LG Room Air Conditioner

Transcription

1 website LG oom Air Conditioner SEVICE MANUAL MODEL: LWHD8000,LWHD8000Y5,LWHD000,LWHD8000Y6 LG CAUTION BEFOE SEVICING THE UNIT, EAD THE SAFETY PECAUTIONS IN THIS MANUAL. ONLY FO AUTHOIZED SEVICE PESONNEL.

2 Air Conditioner Service Manual TABLE OF CONTENTS Safety Precautions...3 Dimensions...6 Outside Dimensions...6 Product Specifications...7 Installation...8 Select the Best Location...8 Installation Check...8 How to Secure the Drain Pipe...8 How to Install...9 Operation...2 Function of Controls...2 Disassembly...3 Mechanical Parts...3 Air handling Parts...4 Electrical Parts...5 efrigerating Cycle...7 Schematic Diagram...20 Electronic Control Device Wiring Diagram...2 Components Location...22 Troubleshooting Guide...23 Pipeing System...23 Troubleshooting Guide...24 Electrical Parts Troubleshooting Guide...26 Electrical Parts...30 Exploded View...36 eplacement Parts List oom Air Conditioner

3 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. WANING CAUTION This symbol indicates the possibility of death or serious injury. This symbol indicates the possibility of injury or damage to property only. Meanings of symbols used in this manual are as shown below. Be sure not to do. Be sure to follow the instruction. WANING Always install the expansion panel(s). Do not place the power cord near a heater. Improper assembly or installation may cause incorrect operation, including injury, fire, and electric shock hazards. It may cause fire and electric shock. Do not use the power cord near flammable gas or combustibles such as gasoline, benzene, thinner, etc. It may cause explosion or fire. Do not disassemble or modify products. It may cause electric shock and failure. Gasolin Service Manual 3

4 Safety Precautions Plug in the power plug properly. Otherwise, it will cause electric shock or fire. Do not operate or stop the unit by inserting or pulling out the power plug. It will cause electric shock or fire. ON ON Do not damage or use an unspecified power cord. It will cause electric shock or fire. Do not modify power cord length. It will cause electric shock or fire. Use the air conditioner on a single outlet circuit. Do not share the outlet with other appliances. It will cause electric shock or fire. Always plug into a grounded outlet. No grounding may cause electric shock. Do not use the socket if it is loose or damaged. It may cause fire and electric shock. Do not operate with wet hands or in damp environment. It may cause electric shock. Ventilate before operating air conditioner when gas goes out. It may cause explosion, fire, and burn. 4 oom Air Conditioner

5 Safety Precautions If water enters the product, turn off the the power switch of the main body of appliance. Contact service center after taking the power-plug out from the socket. It will cause electric shock or failure of machine. Do not clean the air conditioner with water. Water may enter the unit and degrade the insulation. It may cause an electric shock. CAUTION Never touch the metal parts of the unit when removing the filter. They are sharp and may cause injury. Do not block the inlet or outlet. It may cause failure of appliance or performance deteriorate. Ensure that the outer case is not damaged by age or wear. If the outer case is damaged, it must be repaired or replaced immediately. Leaving it damaged could result in the air conditioner falling out of the window, creating a safety hazard. Be cautious not to touch the sharp edges when installing. It may cause injury. Sharp edges Service Manual 5

6 Cool Energy Saver Fan Dry MODE Cool Energy Saver Fan Dry MODE Timer TIME Timer TIME F LOW F2 MED F3 HIGH TEMP FAN SPEED F LOW F2 MED F3 HIGH TEMP FAN SPEED 'F POWE 'F POWE 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. TICE This symbol indicates special notes. Outside Dimensions 492 (9 3 /8") 42 ( 2/32") 497 (9 9/6") 42 ( 2 /32") 30 ( 3/6") 00.3 (3 5/ 6 ") 27.5 ( 3/32") 35 (2 3/8") 347 (3 2/32") 2 (0.4 /6") 22.5(0.8 3/32") 243.3(9 9/6") 492 (9 3/8") 497 (9 9 /6") 35 (2 3/8") 6 oom Air Conditioner

7 Specfications Product Specifications MODELS ITEMS POWE SUPPLY CAPACITY (BTU/h) COOLING INPUT (W) UNNING CUENT (A) E.E. (BTU/W.h) OPEATING INDOO ( C) CONDITION OUTDOO ( C) EFIGEANT (-22) CHAGE EVAPOATO CONDENSE FAN, INDOO FAN, OUTDOO FAN SPEEDS, FAN/COOLING/HEATING FAN MOTO OPEATION CONTOL OOM TEMP. CONTOL AI DIECTION CONTOL CONSTUCTION COMPESSO POTECTO FAN MOTO POWE COD DAIN SYSTEM NET WEIGHT (lbs/kg) OUTSIDE DIMENSION (inch) (W x H x D) (mm) * DB : dry bulb ** WB : wet bulb LWHD8000 LWHD8000Y5 LWHD8000Y6 LWHD000 ø, 5V, 60Hz 8,000 8,000 0, , (DB)* 9.4(WB)** 35(DB)* 23.9(WB)** 370g(3. oz) 420g(4.8 oz) 480g(6.9 oz) 2 OW STACKS, LOUVE-FIN TYPE 2 OW 5 STACKS, STAGHT TYPE TUBO FAN POPELLE TYPE FAN WITH SLINGE ING 3/3 6 POLES EMOTE CONTOLLE THEMISTO VETICAL LOUVE (IGHT & LEFT) HOIZONTAL LOUVE (UP & DOWN) TOP DOWN CHASSIS OVELOAD POTECTO INTENAL THEMAL POTECTO 3 WIE WITH GOUDING ATTACHMENT PLUG (COD-CONNECTED TYPE) DAIN PIPE O SPLASHED BY FAN SLINGE 62/28 62/28 7/32 9 9/ 9 /6 x 2 3 / 8 x 9 3 / 8 /8 497 x 35 x 492 Service Manual 7

8 Installation Installation Select the Best Location. To prevent vibration and noise, make sure the unit is installed securely and firmly. 2. Install the unit where the sun does not shine directly on the unit. 3. The outside of the cabinet must extend outward for at least 2" and there should be no obstacles, such as a fence or wall, within 20" from the back of the cabinet because it will prevent heat radiation of the condenser. estriction of outside air will greatly reduce the cooling efficiency of the air conditioner. CAUTION: All side louvers of the cabinet must remain exposed on the outdside of the structure. 4. Install the unit slanted slightly so the back is slightly lower than the front (about /4"). This will force condensed water to the outside. 5. Install the unit with the bottom about 30"~60" above the floor level. INSIDE COOLED AI 30"-60" OUTSIDE AWNING HEAT ADIATION ABOUT / 4 " Over 20" FENCE Figure Installation Check The setting conditions must be checked prior to initial starting. The following items are especially important checking points when the installation is finished.. Grounding wire (Green or Green and Yellow) is provided in the power cord. The green wire must be grounded. 2. Connect to a single-outlet 5A circuit. (or 20A circuit for Electric Heater Model) 3. To avoid vibration or noise, make sure the air conditioner is installed securely. 4 Avoid placing furniture or draperies in front of the air inlet and outlet. How to Secure the Drain Pipe In humid weather, excess water may cause the Base Pan to overflow. To drain the water, remove the Drain Cap and secure the Drain Pipe to the rear hole of the Base Pan. (Figure. 2) Drain Pipe Drain Cap Figure 2 8 oom Air Conditioner

9 Installation How to Install Window equirements TICE All supporting parts should be secured to firm wood, masonry, or metal.. This unit is designed for installation in standard double hung windows with actual opening widths of 22" to 36". The upper and lower sash must open sufficiently to allow a clear vertical opening of 3" from the bottom of the sash to the window stool. 2. If storm window presents interference, fasten a 2" wide wood strip to the inner window sill across the full width of the sill. The wood strip should be thick enough to raise the height of the window sill so that the unit can be installed without interference by the storm window frame. See Figure. 4. Top of wood strip should be approximately 3/4" higher than the storm window frame (STOM WINDOW FAME) or wood strip (OUT- DOOS) to help condensation to drain properly to the outside. 3. Install a second wood strip (approximately 6" long by /2" wide and same thickness as first strip) in the center of the outer sill flush against the back off the inner sill. This will raise the L bracket as shown Figure If the distance between STOM WINDOW FAME and WOOD STIP MOUNTED ON TOP OF INNE SILL is more than ", two of wood strip are not necessary. Installation INNE SILL INDOOS WOOD STIP MOUNTED ON TOP OF INNE SILL INNE SILL INDOOS " MAX. WOOD STIP FO L BACKET OUTE SILL OUTDOOS 3/4" CLEAANCE STOM WINDOW FAME OUTE SILL Figure 3 OUTDOOS Figure 4 HADWAE TYPE A: EA (SHOT SCEW) TYPE B: 5EA (WOOD SCEW) TYPE C: 3EA (L BACKET) DAIN PIPE 0mm 6mm TYPE D: EA (SEAL STIP) TYPE E: EA (SASH SEAL) TYPE F: 2EA (GUIDE PANEL) TYPE G: EA (SUPPOT BACKET) (Adhesive backed) (Not adhesive backed) Service Manual 9

10 C ool E nergy S aver F an Dry T imer F L OW F 2 ME D F 3 HIG H T E MP F Installation BEFOE INSTALLATION. Insert the guide panels into the guides of the air conditioner. Fasten the curtains to the unit with screws (TYPE A) as shown Figure Cut the adhesive-backed seal strip (TYPE D) to the window width. emove the backing from the seal strip and attach the seal strip to the underside of the bottom window. (Figure. 6) W STAT INSTALLATION. LOCATING UNIT IN WINDOW Open the window and mark center line on the center of the inner sill, as shown in Figure ATTACH L BACKET a. Install the L brackets behind the inner window sill, with the short side of bracket as shown. Use the 2 screws (TYPE A) provided. b. The bracket helps to hold unit securely in place. Be sure to place bracket edge flush against back of inner sill. See Figure. 7. Figure 5 Figure 6 Type A SEAL STIP (TYPE D) INNE SILL OOM SIDE CENTE LINE Type A CAUTION: During the following step, hold unit firmly until window sash is lowered to top channel behind side panel frames. Personal injury or property damage may result if unit falls from window. Figure 7 INNE SILL OUTE SILL TYPE A INSIDE CENTE LINE 3. INSTALL THE AI CONDITIONE IN THE WINDOW a. Carefully lift the air conditioner and slide it into the open window. Make sure the bottom guide of the air conditioner drops into the notches of the L bracket. See Figure. 8. IMPOTANT : When the air conditioner drops into the L bracket, the air conditioner will be centered in window opening as shown in Figure. 9. 8" SHOT SIDE 8" OUTSIDE L BACKET Figure 8 b. While steadying the air conditioner, carefully bring the window sash down behind the upper guide of the air conditioner, as shown in Figure. 0. Figure 9 WINDOW FAME UPPE GUIDE C enter Line SEAL ABOUT /4" BOTTOM GUIDE Figure 0 L BACKET 0 oom Air Conditioner

11 Installation 4. SECUE THE GUIDE PANELS Extend the guide panels (TYPE F) to fill the window opening using 4 screws (TYPE B) to secure them, as shown in Figure.. 5. INSTALL THE SASH SEAL AND SASH LOCK a. Cut the sash seal (TYPE E) to the window width. Stuff the sash seal between the glass and the window to prevent air and insects from getting into the room, as shown in Figure.. b. Fasten the L bracket using a (TYPE A) screw, as shown in Figure.. 6. Window installation of room air conditioner is now completed. See ELECTICAL DATA for attaching power cord to electrical outlet. L Bracket Type A Type B Figure Sash Seal (Type F) TICE EMOVAL FOM WINDOW Trun the air conditioner off, disconnect the power cord, remove the L bracket and the screws installed through the top and bottom of the guide panels, and save for reinstallation later. Close the guide panels. keeping a firm grip on the air conditioner, raise the sash, and carefully tilt the air conditioner backward, draining any condensate water. Lift the air conditioner from the window ad remove the sash seal from between the windows. Service Manual

12 Operation Operation Designed for COOLING ONLY. Powerful and quiet cooling. Top-down chassis for the simple installation and service. Low air-intake, top cooled-air discharge. Built-in adjustable Thermistor Washable one-touch filter Compact size Equipped with reliable and efficient rotary compressor. Function of Controls DISPLAY EMOTE CONTOL F LOW F2 MED F3 HIGH 'F 6 Power Cool Energy Saver Fan Dry Timer TEMP 2 Temp 2 MODE TIME FAN SPEED POWE 5 Fan Speed Timer Mode 4 3 PECAUTION: The emote Control unit will not function properly if strong light strikes the sensor window of the air conditioner or if there are obstacles between the emote Control unit and the air conditioner. POWE BUTTON To turn the air conditioner ON, push the button. To turn the air conditioner OFF, push the button again. This button takes priority over any other buttons. OOM TEMPEATUE SETTING BUTTON This button can automatically control the temperature of the room. The temperature can be set within a range of 60 F to 86 F by F. (6 C to 30 C by C) Select the lower number for lower temperature of the room. OPEATION MODE SELECTION BUTTON Every time you push this button, it will shift among COOL, ENEGY SAVE, FAN and DY. - Energy Saver: If Energy Save mode is selected, the fan stops when the compressor stops cooling.a Approximately every 3 minutes the fan will turn on and check the room air to determine if cooling is needed. FAN SPEED SELECTO Every time you push this button, it is set as follows. (Hi [F3] Low [F] Med [F2] Hi [F3] Low [F]...) ON/OFF TIME BUTTON You can set the time when the unit will turn on or turn off automatically by pressing the timer button. If the unit is operating, this button controls the time it will be turned off. If the unit is off state, this button controls the time it will start. Every time you push this button, the remaining time will be set as follows. - Stopping operation (Hour 2Hours 3Hours 4Hours 5Hours 6Hours 7Hours 8Hours 9Hours 0Hours Hours 2Hours 0Hour Hour 2Hours... ) - Starting operation (Hour 2Hours 3Hours 4Hours 5Hours 6Hours 7Hours 8Hours 9Hours 0Hours Hours 2Hours off Hour 2Hours... ) EMOCON SIGNAL ECEIVE 2 oom Air Conditioner

13 Disassembly Disassembly Before the following disassembly, set the CONTOL BOX to OFF and disconnect the power cord. Mechanical Parts. Front Grille. Open the lnlet grille downward and remove the air filter. 2. emove the screw that fastens the front grille.(see Figure 2) 3. Pull the front grille from the right side. 4. emove the front grille.(there are 4 hooks.) 5. e-install the components by referring to the removal procedure, above. 2. Cabinet. After disassembling the FONT GILLE, remove the 6 screws that fasten the cabinet at both sides. 2. emove the 2 screws that fasten the cabinet at back. 3. Lift the cabinet from the unit. 4. emove the cabinet. 5. e-install the components by referring to the removal procedure, above. 3. Control Box. emove the front grille. (efer to section ) 2. emove the cabinet. (efer to section 2) 3. emove the screw which fasten the power cord. 4. Disconnect the grounding screw from the evaporator channel. 5. emove the 2 screws that fastens the control box cover. 6. emove the housing that connects PCB and motor wire in the control box. 7. emove the nut that fastens the terminal cover. 8. emove the terminal cover. 9. emove all the leads from the overload protector. 0. Discharge the capacitor by placing a 20,000 ohm resistor across the capacitor terminals.. aise the control box upward completely. (See Figure 4) 2. e-install the components by referring to the removal procedure, above. (efer to the wiring diagram found on page 2 in this manual and on the control box.) Figure 2 Figure 3 Figure 4 Service Manual 3

14 Disassembly Air Handling Parts 4. Air Guide and Turbo Fan. emove the front grille. (efer to section ) 2. emove the cabinet. (efer to section 2) 3. emove the control box. (efer to section 3) 4. emove the 4 screws that fasten the brace. 5. emove the brace. 6. emove the 2 screws that fasten the air guide upper. 7. emove the air guide upper.(see Figure 5) 8. emove the 2 screws that fasten the evaporator. 9. Move the evaporator forward and pulling it upward slightly. (See Figure 6) 0. Pull out the hook of orifice by pushing the tabs and remove it. (See Figure 6). emove the clamp with hand pliers which secures the turbo fan. 2. emove the turbo fan. 3. emove the 2 screws that fasten the air guide from the base pan. 4. Move the air guide backward, and pull out from the base pan.(move the air giude lower carefully.) 5. e-install the components by referring to the removal procedure, above. 5. FAN. emove the cabinet. (efer to section 2) 2. emove the brace (efer to section 4) 3. emove the 5 screws which fasten the condenser. 4. Move the condenser to the left carefully. 5. emove the clamp that secures the fan. 6. emove the fan. (See Figure 7) 7. e-install by referring to the removal procedure. Figure 5 Figure 6 6. Shroud. emove the fan. (efer to section 2.2.2) 2. emove the shroud. (See Figure 8) 3. e-install the components by referring to the removal procedure, above. Figure 7 Figure 8 4 oom Air Conditioner

15 Disassembly Electrical Parts 7. Overload Protector. emove the cabinet. (efer to section 2) 2. emove the nut that fastens the terminal cover. 3. emove the terminal cover. (See Figure 9) 4. emove all the leads from the overload protector. 5. emove the overload protector. 6. e-install the components by referring to the removal procedure, above. Figure 9 8. Compressor. emove the cabinet. (efer to section 2) 2. Discharge the refrigerant system using a Freon TM ecovery System. If there is no valve to attach the recovery system, install one (such as a WATCO A-) before venting the Freon TM. Leave the valve in place after servicing the system. 3. emove the overload protector. (efer to section 7) 4. After purging the unit completely, unbraze the suction and discharge tubes at the compressor connections. 5. emove the 3 nuts and the 3 washers which fasten the compressor. 6. emove the compressor. (See Figure 20) 7. e-install the components by referring to the removal procedure, above. Figure Capacitor. emove the control box. (efer to section 3) 2. Open the top cover from the control box. (See Figure 2) 3. Pull out the capacitor from the control box. 4. Disconnect all the leads of capacitor terminals. 5. e-install the components by referring to the removal procedure, above. Figure 2 Service Manual 5

16 Disassembly 0. Power Cord. emove the control box. (efer to section 3) 2. Open the top cover from the control box. (efer to section 9) 3. Disconnect the front panel from the control box. (See Figure 22) 4. Disconnect two leads from the capacitor and relay. 5. Pull out the power cord. 6. e-install the component by referring to the above removal procedure, above. (Use only one ground-marked hole for ground connection.) 7. If the supply cord of this appliance is damaged, it must be replaced by the special cord. (The special cord means the cord which has the same specification marked on the supply cord attached at the unit.) Figure 22. Motor. emove the cabinet. (efer to section 2) 2. emove the turbo fan. (efer to section 4) 3. emove the fan. (efer to section 5) 4. emove the 4 screws that fasten the motor from the air guide. (See Figure 23) 5. emove the motor. 6. e-install the components by referring to the removal procedure, above.(see Figure 23) Figure 23 6 oom Air Conditioner

17 Disassembly efrigerating Cycle 2. Condenser CAUTION: Discharge the refrigerant system using a Freon TM ecovery System. If there is no valve to attach the recovery system, install one (such as a WATCO A-) before venting the Freon TM. Leave the valve in place after servicing the system.. emove the cabinet. (efer to section 2) 2. emove the 4 screws that fasten the brace.(efer to section 4) 3. emove the 5 screws that fasten the condenser and shroud. 4. After discharging the refrigerant completely, unbraze the interconnecting tube at the condenser connections. 5. emove the condenser. 6. e-install the components by referring to notes. (See Figure 23) Figure Evaporator. emove the control box.(efer to section 3) 2. emove the air guide upper. (efer to section 4) 3. emove the 2 screws that fasten the evaporator. 4. Move the evaporator sideways carefully. (efer to section 4) 5. After discharging the refrigerant completely, unbraze the interconnecting tube at the evaporator connections. 6. emove the evaporator. 7. e-install the components by referring to notes. (See Figure 24) Figure Capillary Tube. emove the cabinet. (efer to section s2) 2. After discharging the refrigerant completely, unbraze the interconnecting tube at the capillary tube.(see caution above) 3. emove the capillary tube. 4. e-install the components by referring to notes. Service Manual 7

18 Disassembly TICE eplacement of the refrigeration cycle.. When replacing the refrigeration cycle, be sure to Discharge the refrigerant system using a Freon TM recovery System. If there is no valve to attach the recovery system, install one (such as a WATCO A-) before venting the Freon TM. Leave the valve in place after servicing the system. 2. After discharging the unit completely, remove the desired component, and unbraze the pinch-off tubes. 3. Solder service valves into the pinch-off tube ports, leaving the valves open. 4. Solder the pinch-off tubes with Service valves. 5. Evacuate as follows. ) Connect the vacuum pump, as illustrated figure 25A. 2) Start the vacuum pump, slowly open manifold valves A and B with two full turns counterclockwise and leave the valves open. The vacuum pump is now pulling through valves A and B up to valve C by means of the manifold and entire system. CAUTION: If high vacuum equipment is used, just crack valves A and B for a few minutes, then open slowly with the two full turns counterclockwise. This will keep oil from foaming and being drawn into the vacuum pump. 3) Operate the vacuum pump vaccum for 20 to 30 minutes, until 600 microns of vaccum is obtained. Close valves A and B, and observe vacuum gauge for a few minutes. A rise in pressure would indicate a possible leak or moisture remaining in the system. With valves A and B closed, stop the vacuum pump. 4) emove the hose from the vacuum pump and place it on the charging cylinder. See figure 25B. Open valve C. Discharge the line at the manifold connection. 5) The system is now ready for final charging. 6. echarge as follows : ) efrigeration cycle systems are charged from the High-side. If the total charge cannot be put in the High-side, the balance will be put in the suction line through the access valve which you installed as the system was opened. 2) Connect the charging cylinder as shown in figure 25B. With valve C open, discharge the hose at the manifold connection. 3) Open valve A and allow the proper charge to enter the system. Valve B is still closed. 4) If more charge is required, the high-side will not take it. Close valve A. 5) With the unit running, open valve B and add the balance of the charge. a. Do not add the liquid refrigerant to the Lowside. b. Watch the Low-side gauge; allow pressure to rise to 30 lbs. c. Turn off valve B and allow pressure to drop. d. epeat steps b. and c. until the balance of the charge is in the system. 6) When satisfied the unit is operating correctly, use the pinch-off tool with the unit still running and clamp on to the pinch-off tube. Using a tube cutter, cut the pinch-off tube about 2 inches from the pinch-off tool. Use sil-fos braze and braze pinch-off tube closed. Turn off the unit, allow it to set for a while, and then test the leakage of the pinch-off connection. 8 oom Air Conditioner

19 Disassembly Equipment needed: Vacuum pump, Charging cylinder, Manifold gauge, Brazing equipment. Pin-off tool capable of making a vapor-proof seal, Leak detector, Tubing cutter, Hand Tools to remove components, Service valve. CONDENSE (HIGH PESSUE SIDE) COMPOUND GAUGE MANIFOLD GAUGE B A CAPILLAY TUBE SEE INSETS BELOW EVAPOATO (LOW PESSUE SIDE) COMPESSO LOW HI B A B A EXTENAL VACUUM PUMP CHAGING CYLINDE C Figure 25A-Pulling Vacuum Figure 25B-Charging Service Manual 9

20 Schematic Diagram HVB OOM-TH CN-TH 5V SMAW H 6.2K % 02H 2.K % OSC0B T8.00MG 0B M 5V C0A V A 20K C02A uf 0V x 05P 0K SDA SCL Digit4 (Scan4) Digit3 (Scan3) Digit2 (Scan2) Digit (Scan) Digit0 (Scan0) SEG-a SEG-b SEG-c 3.6V 5V IC0A S736 06P 0K C0F 0F K C02F 03F K Model Auto estart Non Auto estart EEPOM CAT93C46 A0 Vcc A WP 3 A2 SCL GND SDA EEPOM 04P O O 04P 5V 02P 03P 20K 20K 04P K Q03G A0S FAN SW0G D0G TIME SW04G D04G Q02G A0S Q0G A0S TEMP DOWN ON/OFF SW02G SW03G D02G D03G MODE TEMP UP SW05G SW06G D05G D06G 5V X X b c VAref VSS Osc out Osc in /eset TEST 5V COMP SYNC 4WAY LOW Option2 Option Pipe TH oom TH MICOM TMP87CH47U VDD SEG-f SEG-e SEG-d KEY0 SLIDE SW SEG-g ION MED HI eceiver Buzzer LED out LED out2 LED out LED out0 KEY 5V 2H 22H 2.K 2.K % % OH O2H V IC0M ULN2004A 5V C02L 220 0V Vcc 0L K Vout GND ECEIVE 02E 20 0P 20K C0L 680pF 50V HVB 0 Digit Digit a a b f 5 a 3 b 9 c 8 d e f 7 f d c e 4 g e d 6 g g S/V- 4WAY FAN MOTO CAPACITO FAN C HEM MAIN POWE COMP PIPE-TH SW2 SW CN-TELE SMW V (D) C0T 0. 50V CN-TH2 SMW CN-HVB SMW200-03(BL) CN-CONT J5 SMW200-03(YL) CN-2V SMW200-03(WH) CN-4WAY YW396-03AV(YL) CN-MOTO YW396-09AV CN-PW YW396-03AV Y-COMP G4A-A-E-LG FUSE 250VT3.5A 5V C02T Q03T 0T 0.00 C04M K x 2 D0T C03T N448 Q04T 0.00 A04M 25V 5V Q0T C04M Tx Q02T A04M 0 J7 2V Y-COMP Y-4WAY Y-LOW Y-MED Y-HI Model Y-4WAY J07 CN-4WAY CN-TH2 Cool Only O Heat Pump O O O Y-4WAY Y-HI Y-MED Y-LOW 5V 2V C0J 0./275V CN-AC/DC J /2W STAIGHT ZN0J SVC27D-4A SVC27D-4A POWE TANS D02D D03D D02D~D05D N4004 D05D IC0D 782 D04D + C0D C02D C03D V 50V 6V BZ0E PKM3EPY C05D C06D V 50V 2V 2 CN-AC/DC 558-2(YEONHO) (MOLEX) ANGLE 2V 5V IC02D 7805 C04D C05D V 25V 0E K 5V 5V 2F 0K 5V IC0G ULN2004A 6 0G G G G G G G 680 2V COOL DEFOST DY/HEAT TIME FAN E/SAVE X 7 4 X X X O I + O I Schematic Diagram Electronic Control Device 88 SEGMENT 20 oom Air Conditioner

21 Schematic Diagram Wiring Diagram 2 GN/YL (GN) MOTO CAPACITO F C H WH(BL) (ibbed) YL BK BL D YL O O(B) BK D CN-MOTO CN-PW FUSE 250V/T3.5A Y-LOW ZN0J Y-MED POWE TANS CN-AC/DC Y-HI DC2V CN-2V CN-AC/DC DC PCB ASSEMBLY CN-TH THEMISTO SWITCH GN/YL (GN) BK(B) (Plain) COMP. C S OLP BL WIING DIAGAM 3 4 Y-COMP CN-HVB AC PCB ASSEMBLY H.V. ASSEMBLY BK D AI FILTE ASSEMBLY 8 S: Service Parts N: Non Service Parts LOCATION. DESCIPTION Q'TY PE SET EMAKS MOTO ASSY S 2 CAPACITO S 3 COMPESSO S 4 OVELOAD POTECTO S 5 DC PCB ASSEMBLY S 6 AC PCB ASSEMBLY S 7 THEMISTO S 8 PLASMA FILTE ASSY S Service Manual 2

22 Schematic Diagram Components Location. MAIN P.C.B ASSEMBLY CN-AC/DC J CN-2V CN-CON D02D J5 CN-HVB C03T D03D D04D D05D HEAT SINK IC0D Q02T J4 C0D 0T Q0T Q03T J6 C02D D0T C02T J2 C04D Q04T QIC02DT CN-TELE J3 Y-4WAY Y-LOW Y-MED Y-HI J7 C05D CN-TH2 PCB:6870A90068D CN-PW ZN0J 0J E03J J8 CN-MOTO E02J E0J CN-4WAY C0J Y-COMP ASSEMBLY:687A2047C POWE TANS FUSE 250V/T3.5A E04J E05J 2. DISPLAY P.C.B. ASSEMBLY PCB:6870A90067C ASSEMBLY:687A2048A 22 oom Air Conditioner

23 Troubleshooting Guide Troubleshooting Guide Piping System CONDENSE COIL FAN MOTO CAPILLAY TUBE COMPESSO TUBO FAN EVAPOATO COIL Figure 26 is a brief description of the important components and their function in what is called the refrigeration system. This will help you to understand the refrigeration cycle and the flow of the refrigerant in the cooling cycle. COOLED AI EVAPOATO COILS COMPLETE LIQUID BOIL OFF POINT OOM AI HEAT LOAD OOM AI CONITIONE CYCLE OF EFIGEATION SUCTION LINE COOL LOW PESSUE VAPO VAPO INLET CONDENSE COILS HOT DISCHAGED AI MOTO OUTSIDE COOLING AI FO EFIGEANT PASS THOUGH COMPESSO LIQUID PESSUE DOP OIL (LIQUID EFIGEANT) CAPILLAY TUBE Figure 26 LIQUID OUTLET HIGH PESSUE VAPO LIQUID EFIGEANT LOW PESSUE VAPO Service Manual 23

24 Troubleshooting Guide Troubleshooting Guide In general, possible trouble is classified in two kinds. The one is called Starting Failure which is caused from an electrical defect, and the other is ineffective Air Conditioning caused by a defect in the refrigeration circuit and improper application. Unit runs but poor cooling. Ineffective Cooling Check cold air circulation for smooth flow. Check outdoor coil (heat exchanger) & the fan operation. Check heat load increase. Dirty indoor coil (Heat exchanger) Check gas leakage. Clean condenser. Malfunction of fan epair gas leak. Not on separate circuit. Clogged of air filter. eplacement of unit if the unit is beyond repair. Check inside gas pressure. Obstruction at air outlet Adjusting of refrigerant charged. Correct above trouble Malfunction of compressor. Check clogging in refrigeration circuit. eplacement of compressor. epair clogging in refrigeration circuit. Satisfactory operation with temperature difference of inlet & outlet air ; 44~50 F(7~0 C) 24 oom Air Conditioner

25 Troubleshooting Guide Fails to Start Check of power source. Check circuit breaker and fuse. Check of control switch setting. Gas leakage of feeler bulb of thermostat Check of control switch. Compressor only fails to start. Fan only fails to start. Drop of power voltage. Defect of compressor capacitor. Capacitor check. eplacement Improper thermostat setting. Loose terminal connection. Improper wiring. Improper wiring. Defect of fan motor capacitor. Irregular motor resistance ( ). Irregular motor insulation ( ). eplacement of fan motor. Irregular motor resistance ( ) egular but fails to start. Irregular motor insulation ( ) eplacement of compressor (Motor damaged) eplacement of compressor (locking of rotor, metal). Service Manual 25

26 Troubleshooting Guide Electrical Parts Troubleshooting Guide Possible Trouble The unit does not operate. Is the Trans input power AC 5V? Check the Fuse. Check the the wiring diagram. Is the Trans output power about AC 4V? Is shorted the Trans. output? Check the Main PCB pattern. eplace the Trans. Is output Voltage of IC0D DC 2V? eplace D02D~D05D. eplace IC0D. Is output Voltage of IC02D DC 5V? eplace IC02D. Is the reset circuit good? (The No.4 of Micom is 5V.) eplace IC0A, C02A. Is the connection between AC and DC OK? Connect connector exactly. Is the voltage No.8 of Micom DC 5V? Check the PCB pattern. eplace AC PCB Ass'y. 26 oom Air Conditioner

27 Troubleshooting Guide Possible Trouble 2 The compressor does not operate. Is setting Temp. set lower than oom Temp.-0.5 C? Select the setting Temp. to lower Number. Is the voltage No.0 of IC0M 0V? Is the voltage N0.9 of IC0M DC 2V? Does the Unit delay for 3 minutes? Check the Y-COMP. Check the wiring Diagram. eplace IC0M. Wait 3 Minutes. eplace MAIN PCB Ass'y. Possible Trouble 3 The compressor always operate. Is the wire connection of Y-COMP OK? Connect LEAD Wire to Y-COMP again. Check the Y-COMP. Service Manual 27

28 Troubleshooting Guide Possible Trouble 4 FAN does not operate. Is the voltage. or 2 or 4 of IC0M DC 2V? eplace IC0M. Is the voltage.6 or 5 or 3 of IC0M 0V? eplace IC0M. Check the Y-Hi or Y-Med or Y-Lo. Check the wiring diagram. Possible Trouble 5 The function of Energy Saver does not operate. Is the mode key pushed once more from cool mode? Set the mode key to Energy Saver mode. Is the voltage No.3 of CN-AC/DC of AC PCB Ass'y DC 5V? eference to OWNE'S MANUAL. Check the Energy Saver mode key. Check the pattern of AC & DC PCB. 28 oom Air Conditioner

29 Troubleshooting Guide Possible Trouble 6 emote controller does not operate. Is the voltage of Battery over 2.3V? eplace the battery. Is the voltage No.0 of CN-AC/DC on DC PCB Ass'y DC 5V? Check the the PCB pattern. Is the connection of CN-AC/DC OK? Connect connector to CN-AC/DC exactly. eplace eceiver Ass'y. Possible Trouble 7 It displays abnormally on DC PCB Ass y. Is IC0G good? eplace IC0G. Is the connection of CN-AC/DC OK? Connect connector to CN-AC/DC exactly. Does the IC03G (Q0G, Q02G, Q03G for Delux Model) operate normally on DC PCB Ass'y? eplace IC03G (Q0G, Q02G, Q03G for Delux Model). eplace the DC PCB Ass'y. Service Manual 29

30 Troubleshooting Guide Electrical Parts Possible Trouble The unit does not operate. Is the Trans input power AC 5V? Check the Fuse. Check the the wiring diagram. Is the Trans output power about AC 4V? Is shorted the Trans. output? Check the AC PCB pattern. eplace the Trans. Is output Voltage of IC0D DC 2V? eplace D02D~D05D. eplace IC0D. Is output Voltage of IC02D DC 5V? eplace IC02D. Is the reset circuit OK? (The No.4 of Micom is 5V.) eplace IC0A, C0A. Is the connection between AC and DC OK? Connect connector exactly. Is the voltage No.40 of Micom DC 5V? Check the PCB pattern. eplace AC PCB Ass'y. 30 oom Air Conditioner

31 Troubleshooting Guide Possible Trouble 2 The compressor does not operate. Is desired Temp. set lower than oom Temp.-0.5 C? Select the desired Temp. to lower Number. Is the voltage No.0 of IC0M 0V? Is the voltage N0.9 of IC0M DC 2V? Is the Unit for 3 minutes delay? Check the Y-COMP. Check the wiring Diagram. eplace IC0M. Wait 3 Minutes. eplace AC PCB Ass'y. Possible Trouble 3 The compressor always operate. Is the wire connection of Y-COMP OK? Connect LEAD Wire to Y-COMP again. Check the Y-COMP. Service Manual 3

32 Troubleshooting Guide Possible Trouble 4 FAN does not operate. Is the voltage. or 2 or 4 of IC0M DC 5V? eplace IC0M. Is the voltage.6 or 5 or 3 of IC0M 0V? eplace IC0M. Check the Y-Hi or Y-Med or Y-Lo. Check the wiring diagram. Possible Trouble 5 emote controller does not operate. Is the voltage of Battery over 2.3V? eplace the battery. Is the voltage No.0 of CN-AC/DC on AC PCB Ass'y DC 5V? Check the PCB pattern. pattern. Is the connection of CN-AC/DC OK? Connect connector to CN-AC/DC exactly. eplace eceiver Ass'y. 32 oom Air Conditioner

33 Troubleshooting Guide Possible Trouble 6 It displays abnormally on DC PCB Ass y. Are IC0G and IC02G OK? Is the connection of CN-AC/DC OK? eplace IC0G, IC02G. Connect connector to CN-AC/DC exactly. Does the IC03G operate normally on AC PCB Ass'y? eplace IC03G. eplace the DC PCB Ass'y. Service Manual 33

34 Troubleshooting Guide COMPLAINT CAUSE EMEDY Fan motor will not run. Fan motor runs intermittently Fan motor noise. Compressor will not run, but fan motor runs. No power Power supply cord Wire disconnected or connection loose Capacitor (Discharge capacitor before testing.) Will not rotate evolves on overload. Fan Turbo Loose clamper Worn bearings Voltage Wiring Check voltage at outlet. Correct if none. Check voltage to Control Box. If none, check power supply cord. eplace cord if circuit is open. Connect wire. efer to wiring diagram for terminal identification. epair or replace loose terminal. Test capacitor. eplace if not within ±0% of manufacturer's rating. eplace if shorted, open, or damaged. Fan blade hitting shroud or blower wheel hitting scroll. ealign assembly. Units using slinger ring for condenser fan must have /4 to 5 /6 inch clearance to the base. If it hits the base, shim up the bottom of the fan motor with mounting screw(s). Check fan motor bearings; if motor shaft will not rotate, replace the motor. Check voltage. If not within limits, call an electrician. Test capacitor. Check bearings. Does the fan blade rotate freely? If not, replace fan motor. Pay attention to any change from high speed to low speed. If the speed does not change, replace the motor. If cracked, out of balance, or partially missing, replace it. If cracked, out of balance, or partially missing, replace it. Tighten it. If knocking sounds continue when running or loose, replace the motor. If the motor hums or noise appears to be internal while running, replace motor. Check voltage. If not within limits, call an electrician. Check the wire connections, if loose, repair or replace the terminal. If wires are off, refer to wiring diagram for identification, and replace. Check wire locations. If not per wiring diagram, correct. 34 oom Air Conditioner

35 Troubleshooting Guide COMPLAINT CAUSE EMEDY Compressor will not run, but fan motor runs. Compressor cycles on overload. Compressor cycles on overload. Compressor cycles on overload. Insufficient cooling or heating Excessive noise Thermistor Capacitor (Discharge capacitor before servicing.) Compressor Overload Voltage Overload Fan motor Condenser air flow restriction Condenser fins (damaged) Capacitor Wiring efrigerating system Air filter Exhaust damper door Unit undersized Turbo or fan Copper tubing Check the TEMP control. If not at the lowest number, set TEMP control to this setting and restart the unit. Check the continuity of the thermistor. eplace the thermistor if the circuit is open. Check the capacitor. eplace if not within ±0% of manufacturers rating. eplace if shorted, open, or damaged. Check the compressor for open circuit or ground. If open or grounded, replace the compressor. Check the compressor overload, if externally mounted. eplace if open. (If the compressor temperature is high, remove the overload, cool it, and retest.) Check the voltage. If not within limits, call an electrician. Check overload, if externally mounted. eplace if open. (If the compressor temperature is high, remove the overload, cool, and retest.) If not running, determine the cause. eplace if required. emove the cabinet. inspect the interior surface of the condenser; if restricted, clean carefully with a vacuum cleaner (do not damage fins) or brush. Clean the interior base before reassembling. If condenser fins are closed over a large area on the coil surface, head pressures will increase, causing the compressor to overload. Straighten the fins or replace the coil. Test capacitor. Check the terminals. If loose, repair or replace. Check the system for a restriction. If restricted, clean of replace. Close if open. Determine if the unit is properly sized for the area to be cooled. Check the set screw or clamp. If loose or missing, correct. If the turbo or fan is hitting air guide, rearrange the air handling parts. emove the cabinet carefully and rearrange tubing not to contact cabinet, compressor, shroud, and barrier. Service Manual 35

36 Exploded View Exploded View 3090 Owner's Manual W W W0CZZ A oom Air Conditioner

37 eplacement Parts List eplacement Parts List LOCATION. DESCIPTION PAT. LWHD8000Y5 LWHD000 LWHD8000 LWHD8000Y6 EMAK 3040 BASE ASSEMBLY,WELD[SINGLE] 304A004Q 304A004Q 304A004H 3090 CABINET ASSEMBLY,SINGLE 309A0056C 309A0056C 309A0056A 3532 GILLE ASSEMBLY,FONT(SINGLE) 353A2407B 353A2407B 353A24020A 3533 GILLE,INLET 3530A0239B 3530A0239B 3530A0236A COVE 3550A30226A 3550A30226A 3550A30226A 4758 LOUVE,HOIZONTAL 4758A20064A 4758A20064A 4758A20069A LOUVE,VETICAL 4758A20040C 4758A20040C 4758A20040C LOUVE,VETICAL 4758A20040D 4758A20040D 4758A20040D BACE 4800A30002C 4800A30002C 4800A30002C SHOUD 4998A0036A 4998A0036A 4998A0036A FILTE ASSEMBLY,AI CLEANE 523A20023A 523A20023A 523A20023A PANEL,CONTOL 3720A0C 3720A0C 3720A0C CONTOL BOX ASSEMBLY,SINGLE 4995A03L 4995A03L 4995A03J PWB(PCB) ASSEMBLY,MAIN(AC) 687A2047C 687A2047C 687A2047C ESCUTCHEON 383A002E 383A2002E 383A0046A PWB(PCB) ASSEMBLY,MAIN(DC) 687A2048A 687A2048A 687A2048A THEMISTO ASSEMBLY 6323A20004P 6323A20004P 6323A20004P 2640 POWE COD ASSEMBLY 64A A A20037C 3468 MOTO ASSEMBLY,SINGLE 468A2040A 468A2040A 468A2040A DAMPE,VENTILATION 4900A20020A 4900A20020A 4900A20020A DAMPE,VENTILATION 4900A20020B 4900A20020B 4900A20020B OIFICE 4948A20030A 4948A20030A 4948A20030A 3525 TUBE ASSEMBLY,EVAPOATO IN 52A25020A 52A25020A 52A25020A 352A TUBE ASSEMBLY,SUCTION SINGLE 52A2207B 52A2207A 52A2207A 3523 TUBE ASSEMBLY,DISCHAGE SINGLE 52A2237A 52A2237A 52A2237A 552 TUBE ASSEMBLY,CONDENSE OUT 52A2206A 52A2206A 52A2206A TUBE ASSEMBLY,CAPILLAY 520A30646A 5424A34N 52A23020A AI GUIDE ASSEMBLY 5239A2009A 5239A2009A 5239A2009A EVAPOATO ASSEMBLY,FIST 542A0043A 542A0043A 542A0043A CONDENSE ASSEMBLY,FIST 5403A2080A 5403A2080A 5403A2080A ANTI-VIBATION BUSH 5040A495A 5040A495A 5040A495A COMPESSO SET 2520UCBA A2004B 546A90007A FAN, AXIAL 5900A2005A 5900A2005A 5900A2005A FAN, TUBO 5900A20020A 5900A20020A 5900A20020A 2670 EMOTE CONTOLLE ASSEMBLY 67A20034G 67A20034G 67A20034C W48602 CLAMP, SPING 3H02932B 3H02932B 3H02932B W0CZZ CAPACITO, DAWING 0CZZA20005B 0CZZA20005B 0CZZA20005B Service Manual 37

38 P/:3828A29003C January, 2005 Printed in China