Gree Rooftop Packaged Service Manual

Product

1 Models List

Above pictures may be different from actual model. 1 Ton = 12000 Btu/h = 3.517 kW.

2 Nomenclature

3 Feature

4 Product Data

4.1 Operation Range

4.2 Electrical Data

5 Piping Diagram

A conceptual diagram illustrating the refrigerant piping connections for the unit.

Control

1 Operation Flowchart

1.1 Cooling Operation

The cooling operation follows these steps: Power on -> Cooling mode startup -> Indoor fan starts up. If the indoor temperature is higher than the set temperature, the outdoor fan and compressor start up. If the indoor temperature is lower than the set temperature, the outdoor fan and compressor stop. If the compressor stop time exceeds 3 minutes, the compressor remains stopped.

1.2 Heating Operation

The heating operation follows these steps: Power on -> Heating mode startup. If the indoor temperature is lower than the set temperature, the outdoor fan and compressor start up, followed by anti-cold wind control (when compressor starts) and indoor fan startup. If the indoor temperature is higher than the set temperature, the outdoor fan and compressor stop, and the indoor fan blows residual heat. If the compressor stop time exceeds 3 minutes, the indoor fan stops.

2 Wired Controller

2.1 Display View

The wired controller features an LCD display showing status icons, fan speed, swing status, button prompts, temperature, operating mode, and clock/project number. The status column displays various icons indicating functions like air status, filter clean reminder, child lock, error status, defrosting, power off memory, absence, quiet status, energy-saving, sleep, timer status, group control, and WiFi status.

When wired controller is connected with different indoor units, some functions will be different.

When wired controller is connected with different indoor units, some functions will be different.

2.2 Operation View

The wired controller has buttons for FAN speed adjustment (auto, low, medium-low, medium, medium-high, high), temperature setting/cursor movement/parameter setting, ON/OFF/back, page turning/cursor movement/parameter setting, MODE selection (Auto, Cool, Dry, Fan, Heat), MENU/OK for mode selection and parameter confirmation, and SWING for swing status adjustment.

3 Installation of Wired Controller

3.1 Standard Accessories

Diagrams show the dimensions of the wired controller and its parts.

3.2 Installation Position and Requirement

• It is not allowed to install the wired controller in wet places.
• It is not allowed to install the wired controller in places with direct sunlight.
• It is not allowed to install the wired controller near high-temperature objects or places likely to be spattered with water.

3.3 Installation of Wired Controller

Installation involves selecting the correct 2-core signal wire (0.75mm², length < 30m, recommended 8m). Before installation, cut off power. Thread the wire through the installation hole and the back of the soleplate. Fix the soleplate to the wall using screws. Connect the 2-core twisted pair to wiring terminals "H1" and "H2", then tighten. Arrange wires in the back of the panel and buckle the panel onto the soleplate.

A diagram illustrates the installation steps.

3.4 Removal of Wired Controller

A diagram shows the procedure for removing the wired controller.

4 Operation Instruction

4.1 ON/OFF

Press the power button to turn the air conditioner on or off. "ON" and "OFF" interfaces are displayed.

4.2 Mode Setting

Pressing the "MODE" button cycles through available operating modes (e.g., Auto, Cool, Dry, Fan, Heat). Available modes may differ by model. In Auto mode, icons indicate whether the unit is cooling or heating.

4.3 Temperature Setting

Use the temperature up/down buttons to adjust the set temperature by 0.5/1 degree increments. Holding the buttons adjusts the temperature every 0.3 seconds. Temperature setting adjustment in Auto mode is only available for packaged unit indoor units.

4.4 Fan Setting

Pressing the "FAN" button cycles through fan speeds: auto, low, medium-low, medium, medium-high, and high. Fan speed is fixed at low in Dry mode. In Auto fan speed, the unit adjusts speed based on room temperature for stability and comfort.

4.5 Function Setting

Access the "Function" menu from the homepage to turn functions ON or OFF. Some functions allow detailed parameter settings. Functions not applicable in certain circumstances are displayed in grey and can be skipped.

4.5.1 Turbo Setting

Turbo fan function activates the highest fan speed, indicated by "turbo fan" on the homepage. It can be turned ON/OFF via the function page or cancelled by pressing the "FAN" button on the homepage, reverting to auto fan speed.

4.5.2 Save Setting

The Save function allows operation within a narrow temperature range for energy saving. It can be turned ON/OFF from the function page. Detailed temperature limits for Cooling/Dry (minimum) and Heating (maximum) can be set. When the set temperature exceeds these limits, an icon blinks and a buzzer sounds.

4.5.3 Filter Clean Reminder Setting

This function tracks operating time and reminds users to clean the filter. Users can enable/disable the reminder, set environmental cleanliness level (1-3, indicating good, general, or bad cleanliness), and adjust the cleaning period (e.g., 5500h-10000h for light pollution). When the cleaning time is reached, a filter icon appears, and a reminder pops up on the homepage. A "Done" or "Skip" action resets the timer.

4.6 Universal Setting

The "Set" page allows configuration of various settings:

4.6.1 Time Format Setting

Users can select between 12-hour or 24-hour time formats.

4.6.2 System Time Setting

The system clock (hour, minute, year, month, day) can be set by navigating to the "Clock" item and using the adjustment buttons.

4.6.3 Temperature Setting Precision

Users can choose temperature precision settings of 0.5 or 1 degree.

4.6.4 Temperature Unit Setting

The temperature unit can be set to Celsius (°C) or Fahrenheit (°F).

4.6.5 Display Language Setting

Users can select the display language from a list of available options.

4.7 Timer Setting

The wired controller supports daily, weekly, two-week, and timer-off settings. Timer periods can be enabled, and settings include time, ON/OFF status, working mode, set temperature, and fan speed.

4.7.1 Daily Timer Setting

Allows setting up to four independent daily timer periods with specific operational parameters.

4.7.2 Weekly Timer Setting

Enables setting timers for each day of the week, with up to four periods per day, operating on a weekly cycle.

4.7.3 Two-week Timer Setting

Allows setting timers for each day over a two-week period, operating on a two-week cycle.

4.7.4 Timer OFF Setting

The unit can be set to turn off automatically after a specified number of hours (adjustable in 0.5-hour increments). The time is displayed in 12-hour format.

5 Error Display

When an error occurs, the wired controller's temperature display zone shows an error code. Multiple errors are displayed sequentially. If an error occurs, turn off the unit and contact a professional for repair. For example, E1 indicates system high pressure protection.

5.1 Table of Codes of Unit

Installation

1 Units Install

1.1 Installation Positions

To ensure proper function, the unit must be installed according to these principles:

• Install where outdoor fan discharge air does not return and sufficient space for repair is provided.
• The site must have good ventilation for adequate air intake and exhaust.
• The installation site must be strong enough to support the unit's weight, insulate noise, and prevent vibration. Ensure wind and noise do not affect neighbors.
• Avoid direct sunlight on the unit; a sun shield is recommended.
• The site must allow for drainage of rainwater and defrosting water.
• Ensure the unit is not influenced by rubbish or oil fog.
• The air exhaust outlet should not face strong wind.
• The unit must be fixed on a stable and solid floor surface.

1.2 Matters Need Attention

1.2.1 Lifting Method

Do not remove package materials before installation. Keep the unit upright and do not drop it. Rig the unit using lifting holes in the base rails. Place the unit on the roof curb, maintaining a 1/4 inch (6.4mm) clearance between the roof curb and the base rail inside. Remove rigging skids and package materials after positioning. Spreader bars are required to prevent rigging straps from damaging the unit. All panels must be in place during rigging. The height between the top of the unit and rigging cable connection points should be 36-54 inches (914-1371mm).

1.2.2 Installation Pedestal

The unit must be placed on a horizontal, rigid pedestal, preferably concrete. The pedestal's height dimension must be sufficient for drainpipe installation. The unit must be fixed to the pedestal with bolts. The pedestal location must support the unit's weight to prevent overturning or falling in extreme conditions like earthquakes or typhoons. Diagrams show installation hole sizes for different models.

The diagrams may be different from the actual model. The diagram is for a pedestal made of concrete. The high dimension of the pedestal must be enough to install the drainpipe.

1.2.3 Duct work

Duct design and installation must conform to local engineering criteria, limiting restrictions and maintaining suitable air velocity. Air supply and intake ducts should be insulated to prevent thermal leakage and condensation. Ducts must be fixed by prefabricated boards of the ceiling using iron supports. Duct joints must be sealed to prevent leakage. The edge of the air intake duct must be at least 150mm away from the wall. Silencing and shock absorption should be considered, with noise sources kept away from occupied areas. The air intake should not be located above areas where people stay. The return air duct should not terminate in areas that can introduce toxic or objectionable fumes. Each installation requires a return air filter, either at the unit or externally. Building conditions and maintenance convenience should guide installation methods.

1.3 Dimension

1.3.1 Dimension of Units

Tables provide detailed dimensions (in inches and mm) for models GK-H02TC/NhA-D(U), GK-H03TC/NhA-D(U) and GK-H04TC/NhA-D(U), GK-H05TC/NhA-D(U), including overall dimensions, air supply/return sizes for side and bottom vents.

Above diagrams may be different from actual model.

1.3.2 Installation Clearance Data

Above diagrams may be different from actual mode.

2 Drain Piping Work

2.1 Installation Procedure

After unit installation, check its levelness. Condensate outlets are blocked by rubber plugs from the factory and must be removed. Condensate removal is done by attaching a PVC pipe to the drain pan, terminated according to local codes. The indoor coil condensate drain ends with a threaded 3/4" (NPT) or 1-1/5" stub tube. A trap must be installed for proper drainage and to prevent debris intake.

2.2 Matters of Attention

The condensate pipe should be installed with an inclining angle of 5-10° for drainage. As the unit operates under negative pressure, a backwater elbow is required. The requirement for the elbow is A = BP/10 + 20 (mm), where P is the absolute pressure inside the unit in Pascals. After electrical installation, test the drainage system.

Above diagrams may be different from actual mode.

Drain connection size: 3/4" (NPT).

3 Electric Wiring Work

3.1 Wiring Principle

3.1.1 Precautions

• Before connecting lines, read the unit nameplate for voltage, circuit ampacity, and capacity information. Connect lines according to the schematic diagram.
• The unit requires a special power supply line with an electricity leakage switch and air switch for overload conditions. Test the leakage switch monthly.
• The unit must be grounded to prevent hazards from insulation failure.
• Lay out power cords through cable troughs or wiring pipes. Connect power cords into the electric box through cable-cross loops to prevent scratches from sheet metal edges.
• Maintain a distance of over 150mm between power lines and low voltage connections.
• All line connections must conform to the schematic diagram; incorrect connections can cause abnormal operation or damage.
• Ensure no cable contacts refrigerant pipes, the compressor, or moving parts like the fan.
• Do not change internal line connections. The manufacturer is not liable for losses from wrong connections.
• If the supply cord is damaged, it must be replaced by the manufacturer, service agent, or a qualified person to avoid hazards.
• All supplied components, materials, and electrical operations must comply with local principles.

3.1.2 Connect Wiring to the Terminals

CAUTIONS: Check power supply voltage against the nameplate. Ensure power supply capacity is sufficient. Circuit installation must be done by a professional technician. Fixed circuits require an electricity leakage protection switch and an air switch with at least 3mm electrode contact space. For single wire connection, peel 25mm of insulation, remove the terminal screw, bend the wire into a circle, and fix it to the terminal board. For stranded wires, peel 10mm of insulation, remove the terminal screw, clamp a round terminal onto the wires, and fix it to the terminal board.

Diagrams show wire stripping and terminal connection methods.

3.1.3 Electrical Connections-supply Voltage:

For single-phase power supply units: Remove the electric box cover, pass the cable through the rubber ring, connect the power supply cable to terminals and the grounding screw, and use a cable fastener to secure the cable. For Low Voltage Connections: Use copper conductors for low voltage wiring. The communication line wire size should be no less than 0.75mm². Remove the electric box cover, pass the signal cable through the rubber ring, connect the signal cable to "H1", "H2" terminals, and secure the cable with a fastener.

CAUTIONS: Take care during connections to avoid malfunction due to electromagnetic interference. The signal line must be separated from the power line. If the unit is in an area prone to electromagnetic interference, use shielded or double-twisted cable for the signal line.

3.2 Electric Wiring Design

Diagrams illustrate the electrical wiring for units without and with electric heaters, including specific diagrams for models with LYQ-08-F and LYQ-08-G, LYQ-08-H.

Maintenance

1 Flow Chart of Troubleshooting

1.1 Troubleshooting Flow Chart of Main Control Malfunction

• E1 System High Pressure Protection: Check if the high pressure switch wiring is correct and if the switch works normally. Verify outdoor and indoor ambient temperatures are within the normal range. If issues persist, replace the main board.
• E2 Freeze Protection: This is a normal protection. If it occurs frequently, check for filth blockage in the indoor filter or abnormal indoor air outlet. Clean the filter and check air outlet/return pipes.
• E3 Refrigerant Lacking Protection or System Low Pressure Protection: Check if the system low pressure is lower than 0.05MPa. Charge refrigerant as required. If the issue persists, check for pipeline leakage, weld repairs, and recharge. Verify low pressure switch and its wiring are normal. If all else fails, replace the main control board.
• E4 Discharge Protection: Check the discharge temperature sensor and its wiring. If the temperature around the sensor exceeds 115°C, check for pipeline leakage, weld repairs, and recharge. If the sensor is faulty, replace it. If the issue persists, replace the discharge temperature sensor or the main control board.
• Temperature Sensor Errors (A5, A7, b2, b3, b4, C1, C6, CA, Cb, F3, FJ): Check if the temperature sensor on the mainboard is correctly inserted. Disconnect the sensor and measure its resistance for normality. Replace the temperature sensor if faulty. If the sensor is fine, replace the mainboard.
• Pressure Sensor Errors (e1, e3): Check for loose or dirty interfaces between the mainboard and the sensor. Ensure proper contact between the pressure sensor and the pressure detection point. If the problem is resolved after replacing the sensor, the original sensor was faulty. Otherwise, the detection circuit or main board may be improper.
• EA Refrigerant Leakage: If the refrigerant sensor detects a leak, the unit displays "EA", sounds an alarm, forces the indoor fan ON, and stops the outdoor unit. Troubleshooting involves finding and repairing leaks in piping or heat exchangers, then re-evacuating and recharging refrigerant.
• FE Malfunction of Refrigerant Sensor: If the refrigerant sensor fails or reaches the end of its 15-year lifespan, the unit displays "FE", sounds an alarm, forces the indoor fan ON, and stops the outdoor unit. Check sensor wiring; if unresolved, replace the sensor.
• E0 Indoor Fan Error: Check if the indoor fan speed is too slow, stopped, or if the protection signal is abnormal. Verify control line connections to the mainboard. Replace the indoor fan if the error persists after connection checks. If the error continues, replace the mainboard.

1.2 Troubleshooting Flow Chart of Drive Malfunction

• P0 Drive Module Reset: Indicates reset protection for the compressor drive board. If the problem persists after power cycling multiple times, the compressor drive board likely operates improperly and needs replacement.
• P7 Module Temperature Sensor Circuit Error: Indicates an abnormal temperature sensor on the compressor drive board. If the issue persists after power cycling, the compressor drive board needs replacement.
• PH High Voltage Protection of DC Bus: Triggered when input voltage exceeds 110%. Check if the unit's input voltage exceeds the limit and adjust to rated voltage. If the voltage is normal, the compressor drive board may be operating improperly and needs replacement.
• PL Low Voltage Protection of DC Bus: Triggered when input voltage falls below 90%. Check if the unit's input voltage is below the limit and adjust to rated voltage. If the voltage is normal, the compressor drive board may be operating improperly and needs replacement.
• P6 Drive Board Communication Error: Occurs when the unit fails to detect the inverter compressor driver for 30 seconds. Check communication cable connections between the mainboard and the driver. If connections are proper, check if the compressor drive board is normal; if not, replace it. If the drive board is normal, the mainboard may be abnormal and needs replacement.
• Lc Compressor Startup Failure: Indicates inverter compressor startup failure. Check U, V, W phase connections of the compressor. Verify resistance between compressor windings and grounding insulation. If these are normal, the compressor drive board may be operating improperly and needs replacement. If the compressor itself is damaged (indicated by other simultaneous faults like H7 or P5), it should be replaced.
• H5 Module Current Protection / P8 Module Temperature Protection: Indicates module current or temperature protection. Check compressor UVW cable connections and resistance/insulation. If normal, check for system blockages, high ambient temperature, or heavy compressor load. If these are resolved and the issue persists after power cycling, the compressor drive board may be faulty and needs replacement. If compressor issues are identified, address them accordingly.
• L3 Outdoor Fan 1 Error / LA Outdoor Fan 2 Error: Mainboard does not receive the outdoor fan signal within 30s after startup. Check outdoor fan wiring connections to the mainboard. If connections are correct, the outdoor fan may be damaged. If it's a new unit or motor with correct wiring, a program error might be present.
• A1 Outdoor fan IPM module protection: Indicates IPM module malfunction due to lack of phase, phase reversal, overloaded fan current, damaged IPM module, low 15V power supply, abnormal PWM signal, or abnormal current sampling circuit. Troubleshooting involves checking phase connections, system load, and drive board components.
• AJ Outdoor Fan Non-synchronism Protection: Occurs when rotor position cannot be detected or running speed differs significantly from the set speed. Possible causes include incorrect phase wiring, bad phase connections, system blockage, short of refrigerant/oil, or damaged drive board components.

2 Wiring Diagram

Diagrams show conceptual wiring for the unit. It is essential to refer to the actual wiring diagram affixed to the unit for precise connections.

3 Disassembly and Assembly Procedure of Main Parts

3.1 Model: GK-H02TC/NhA-D(U), GK-H03TC/NhA-D(U)

Detailed step-by-step procedures with handling instructions are provided for disassembling and assembling the Compressor, Condenser Fan Motor, Supply Blower Motor, and Electric Box Assembly. These include disconnecting power, recovering refrigerant, removing/installing components, reconnecting wiring, and recharging refrigerant where applicable. Diagrams illustrate each step.

3.2 Model: GK-H04TC/NhA-D(U), GK-H05TC/NhA-D(U)

Similar detailed step-by-step procedures with handling instructions are provided for disassembling and assembling the Compressor, Condenser Fan Motor, Supply Blower Motor, and Electric Box Assembly for these larger models. Diagrams illustrate each step.

4 Exploded Views and Spare Part List

4.1 Model: GK-H02TC/NhA-D(U), GK-H03TC/NhA-D(U)

A comprehensive list of parts with their corresponding codes and quantities is provided, covering components from the rear grill to the compressor and various sensors and valves.

4.2 Model: GK-H04TC/NhA-D(U), GK-H05TC/NhA-D(U)

A comprehensive list of parts with their corresponding codes and quantities is provided for these models, detailing components such as the rear grill, fans, motors, control boards, heaters, sensors, valves, and heat exchangers.