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Weltem WPC-3000P Service Manual

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Portable Air Conditioners
SERVICE MANUAL
WPC-3000P, WPC-4000P, WPC-5000P

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Summary of Contents for Weltem WPC-3000P

  • Page 1 Portable Air Conditioners SERVICE MANUAL WPC-3000P, WPC-4000P, WPC-5000P...
  • Page 2 WPC-3000P / WPC-4000P / WPC-5000P Service Manual Table of Contents GENERAL DESCRIPTION................4 General air conditioning system Portable air conditioning system SPECIFICATIONS....................5 Exterior Dimension Diagram Technical Specifications CONSTRUCTION....................7 Internal Structure REFRIGERANT SYSTEM CONSTRUCTION............10 Compressor Compressor lubrication Condenser Capillary Tube Evaporator Accumulator ELECTRICAL SYSTEM..................15...
  • Page 3 WPC-3000P / WPC-4000P / WPC-5000P Service Manual ASSEMBLY.....................31 Component parts General Safety Information Troubleshooting chart DISASSEMBLY....................35 Disassembly Control panel removal Electrical parts and relay board removal Fan motor removal REFRGERANT SYSTEM REPAIR...............44 Brazing Charging the System with R-410A Refrigerant Connection of gauge manifold...
  • Page 4 2) The WPC-3000P,WPC-4000P,WPC-5000P have Cooling Air the following features. 3) The innovative design of the WPC-3000P, WPC-4000P,WPC-5000P has resulted in one compact unit, replacing the need for two separate units. 4) With the whole cooling system built into...
  • Page 5 WPC-3000P / WPC-4000P / WPC-5000P Service Manual SPECIFICATIONS Exterior Dimension Diagram WPC-3000P, 4000P, 5000P mm(Inch) 113.559 158.2 ( 4.4708 ) ( 6.228 ) 672.309 ( 26.468 ) 88.5 ( 3.48 ) 343 ( 13.5039 ) 520 ( 20.4724 ) page 5...
  • Page 6 WPC-3000P / WPC-4000P / WPC-5000P Service Manual Technical Specifications Specifications Unit WPC-3000P WPC-4000P WPC-5000P Cooling Capacity Btu/h 13,200 16,800 21,200 Phase Single Single Single Power Supply Volts 220V Hertz Power Consumption Watts 1,058 1,740 2,200 Rated Current Amps 15.8 10.9 Btu/Wh 11.0...
  • Page 7 WPC-3000P / WPC-4000P / WPC-5000P Service Manual CONSTRUCTION Internal Structure WPC-3000P Cowl Top Front Cover Cond Scroll B Cond Scroll A Display Case Cover Top Base Cover Duct Base Nozzle Ass'Y Cond Motor BKT Cond Fan Display Motor Display Case...
  • Page 8 WPC-3000P / WPC-4000P / WPC-5000P Service Manual CONSTRUCTION Internal Structure WPC- 4000P Cowl Top Base Cover Cond Scroll A Top Front Cover Cond Scroll B Duct Base Display Nozzle Ass'Y Case Cover Display Cond Motor BKT Cond Fan Display Case...
  • Page 9 WPC-3000P / WPC-4000P / WPC-5000P Service Manual CONSTRUCTION Internal Structure WPC- 5000P Cowl Top Base Cover Cond Scroll B Cond Scroll A Top Front Cover Duct Base Nozzle Ass'Y Display Case Cond Motor BKT Cover Cond Fan Display PCB Motor...
  • Page 10 WPC-3000P / WPC-4000P / WPC-5000P Service Manual REFRIGERANT SYSTEM CONSTRUCTION Condenser Accumulator Evaporator Capillary tube Compressor Drier 10 page...
  • Page 11 WPC-3000P / WPC-4000P / WPC-5000P Service Manual Compressor The construction of a rotary type compressor is divided into two mechanisms; the drive mechanism (compressor motor), and the compression mechanism (compres- sor). When the rotor shaft of the motor (drive mechanism) turns, the roller (com- pression mechanism) rotates to compress the refrigerant.
  • Page 12 WPC-3000P / WPC-4000P / WPC-5000P Service Manual Compressor operation Discharge 1) Start of compression Blade Valve 1) The cylinder is filled with low pressure gas. 2) Since pressure in the discharge chamber is higher than in the cylinder, the dis- charge valve is kept closed.
  • Page 13 WPC-3000P / WPC-4000P / WPC-5000P Service Manual Compressor lubrication The lubrication system is comprised of a hollow shaft, an oil scraper mounted at the end face, hollow shaft, a shaft journal (shaft bearing), and the lubrication groove for the shaft journal.
  • Page 14 WPC-3000P / WPC-4000P / WPC-5000P Service Manual Capillary Tube The capillary tube is a long thin tube that utilizes line flow resistance as an expansion valve. The length and the inner diameter of the capillary tube are determined according to the...
  • Page 15 WPC-3000P / WPC-4000P / WPC-5000P Service Manual ELECTRICAL SYSTEM Circuit Diagram WPC-3000P,5000P WPC-3/4/5MP FC-S2.0 FLOAT SWITCH Power Remote Control (Option) DRAIN PUMP TIMER DOWN (Option) BLOWER COOL POWER PRESSURE HIGH SWITCH PRESSURE (Option) SWITCH (HP) (LP) OUT_TEMP SENSOR ICE_TEMP SENSOR...
  • Page 16 WPC-3000P / WPC-4000P / WPC-5000P Service Manual WPC-4000P WPC-4MP FC-S2.0 Power Remote FLOAT Control (Option) SWITCH DRAIN PUMP (Option) HIGH PRESSURE PRESSURE SWITCH TIMER DOWN (Option) SWITCH BLOWER COOL POWER (HP) (LP) OUT_TEMP SENSOR ICE_TEMP SENSOR IN_TEMP SENSOR (FUSE) MOTOR...
  • Page 17 WPC-3000P / WPC-4000P / WPC-5000P Service Manual Operation CONTROL PANEL · Press the power button for 2 seconds to activate the product. · Press the power button for 2 seconds while driving to stop the product. · Self-diagnosis will be performed to test for abnormalities, after marking “VER”...
  • Page 18 WPC-3000P / WPC-4000P / WPC-5000P Service Manual 1) Cooling mode · The basic operation is based on “out” control. (discharge temperature TH1) · On/off the operation of the compressor. (COOL ↔ BLOWER) · The set temperature cannot be changed and it operates which is set to 0 degrees Celsius.
  • Page 19 WPC-3000P / WPC-4000P / WPC-5000P Service Manual 1) It is a mode that prevents the operation of the rest of the buttons except for power. · It can be operated and released by pressing for 2 seconds. ← ← Example of...
  • Page 20 WPC-3000P / WPC-4000P / WPC-5000P Service Manual Program Setting Temperature Se�ng Program Se�ng (Auto save when no se�ng is made in each mode) Keep pressing more than 2 seconds Temperature dependence Delay �me Change Change Change ℉ Target Temperature Devia�on How to save the se�ng...
  • Page 21 DC and used for relay coil activation. The 12 V (DC) power is sent to the control panel assembly. 1) Power supply requirements The WPC-3000P, WPC-4000P requires a single-phase 115 V, 60 Hz power supply. The WPC-5000P require a single-phase 208/230 V, 60 Hz power supply. 2) Relay board fuse The relay board fuse is the only serviceable component on the relay board assem- bly.
  • Page 22 WPC-3000P / WPC-4000P / WPC-5000P Service Manual 3) Input Signal The relay board receives inputs from the control panel, sensors, and external devices to perform device control. Control Panel Input Symbol Indication Function Connector If POWER BUTTON is pressed during operation, unit ON/OFF Button stops.
  • Page 23 WPC-3000P / WPC-4000P / WPC-5000P Service Manual Control Specifications 1) EVAPORATOR FAN MOTOR • When the BLOWER button is pressed, the RL1/3 (fan motor HI/LOW) relay on the relay board turns on, operating the fan. Specifications: - RL1/3 (Fan motor HI-LOW) relay output: 10 A at AC 250 V 2) Compressor start control •...
  • Page 24 WPC-3000P / WPC-4000P / WPC-5000P Service Manual 4) Compressor time delay control (compressor protection) Compressor protection consists of a time delay program within the microproces- sor. This program prevents a heavy load from being applied to the compressor motor when restarting the unit (room/cool mode or spot/cool mode) after a very short period of time.
  • Page 25 WPC-3000P / WPC-4000P / WPC-5000P Service Manual Self-Diagnostic Codes Self-diagnostic codes are displayed on the Display Panel under the following conditions. SELF-DIAGNOSTIC ALARM CODES Alarm Display Problem Cause Corrective Action • Do not use the air • Ambient tempera- conditioner if ambi-...
  • Page 26 WPC-3000P / WPC-4000P / WPC-5000P Service Manual SELF-DIAGNOSTIC ALARM CODES Alarm Display Problem Cause Corrective Action TH1(Outlet) Abnormal temper- temperature sen- Contact a qualified ature sensor value sor has a loose or service agent broken connection TH2(Inlet) Abnormal temper- temperature sen-...
  • Page 27 WPC-3000P / WPC-4000P / WPC-5000P Service Manual Compressor 1) Compressor motor • The compressor motor is a single-phase motor and is contained within the same housing as the compressor. Specifications: Rated Voltage CAPACITY WPC-3000P 115V 3280W ±5% WPC-4000P 115V 4170W ±5%...
  • Page 28 WPC-3000P / WPC-4000P / WPC-5000P Service Manual Fan Motor • The fan motor is a single phase, induction type. The motor rotates the fan on both the evapora- tor side and the condenser side at the same time. • The following table shows the specifications of the fan motor used for each model.
  • Page 29 WPC-3000P / WPC-4000P / WPC-5000P Service Manual Temperature Sensor • Outlet temp sensor (TH1) is installed on top of the evaporator, and detects evaporator outlet temperature as a resistance value. • Inlet temp sensor (TH2) is installed in front of evapo- rator, and detects evaporator inlet temperature as a resistance value.
  • Page 30 WPC-3000P / WPC-4000P / WPC-5000P Service Manual Drain Tank Switch • The drain switch acti vates and stop the operati on of compressor motor and fan motor when approximately 3.17 gal (12 L) of drain water accumulates in the drain tank. At the same ti me, control panel display “FT”, and compressor and fan operati ons stop.
  • Page 31 WPC-3000P / WPC-4000P / WPC-5000P Service Manual ASSEMBLY Component parts Cool air outlet hose Top fan exhaust fl ange Display / Control board Evaporater / fi lter Condenser / fi lter tank Guide bar for condensate water Electrical access panel...
  • Page 32 WPC-3000P / WPC-4000P / WPC-5000P Service Manual General Safety Information Please read this manual carefully for instructions on correct installation and usage. Please read all safeguards. 1. Transport and store the unit in an upright position only. Leave unit in an upright position for at least 3 hours before first use.
  • Page 33 WPC-3000P / WPC-4000P / WPC-5000P Service Manual 17. AVOID the use of adapter plugs or extension cords. If it is necessary to use an extension cord or an adapter plug to operate the unit, ensure that they are correctly rated for the application. Consult a local qualified electrician and all local electrical codes to ensure proper setup.
  • Page 34 WPC-3000P / WPC-4000P / WPC-5000P Service Manual Troubleshooting chart Symptom Possible Cause(s) Corrective Action 1. Remove blockage from drain hose High water level in conden- Water leakage 2. Remove any object stuck sate tank undeerneath of the black panel nuder the water tank 1.
  • Page 35 WPC-3000P / WPC-4000P / WPC-5000P Service Manual DISASSEMBLY Disassembly 1) Unplug the product before disassembly (For Safety) Cooling Air Duct 2) Turn the cooling air ducts to remove them. 3) Remove two (2) support lines and remove front panel. Front Cover...
  • Page 36 Front Cover WPC-3000P / WPC-4000P / WPC-5000P Service Manual Cond Filter Water Tank 6) Take out the twelve (12) screws, Back Cover and then remove the back cover panel. Screws (4) Cooling Air Duct LF Cover Screws (12) 7) Take out the six (6) screws,...
  • Page 37 Screws (15) Top Base Cover WPC-3000P / WPC-4000P / WPC-5000P Service Manual Top Front Cover 9) Unfasten the connector from the Control panel control panel and then remove the front panel. Screws (4) Cond Filter Water Tank Connector Control panel 10) Take out the two (2) screws.
  • Page 38 WPC-3000P / WPC-4000P / WPC-5000P Service Manual Control Panel Removal 1) Take out the four (4) screws, and then remove the control panel. Control panel Connector TOP COVER - DISPLAY 분리 38 page...
  • Page 39 WPC-3000P / WPC-4000P / WPC-5000P Service Manual Electrical parts and relay board removal WPC-3000P / 5000P TH-3 TH-1 HP(PS) TH-2 Data cable connector Capacitor for 16 17 Motor L - 1A N - 1A Capacitor for Compressor 16 17 25 26 27 28 29 30...
  • Page 40 WPC-3000P / WPC-4000P / WPC-5000P Service Manual Electrical parts and relay board removal WPC-4000P TH-3 TH-1 HP(PS) TH-2 Data cable connector Capacitor for Motor L - 1A N - 1A Capacitor for Compressor 16 17 25 26 27 28 29 30...
  • Page 41 WPC-3000P / WPC-4000P / WPC-5000P Service Manual WPC-3000P/5000P Control Box Capacitor for Motor Capacitor for Compressor Terminal Block page 41...
  • Page 42 WPC-3000P / WPC-4000P / WPC-5000P Service Manual WPC-4000P Control Box Capacitor for Motor Capacitor for Compressor Terminal Block 42 page...
  • Page 43 WPC-3000P / WPC-4000P / WPC-5000P Service Manual Fan Motor Removal 1) Bell mouse Eva Top Cover 2) Condenser Fan 6) Fan Motor 5) Evaporator Fan 3) Housing for Condenser Fan 4) Motor Bracket on Plate Housing for Evaporator Fan 1) Take off the four (4) bolts , and then remove the bell mouse.
  • Page 44 WPC-3000P / WPC-4000P / WPC-5000P Service Manual REFRIGERANT SYSTEM REPAIR Brazing • In the event of a leak, obstruction, or trouble in the refrigerant system of the unit, replace or repair the defective component. After replacing defective component, braze all connections.
  • Page 45 WPC-3000P / WPC-4000P / WPC-5000P Service Manual 3) Cleaning brazing filler metal and piping • When the refrigerant system has been opened, exposure to heat may cause the brazing filler metal to stick to the inside and outside of the piping. Brazing filler metal may also combine with oxygen in the air to form an oxide film.
  • Page 46 WPC-3000P / WPC-4000P / WPC-5000P Service Manual Charging the System with R-410A Refrigerant • Always ensure that the refrigerant system has been properly evacuated before charging with the specified amount of R-410A. • Equipments is only for R-410A. • Liquid charge (no gas charge).
  • Page 47 WPC-3000P / WPC-4000P / WPC-5000P Service Manual Connection of gauge manifold 1) Properly remove the crushed end of the pinch-off tube at the high pressure side and Charging Hose Side the low pressure side of the refrigerant cycle Refrigerant with a pipe cutter.
  • Page 48 WPC-3000P / WPC-4000P / WPC-5000P Service Manual Refrigerant Charging Work (1)Refrigerant charging 1) Remove the charging hose from the vacuum pump, and connect it to the refrigerant cyl- Valve Setting Specified Amount inder (R-410A). of Refrigerant Open Closed Closed Closed...
  • Page 49 WPC-3000P / WPC-4000P / WPC-5000P Service Manual WARNING •Do not attempt any repair on a charged system. WARNING • Before checking for gas leaks, fully confirm that there is nothing flammable in the area to cause an explosion or fire. Contact of refrigerant with an open fire generates toxic gas.
  • Page 50 154, Jayumuyeok 3-gil, Masanhoewon-gu, Changwon-City, Gyeongsangnam-do, 51340 Korea TEL: +82-55-294-9200(ext.2) FAX: +82-55-294-9220 http://www.weltem.com...

This manual is also suitable for:

Wpc-4000pWpc-5000p