Airwell GCD 036 DCR User manual

DC Inverter 10.0 / 12.5 / 14.0 kW
MARCH  2009
Outdoor Units Indoor Units
GCD 036 DCR
DLS 36
DHC 36
CKD 036
FBD 036
GC 36 DCI DLS 36
DHC 36
GC 43 DCI
DLS 43
DHC 43
CKD 045
FBD 045
GC 60 DCI CD 60
REFRIGERANT R410A
HEAT PUMP
SM GCDDCI 1-A.3 GB

A
LIST OF EFFECTIVE PAGES
SM GCDDCI 1-A.3 GB
LIST OF EFFECTIVE PAGES
Note: Changes in the pages are indicated by a “Revision#” in the footer of each effected page
(when none indicates no changes in the relevant page). All pages in the following list represent
effected/ non effected pages divided by chapters.
Dates of issue for original and changed pages are:
Original ....... 0 ........ February 2007
Total number of pages in this publication is 215 consisting of the following:
Page
No.
Revision
No. #
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No.
Revision
No. #
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No.
Revision
No. #
Title.......................3
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4-1 - 4-3 ................3
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16-1-16-6 ..............3
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Zero in this column indicates an original page.
*Due to constant improvements please note that the data on this service manual can be modified with out notice.
** Photos are not contractual.

i
TABLE OF CONTENTS
SM GCDDCI 1-A.3 GB
Table of Contents
1. INTRODUCTION ...................................................................................................1-1
2. PRODUCT DATA SHEET......................................................................................2-1
3. RATING CONDITIONS..........................................................................................3-1
4. OUTLINE DIMENSIONS .......................................................................................4-1
5. PERFORMANCE DATA & PRESSURE CURVES ................................................5-1
6. AIRFLOW CURVES ..............................................................................................6-1
7. SOUND LEVEL CHARACTERISTICS ..................................................................7-1
8. ELECTRICAL DATA..............................................................................................8-1
9. WIRING DIAGRAMS .............................................................................................9-1
10. REFRIGERATION DIAGRAMS.............................................................................10-1
11. TUBING CONNECTIONS......................................................................................11-1
12. CONTROL SYSTEM .............................................................................................12-1
13. TROUBLESHOOTING ..........................................................................................13-1
14. SERVICING ...........................................................................................................14-1
15. EXPLODED VIEWS AND SPARE PARTS LISTS.................................................15-1
16. OPTIONAL ACCESSORIES .................................................................................16-1
17. APPENDIX A .........................................................................................................17-1

1-1
INTRODUCTION
SM GCDDCI 1-A.3 GB
1. INTRODUCTION
1.1 General
The new GCD 036 DCR, GC 36-43-60 DC INVERTER split unit range comprises the
following RC (heat pump) models:
• DLS 36 • CKD 036
• DLS 43 • CKD 045
• DHC 36 • FBD 036
• DHC 43 • FBD 045
• CD 60
Remote control compatibility
The units are compatible with remote controls RC3, RC4, RCW1, RCW2, RC7.
Inverter description
Unlike standard units (fix RPM) that are selected according to their nominal capacity to
overcome the maximum required load, DC Inverter units can be selected to a smaller
nominal capacity range unit.
It made possible due to the ability of inverters to reach a much higher capacity level
(indicated as Maximum Capacity) which is around 115-130% of the nominal capacity.
1.2 Main Features
High Technology
•Sine wave DC Compressor drive.
•DC-BL-SL (DC Brush-Less Sensor less) Inverter Compressor.
•DC-BL Inverter Outdoor Fan.
•Fuzzy Logic Adaptive Control.
System Features
•Variable cooling and heating capacity from 30% to 115% (of rated capacity).
•High COP “A-B” class energy rating (Most units).
•Low noise levels.
•Pre-charged system up to 30m.
•Tubing up to 70m length / 30m height difference.
•Networking connectivity.
•Current limitation setting for circuit breaker size reduction (if required).
•Dry contact inputs:
Standby.
Night mode (for silent operation in cooling).
 Power Shedding (to control maximum power consumption).
•Dry contact output:
Alarm
 Base Heater
Crank Case Heater

1-2
INTRODUCTION
SM GCDDCI 1-A.3 GB
•HMI Display consists of 7-segments shows system diagnostics and setup.
•Monitoring software (PC port for high level service).
•Cooling operation at outdoor temperature down to -10°C.
•Heating operation at outdoor temperature down to -15°C.
•Up to 100Pa (GC 36-43 DCI) and 200Pa (GC 60 DCI) External static pressure.
1.3 Indoor Unit
1.3.1 DLS
The DLS DCI indoor unit is a low silhouette ducted unit, and can be easily fitted to many
type of residential and commercials applications.
•Low silhouette units 300 mm height.
•High technology plastic fan and fan housing.
•Drain pool at bottom of unit with internal downward slope.
•Over-flow switch, stops compressor operation in case of a blocked drainage.
•Bended coil hydrophilic coated aluminum fins.
•3-speed fan motor and an extra speed in case a higher external static pressure
required.
•Tubing connections at the back of the unit to allow easy outlet to both sides of the
unit.
•Easy installation and service access.
•Infrared remote control with liquid display unit (LCD).
•Field options:
(1) External water pump.
(2) Airconet connection.
(3) Plenum kit for connection of flexible duct hoses at air outlet.
1.3.2. CASSETTE - CKD
The CKD 036, 045DCI 90x90cm is part of the new indoor unit family of cassette units.
It is an extension of the present 60x60 CK/CN DCI family.
These new models will support the light commercial line and addition to the 4-5-6HP
family.
It comprises of the following features:
New and modern design for easy integration in all decors.x
Designed for integration in suspended ceilings.x
Integrated condensate drainage lift pump.x
Four motorized air distribution flaps.x
Air distribution to an adjacent room.x
High efficiency filtration.x
Fresh air intake.x
Easy access to electrical components without the need forx
Opening of ceiling.
AIR RENEWAL
outside inside
adjacent room main room
AIR CONDITIONING OF AN
ADJACENT ROOM

1-3
INTRODUCTION
SM GCDDCI 1-A.3 GB
1.3.3. Floor / Ceiling - FBD
The FBD 036, 045 DCI is part of the new indoor unit family of floor / ceiling units.
These new models will support the light commercial line and addition to the 4-5-6HP
family.
It comprises of the following features:
New and modern design for easy integration in all decors.x
Horizontal and Vertical installations.x
Motorized air distribution flaps.x
1.4 Filtration
•The unit is equipped with pre filters.
•Easy and versatile access, rear or bottom, can be easily adjusted by the installer.
1.5 Control
The micro processor indoor controller, and an infrared remote control, supplied as
standard, provides complete operating function and programming.
For further details, please refer to the Operation Manual, Appendix A.
1.6 Outdoor Unit
The DCI outdoor units can be installed as floor or wall mounted units by using a wall-
supporting bracket. The metal sheets are protected by anti- corrosion paint work allowing
long life resistance. All outdoor units are pre-charged. For further information, please
refer to the Product Data Sheet, Chapter 2.
•Compressor mounted in a soundproofed compartment.
•Improved 3-blades axial fans for noise reduction.
•Outdoor coil with hydrophilic fins optimized for operation with R410A refrigerant.
•Fan grill air outlet.
•Service valves” flare” type connection.
•Service ports for high/ low pressure measurement.
•Interconnecting wiring terminal blocks.
1.7 Tubing Connections
Flare type-interconnecting tubing to be produced on site.
Units can be installed with 70-meter pipe length and 30 meter height difference without
oil traps.
For further details, please refer to the Installation Manual, Chapter 17.
1.8 Accessories
No. Item
1. RCW Wall Mounted Remote Control
2. RCW2 (BMS) Wall Mounted Remote Control
3. Base Heater
4. Crank case Heater
5. Room thermostat
For further details, please refer the Optional Accessories, Chapter 16.

1-4
INTRODUCTION
SM GCDDCI 1-A.3 GB
1.9 Inbox Documentation
Each unit includes its own installation and operation manuals.
1.10 Matching Table
1.10.1 R410A
OUTDOOR
UNITS
INDOOR UNITS
MODEL
DLS 36
DCI
DLS 43
DCI
DHC 36
DCI
DHC 43
DCI
CKD 036
DCI
CKD 045
DCI
FBD 036
DCI
FBD 045
DCI
CD140
DCI
DCR 036 
DCI 36 
DCI 43 
DCI 60 

2-1
PRODUCT DATA SHEET
SM GCDDCI 1-A.3 GB
2. PRODUCT DATA SHEET
2.1 DLS 36 DCI / GCD 036 DCR
Model Indoor Unit DLS 36 DCI
Model Outdoor Unit GCD 036 DCR
Installation Method DUCTED
Characteristics Units Cooling Heating
Capacity - Nominal (Minimum ~ Maximum)(1) Btu/hr 34,120 (9,550 - 38,200) 38,200 (9,200 - 42,650)
kW 10.0 (2.8 – 11.2) 11.2 (2.7-12.5)
Power Input - Nominal (Minimum ~ Maximum)( (1) W 3,330 (950 - 4,100) 3,290 (660 - 4,100)
EER (Cooling) / COP (Heating)(1) W/W 3.0 3.4
Energy Efficiency Class - “B” “B”
Power Supply V/Ph/Hz 220-240/1/50
Rated Current (Nominal) A 15.0 14.7
Starting Current A <10
Circuit Breaker Rating A 25
INDOOR
Fan Type & Quantity CENTRIFUGAL x1
Fan Speed H/M/L RPM 880 710 610
Airflow(2) H/M/L m3/hr 2025 1500 1210
External Static Pressure Min-Nom-
Max Pa 20-37-100
Sound Power Level(3) H/M/L dB (A) 71 67 62
Sound Pressure Level (4) H/M/L dB (A) 52 49 47
Moisture Removal (Nominal) L/hr 3.3
Condensate Drain Tube I.D. mm 19
Dimensions W/H/D mm 854 297 816
Weight kg 33
Package Dimensions W/H/D mm 1010 342 917
Packaged Weight kg 38
Units per Pallet Units 6
Stacking Height Units 6
OUTDOOR
Refrigerant Control Electronic Expansion Valve
Compressor Type, Model Twin-Rotary
Motor type DCBL Inverter
Fan Type & Quantity Axial 2x 400mm
Fan Speed RPM 1100-100 (continuous)
Airflow Max m3/hr 4,150
Sound Power Level Nom C/H dB (A) 67 69
Sound Pressure Level (4) Nom C/H dB (A) 57 59
Dimensions W/H/D mm 900 970 340
Weight kg 76
Package Dimensions W/H/D mm 985 1020 435
Packaged Weight kg 81
Units per Pallet Units 6
Stacking Height Units 2
Refrigerant Type R410A
Refrigerant Charge (STD connected Tube
Length) kg (m) 2.5 / 30
Additional Charge g/m 30
Connections
Between Units
Liquid Line In (mm) 3/8”
Suction Line In (mm) 5/8”
Max. Tubing Length m 70
Max. Height Difference m 30
Operation Control Type LCD Remote Control
Heating Elements kW BH 70W - optional
Others
(1) Rating conditions in accordance with ISO 5151 and ISO 13253 (for ducted units).
(2) Airflow in ducted units; at nominal external static pressure.
(3) Sound power in ducted units is measured at air discharge.
(4) Sound pressure level measured at 1.0 meter distance from unit.

2-2
PRODUCT DATA SHEET
SM GCDDCI 1-A.3 GB
2.2 DLS 36 DCI / GC 36 DCI
Model Indoor Unit DLS 36 DCI
Model Outdoor Unit GC 36 DCI
Installation Method DUCTED
Characteristics Units Cooling Heating
Capacity - Nominal (Minimum ~ Maximum) (1) Btu/hr 34100(10900÷39200) 38200(9200 ÷ 42650)
kW 10.0(3.8 ÷ 11.5) 11.2(2.6 ÷ 12.5)
Power input - Nominal (Minimum ~ Maximum)(1) kW 3.125(1.400 ÷ 4.400) 3.390(1.000 ÷ 4.450)
EER (Cooling) or COP(Heating) (1) W/W 3.2 3.3
Energy Efficiency Class “A” “C”
Power supply V/Ph/Hz 230 / 1 / 50
Rated current (Nominal) A 14.0 15.2
Starting current A 10
Circuit breaker rating A 25
INDOOR
Fan type & quantity Centrifugal x 1
Fan speeds H/M/L RPM 880 / 665 / 550
Air flow (2) H/M/L m3/hr 2025 / 1490 / 1210
External static pressure Min-Max Pa 20 -100
Sound power level (3) H/M/L dB(A) 71 / 67 / 62
Sound pressure level (4) H/M/L dB(A) 52 / 49 / 47
Moisture removal (Nominal) l/hr 3.3
Condensate drain tube I.D mm 19
Dimensions WxHxD mm 854/297/816
Weight kg 33
Package dimensions WxHxD mm 1010/342/917
Packaged weight kg 38
Units per pallet units 6
Stacking height units 6
OUTDOOR
Refrigerant control Electronic Expansion Valve
Compressor type, model Scroll
Motor type DCBL Inverter
Fan type & quantity Axial 2 x 493 Ømm
Fan speeds H/L RPM 900 – 100 (Continuous)
Airflow Max m3/hr 5.200
Sound power level(3) Nom C/H dB(A) 67 / 69
Sound pressure level(4) Nom C/H dB(A) 56 / 57
Dimensions WxHxD mm 900 / 1255 / 340
Weight kg 110
Package dimensions WxHxD mm 985 / 1395 / 435
Packaged weight kg 120
Units per pallet Units 1
Stacking height units 1
Refrigerant type R410A
Refrigerant charge(standard connecting tubing
length) Kg(m) 2.9 / 30
Additional charge per 1 meter g/m 38
Connections between
units
Liquid line In.(mm) 3/8" (9.52)
Suction line In.(mm) 5/8" (15.875)
Max.Tubing Length m. 70
Max.Height Difference m. 30
Operation control type LCD Remote control
Heating elements kW —
Others
(1) Rating conditions in accordance with ISO 5151 and ISO 13253 (for ducted units).
(2) Airflow in ducted units; at nominal external static pressure.
(3) Sound power in ducted units is measured at air discharge.
(4) Sound pressure level measured at 1.0 meter distance from unit.

2-3
PRODUCT DATA SHEET
SM GCDDCI 1-A.3 GB
2.3 DLS 43 DCI / GC 43 DCI
Model Indoor Unit DLS 43 DCI
Model Outdoor Unit GC 43 DCI
Installation Method Ducted
Characteristics Units Cooling Heating
Capacity - Nominal (Minimum ~ Maximum) (1) Btu/hr 42650(16050÷47750) 47750(15000÷54600)
kW 12.5 (4.7 ÷ 14.0) 14.0 (4.4 ÷ 16.0)
Power input - Nominal (Minimum ~ Maximum) (1) kW 4.170 (1.500 ÷ 5.700) 4.300 (1.100 ÷ 5.500)
EER (Cooling) or COP(Heating) (1) W/W 3.0 3.25
Energy efficiency class “B” “C”
Power supply V/Ph/Hz 230 / 1 / 50
Rated current (Nominal) A 19.7 19.0
Starting current A 10
Circuit breaker rating A 32
INDOOR
Fan type & quantity Centrifugal x 1
Fan speeds H/M/L RPM 890 / 720 / 640
Air flow (2) H/M/L m3/hr 1980 / 1480 / 1200
External static pressure Min-Max Pa 30-100
Sound power level (3) H/M/L dB(A) 71 / 67 / 62
Sound pressure level (4) H/M/L dB(A) 52 / 49 / 47
Moisture removal (Nominal) l/hr 4.6
Condensate drain tube I.D mm 19
Dimensions WxHxD mm 854 / 297 / 816
Weight kg 33
Package dimensions WxHxD mm 1010 / 342 / 917
Packaged weight kg 38
Units per pallet units 6
Stacking height units 6
OUTDOOR
Refrigerant control Electronic Expansion Valve
Compressor type, model Scroll
Motor type DCBL Inverter
Fan type & quantity Axial 2 x 493 Ømm
Fan speeds H/L RPM 900 – 100 (Continuous)
Air flow H/L m3/hr 5,700
Sound power level(3) Nom C/H dB(A) 69 / 70
Sound pressure level(4) Nom C/H dB(A) 56 / 58
Dimensions WxHxD mm 900 / 1255 / 340
Weight kg 110
Package dimensions WxHxD mm 985 / 1395 / 435
Packaged weight kg 120
Units per pallet Units 1
Stacking height units 1
Refrigerant type R410A
Refrigerant charge(standard connecting
tubing length) Kg(m) 3.1 / 30
Additional charge per 1 meter g/m 38
Connections
between units
Liquid line In.(mm) 3/8" (9.52)
Suction line In.(mm) 3/4" (19.0)
Max.Tubing Length m. 70
Max.Height Difference m. 30
Operation control type LCD Remote control
Heating elements kW
Others
(1) Rating conditions in accordance with ISO 5151 and ISO 13253 (for ducted units).
(2) Airflow in ducted units; at nominal external static pressure.
(3) Sound power in ducted units is measured at air discharge.
(4) Sound pressure level measured at 1.0 meter distance from unit.