EVAPORATOR) Suction Accumlator COMPRESSOR HEAT EXCHANGE (CONDENSER) LIQUID SIDE Strainer Electronic Expansion Valve Strainer 2-WAY VALVE COOLING HEATING GAS SIDE 3-WAY VALVE 4-Way valve Muffler Di s charge HEAT EXCHANGE (EVAPORATOR)
  • Page 23 BN(BK) RECEIVER AND TUBE TEMP. ROOM TEMP. SENSOR SENSOR DISPLAY BOARD BU(WH) DISPLAY YEGN(GN) POWER AC-L TERMINAL BLOCK ROOM TUBE DISP1 DISP2 N(1) COM-OUT AP2 PRINTED CIRCUIT BOARD JUMP L-OUT YEGN SWING-UD YEGN EVAPORATOR STEPPING MOTOR FAN MOTOR...
  • Page 24 BN(BK) ROOM TEMP. TUBE TEMP. RECEIVER AND SENSOR SENSOR DISPLAY BOARD BU(WH) DISPLAY YEGN(GN) POWER AC-L TERMINAL BLOCK ROOM TUBE DISP1 DISP2 N(1) COM-OUT AP2 PRINTED CIRCUIT BOARD JUMP L-OUT YEGN SWING-UD PG PGF YEGN HEALTH-L HEALTH-N EVAPORATOR COLD PLASMA GENERATOR STEPPING MOTOR...
  • Page 25 POWER TUBE RECEIVER AND ROOM BU(WH) TEMP. SENSOR TEMP. SENSOR DISPLAY BOARD BN(BK) YEGN(GN) TERMINAL BLOCK ROOM DISP1 DISP2 TUBE N(1) COM-OUT MAIN BOARD AP1: YEGN JUMP AC-L L-OUT 4YEGN SWING-UD K7(K4) EVAPORATOR SWING MOTOR MOTOR RECEIVER AND POWER DISPLAY BOARD TUBE ROOM TEM.
  • Page 26 POWER RECEIVER AND TUBE ROOM BU(WH) TEMP. SENSOR TEMP. SENSOR DISPLAY BOARD BN(BK) YEGN(GN) TERMINAL BLOCK ROOM DISP1 DISP2 TUBE N(1) COM-OUT AP1: MAIN BOARD YEGN JUMP AC-L L-OUT K7(K4) 4YEGN PGF PG SWING-UD HEALTH-L HEALTH-N EVAPORATOR COLD PLASMA GENERATOR SWING MOTOR MOTOR...
  • Page 27 TUBE OUTROOM EXHAUST TEM.SENSOR TEM.SENSOR TEM.SENSOR RT1 RT2 RT3 YEGN θ θ θ LX1-1 LX1-2 AC-L2 AC-L3 N(1) AC-N1 COM-OUT AC-N AC-N2 AC-L OVC-COMP YEGN AC-L1 AC-L OFAN MID.ISOLATION SHEET ELECTRIC BOX L2 L2 NOTE: YEGN Motor ground only applies to the YEGN iron shell motor.
  • Page 33 ON/OFF Press it to start or stop operation. MODE Press it to select operation mode (AUTO/COOL/DRY/FAN/HEAT). Press it to decrease temperature setting. Press it to increase temperature setting. Press it to set fan speed. Press it to set swing angle. HEALTH SAVE Press it to turn on or off health function.

  • Page 34: Digital Display

    Up & down swing icon: is displayed when pressing the up & down swing button. Press this button again to clear the display. Left & right swing icon: is displayed when pressing the left & right swing button.Press this button again to clear the display. SET TIME display: After pressing TIMER button, ON or OFF will blink.This area will show the set time.
  • Page 35 ●In static swing condition, pressing button, the swing angle of left & right louver changes as below: ●If the unit is turned off during swing operation,the louver will stop at present position.(Optional for some models) X-FAN: Pressing X -FAN button in COOL or DRY mode,the icon "X-FAN" is displayed and the indoor fan will continue operation for 2 minutes in order to dry the indoor unit even though you have turned off the unit.After energization, X-FAN OFF is defaulted.
  • Page 36 COOL light (blue) DRY light (green) POWER LED (red) HEAT light (orange) ON/OFF Unit ON/OFF button...
  • Page 39 O(0 )
  • Page 42 O(0 )
  • Page 47 120.5 548.5 Φ55 Φ55 41.3 41.3 54.5...
  • Page 48 Burr removal 1. Completely remove all burrs from the cut cross section of pipe/tube. 2. Put the end of the copper tube/pipe in a downward direc- 18K Unit tion as you remove burrs in order to avoid dropping burrs Φ55 Φ55 into the tubing.

  • Page 49: Outside Diameter

    3.2 Connection of piping 5. Insert the connecting cable fully into the terminal block and se- cure it tightly with screws. 1. Align the center of the pipes and suffi ciently tighten the flare nut by hand. 6. Tightening torque: 1.2 N•m (0.12 kgf•m). 7.

  • Page 50: Installing Indoor Unit

    6. Installing indoor unit How to replace the drain plug and drain hose In the case of bending or curing refrigerant pipes, keep the follow- • How to remove the drain cap ing precautions in mind. Clamp drain cap with needle-nose pliers, and pull out. Abnormal sound may be generated if improper work is conducted.

  • Page 51: Air Intake

    4. Bundle the piping and drain hose together by wrapping them with vinyl tape for enough to cover where they fit into the rear piping 1. Installation of Outdoor Unit housing section. (1) Install the unit where it will not be tilted by more than Indoor unit installation 3°.

  • Page 52: Air Purge

    2. Align the center of the pipings and sufficiently tighten the fl are 5. Close the low pressure valve handle of gauge manifold. nut by hand. 6. Open fully the valve stem of the packed valves (both sides of Gas and Liquid). 7.

  • Page 53: Indoor Unit

    The screws are packed with the terminal board. 1. Check that all tubing and wiring have been properly connected. Terminal block 2. Check that the gas and liquid side service valves are fully open. 1. Gas Leak Test Check the flare nut connections for gas leaks with a gas leak Yellow-green Blue Black...
  • Page 65 AUTO HEALTH X-FAN HUMIDITY FILTER TURBO HOUR ON/OFF ON/OFF MODE X-FAN TEMP TIMER TURBO SLEEP LIGHT...
  • Page 70 AUTO HEALTH X-FAN HUMIDITY FILTER TURBO HOUR ON/OFF ON/OFF MODE X-FAN TEMP TIMER TURBO SLEEP LIGHT...
  • Page 81 9 10 11 12 13 14 15...
  • Page 83 Measure insulation resistance The breaker trips at once when it to ground to see if there is any is set to “ON”. leakage. Trip of breaker or blow of fuse The circuit or the part of the air conditioner has malfunction. They heat and break the insula- tion and lead to short circuit or The breaker trips in few minutes...
  • Page 84 Improper set of temperature Adjust set temperature If cooling (heating) load is Check the forecasted load of cooling (heating) proper Check and fill the leakage, then The refrigerant has leakage or is vacuumize it and supplement the re- insufficient frigerant as required Leakage between the high pres- Replace the compressor sure and the low pressure in-...
  • Page 85 The indoor fan motor is burned or breaks or has the heat protector Replace the fan motor or the defective part. malfunction. The built-in heat protector of the Replace the fan motor The fan does not motor breaks frequently because the run when it is set motor is abnormal.
  • Page 86 The torque of the swing motor is not enough First, check whether the connection is Wrong connection The swing fan wrong. If no, replace the parts does not run. The controller is damaged(IC2003 is damaged, the swing relay can not close, etc) C o n t r o l l e r m a l f u n c t i o n ( I C 2 0 0 3 Change controller...
  • Page 98 Test4 Test2 Test3 Test1 Test9 Tset8 Test5 Test7 Test6 Test11 Test13 Test10 Test12...
  • Page 100 Turn on the unit and wait 1 minute Use DC voltmeter to measure the voltage on the two ends of electrolytic capacitor Fault with the voltage Replace the control testing circuit on Voltage higher than 200V? panel AP1 control panel AP1 Measure the AC voltage between terminal L and N on wiring board XT(power supply)
  • Page 102 Energize and switch on Use AC voltmeter If the voltage Check the supply to measure the IPM protection between terminal L voltage and voltage between occurs after the and N on wiring machine has run for terminal L and N restore it to board XT is within a period of time?
  • Page 103 Overheat and high temperature protection Normal protection, please operate it after the outdoor ambient temp- Is outdoor ambient temperature higher than 53? erature is normalized. 20 minutes after the complete unit is powered off. Improve the heat Is heat dissipation of the indoor unit dissipation environ- and outdoor unit abnormal? ment of the unit...
  • Page 104 Power on the unit Restart it up after Is stop time of the compressor 3 minutes longer than 3 minutes? Does startup fail? Connect the wires as Are the wires for the compressor connected per the connection correctly? Is connection sequence right? diagram Replace the control panel AP1 If the fault is eliminated?
  • Page 105 Out of step occurs in Out of step occurs once the operation unit is powered on. Check if the fan terminal Is stop time of the Replace the fan Is the outdoor fan working OFAN is connected correctly compressor longer than capacitor C1 normally? 3 minutes?
  • Page 106 20 minutes after the complete unit is powered off Is the terminal FA for the Connect the electronic expansion valve wires correctly connected correctly? Resistances between the first four pins close to the terminal hole and the fifth pin are almost the same, less than 100 ohm.
  • Page 107 Start Check wiring of the reactor (L) of the outdoor unit and the PFC capacitor Replace it as per the Whether there is any wiring diagram and If the fault is eliminated? damage or reconnect the wires short-circuit? Remove the PFC capacitor and measure resistance between the two terminals.
  • Page 108 Start Did the equipment operate normally before the failure occurs? Check the wiring of the indoor and outdoor units with reference to the wiring diagram Check wiring inside of the indoor and outdoor Is the connection right? units Correctly connect the corresponding wires for The AP1 voltage Are wires broken?
  • Page 110 Turn on the unit and wait 1 minute Use DC voltmeter to measure the voltage on the two ends of electrolytic capacitor Fault with the voltage Replace the control testing circuit on Voltage higher than 200V? panel AP1 control panel AP1 Measure the AC voltage between terminal L and N on wiring board XT(power supply)
  • Page 112 Energize and switch on Use AC voltmeter Check the supply to measure the If the voltage IPM protection voltage and voltage between between terminal L and N on wiring occurs after the machine has run for restore it to terminal L and N board XT is within a period of time? on the wiring...
  • Page 113 High temperature, overload protection If the outdoor ambient temperature is higher than 53 ºC in Normal protection, please use it after improving ambient temperature cooling mode?/if the ambient temperature of indoor of indoor and outdoor unit and outdoor unit is too high? If the radiating of outdoor Improve the radiating and indoor unit is well?
  • Page 114 Energize the unit and start it If the stop time is not enough and the If the stop time of compressor high and low pressure of system is not is more than 3min? balance , please start it after 3min Improve the connection situation If the compressor wire COMP(UVW) is of control board AP1 and...
  • Page 115 Synchronism Synchronism after occurred during energize the unit operation and start it Check if the fan Replace fan If the stop time of If the outdoor fan works terminal OFAN is capacitor C1 normally? compressor is more than connected well 3min Replace Improve the radiating...
  • Page 116 After the u nit de-energized for 20min If the overload protector SAT is well connected? Under ambient temperature, test the resistance of overload protector with ohmic meter, the resistance value<10000Ω Connect the wire If the wiring terminal FA of electron well according to expansion is well connected? wiring disgram...
  • Page 117 Start If the unit is operating normally before malfunction Check connection wire of indoor and outdoor unit with circuit diagram Check if the controller connection Connection wire inside indoor and outdoor correct? electric box is loose Connect wire of indoor and outdoor unit If the connection wire according to...
  • Page 118 Start Test voltage valueof Test10 position in diagram with voltage meter Number jumping Test voltage value of Test 13 position in diagram with voltage meter Number jumping Outdoor unit malfunction Test voltage value of Test 10 position in diagram with voltage meter Number jumping Test voltage value...
  • Page 122 Steps Procedure Points 1. External features If ON/OFF button is kept pushing for 5 seconds, aforced cooling op- eration willbe carried out for approx. 15minutes. 2. Removing air filters Pull protrusions on left and right sides of panel with fingers and open front grille all the way.
  • Page 123 Steps Procedure Points 3. Remove panel Support the front panel by one hand, while remove the rotation Pull down horizontal blade axis at the upper center by the by pulling forward. other hand. And pull out the front panel forward to remove. Horizontal blade Remove horizontal blade by pulling forward.
  • Page 124 Steps Procedure Points 4. Remove electric box cover screws Remove a electric box cover mounting screw. Open electric box cover upward. electric box cover A switch for field setting is not provided in particular. screws 5. Remove front case Remove the 3 screws, in the right and the left, Screw stoppers inside the which fix the main body...
  • Page 125 Steps Procedure Points 6. Remove the vertical blade Hooks Unfasten the hooks at the upper 2 positions. A set of vertical blade has 6 fins as on ASSY. (It is impossible to replace only one fin.) The set of vertical blades is not marked for difference between right and left.
  • Page 126 Steps Procedure Points 7. Remove electrical box Disconnect the c able clamp Pay attention to the direction of the retainer of the thermistor so that the retainer will not touch the harness (same as the existing models.) Terminal board Disconnect the connection wires.
  • Page 127 Steps Procedure Points Remove fan motor Signal fan motor Signal Wire Wire Remove a screw on the electrical box. Bottom frame Pull up the electrical box forward to remove. Hook...
  • Page 128 Steps Procedure Points 8. Remove the shield plate and control PCB Hooks Unfasten the hooks at the upper 2 positions of the shield plate. Remove the electrical box according to the “Removal of Electrical Box”. shield plate (1) Unfasten the hook at the lower position, and remove the shield plate (1).
  • Page 129 Steps Procedure Points Take off wiring terminal Display PCB ASSY Remove display PCB sub-Assy. Remove swing motor. Swing motor...
  • Page 130 Steps Procedure Points The control PCB is To remove the control integrated with the power PCB, unfasten the 2 hooks at the upper part supply PCB. from the rear side. Lift up the upper part of the control PCB, and remove it.
  • Page 131 Steps Procedure Points 9. Remove the refrigerant piping CAUTION If gas leaks, repair the spot of Lift the indoor unit by a leaking, then collect all wooden base. refrigerant from the unit. After conducting vacuum drying, recharge proper amount of refrigerant.
  • Page 132 Steps Procedure Points 10. Remove evaporator assy When the pipings are disconnected, protect the Remove the indoor unit both openings from entering from the installation moisture. plate. Liquid piping Gas piping Auxiliary piping Piping fixture Release the hook of the piping fixture on the back of the unit.
  • Page 133 Steps Procedure Points Loosen the 2 screws, in the right and the left, which fix the evaporator assy. Auxiliary piping Widen the auxiliary piping to the extent of 10°~20°. evaporator Pull the evaporator assy to the front side to undo the hooks completely, and then lift it.
  • Page 134 Steps Procedure Points 11. Remove cross flow fan and fan motor Remove cross flow fan and fan motor. Bearing Remove the rubber cushion of the bearing. Remove the screws at the joint of the cross flow blade and the motor.
  • Page 135 Steps Procedure Points Take down the motor sub-assy. Remove fan motor.
  • Page 136 Steps Procedure 1.Remove big handle Before disassamble． Remove 1 connection screw fixing big handleand then removethe big handle. big handle 2. Remove top cover top cover Remove 3 connection screws among top cover plate, front panel and right sideplate. Then remove top cover plate.
  • Page 137 3.Remove grille and front panel Remove connection screws between the front grille and the front panel. Then remove the front grille. Remove connection screws connecting the front panel with the chassis and the motor support, and then remove the front panel. Grille Panel 4.Remove axial flow blade...
  • Page 138 6.Remove electric box assy Electric box assy Remove the 2 screws fixing the cover of elec- tric box. Lift to remove the cover. Loosen the wire and disconnect the terminal. Lift to re- move the electric box assy. 7.Remove 4-way valve assy Unscrew the fastening nut of the 4-way Valve 4-way Valve Assy Assy coil and remove the coil.
  • Page 139 9.Remove motor and motor support Motor support Remove the 4 tapping screws fixing the motor. Pull out the lead-out wire and remove the Motor motor. Remove the 2 tapping screws fixing the motor support. Lift motor support to re- move it. 10.Remove clapboard sub-assy Clapboard Sub-Assy Loosen the screws of the Clapboard Sub-Assy .
  • Page 140 11.Remove Compressor Remove the 2 screws fixing the gas valve. Unsolder the welding spot connecting gas valve and air return pipe and remove the gas valve. (Note: it is necessary to warp the gas valve when unsoldering the welding spot.) Remove the 2 Liquid valve screws fixing liquid valve.
  • Page 141 Steps Procedure 1. Remove top panel Twist off the screws used for fixing the handle and v alve cover , pull the handle and v alve cover up ward to remove it. handle valve top panel Remove the 3 screws connecting the top panel with the front panel and the right side plate, and then remove the top panel.
  • Page 142 Remove the 5 screws connecting the panel with the chassis and the motor support, and then remove the panel. Remove the 6 screws connecing the left side plate and right side plate and then remove rear grill rear grill panel 3.
  • Page 143 4. Remove fan motor axial flow blade Remove the nuts fixing the blade and then remove the axial flow blade. motor support Remove the 4 tappin g screw s fixing the motor; disconnect the leading wire insert of the motor and then remove the moto r. Remove the 2 tappin g scre ws fixing the motor support and then pull the motor support up wa rds to remove it.
  • Page 144 6.Remove soundproof sponge Since the piping ports on the soundproof sponge are torn easily, remove the soundproof sponge carefully soundproof sponge 7. Remove Isolation sheet Remove the 3 screws fixing the isolation sheet and then remove the Isolation sheet. Isolation sheet 8.
  • Page 145 9. Remov e compressor Remove the 3 foot nuts fixing the compressor and then remove the compressor. compressor 10.Remove condenser sub-assy capillary sub-assy support Remove the screws connecting the support (condenser) and condenser assy,and then remove the support(condenser). condenser sub-assy Remove the chassis sub-assy and condenser sub-assy.
  • Page 146 condenser sub-assy Dissemble the chassis sub-assy and condenser sub-assy. chassis sub-assy...
  • Page 147 Steps Procedure 1. Remove top panel handle and Twist off the screws used for fixing the handle and v alve cover , pull the handle and v alve cover up ward to remove it. valve cover top panel Remove the 3 screws connecting the top panel with the front panel and the right side plate, and then remove the top panel.
  • Page 148 Remove the 5 screws connecting the panel with the chassis and the motor support, and then remove the panel. panel 3. Remove right side plate and left side plate right side plate Remove the scre ws connecting the right side plate with the chassis, the valve support and the electric box, and then remove the right side plate assy .
  • Page 149 4. Remove fan motor and axial flow blade axial flow blade Remove the nuts fixing the blade and then remove the axial flow blade. fan motor fixing frame Remove the 4 tapping screws fixing the motor; disconnect the leading wire insert of the motor and then remove the motor.
  • Page 150 4-way valv e assy 6.Remove soundproof sponge and Since the piping ports on the soundproof sponge are torn easily, remove the soundproof sponge carefully 4-way valv e assy Discharge the refrigerant completely;unsolder the pipelines connecting the compressor and the condenser assy,and then remove the 4-way valve assy.

  • Page 151: Cut Off Valve

    8. Remov e Cut off Valve and Valve Support Remove the 2 bolts fixing the valve subassemblies. Unsolder the welding joint connecting the gas valve and the return air pipe. Remove the gas valve. (Note: When unsoldering the soldering joint, wrap the gas valve with wet cloth completely to avoid damage to the valve caused by high temperature.) Unsolder the welding joint connecting the liquid valve...
  • Page 152 condenser sub-assy 11.Remove condenser sub-assy Remove the chassis sub-assy and condenser sub-assy. chassis sub-assy...

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