LG Room Air Conditioner

Transcription

1 LG oom Air Conditioner SEVICE MANUAL LG MODEL: HBLG8003,LB8000E,LW8000E,HBLG003,LWHD006,L006 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...5 Outside Dimensions...5 Product Specifications...6 Installation...7 Select the Best Location...7 Installation Check...7 How to Secure the Drain Pipe...7 How to Install...8 Operation... Function of Controls... Disassembly...4 Mechanical Parts...4 Air handling Parts...5 Electrical Parts...6 efrigerating Cycle...8 Schematic Diagram... Wiring Diagram... Electronic Control Device... Components Location...3 Troubleshooting Guide...4 Pipeing System...4 Troubleshooting Guide...5 Electrical Parts Troubleshooting Guide...7 Electrical Parts...3 Exploded View...37 eplacement Parts List...38 oom Air Conditioner

3 Safety Precautions Safety Precautions Precautions To prevent injury and property damage, follow these instructions. Incorrect operation due to ignoring instructions might cause harm or damage, the seriousness of which is indicated by the following symbols. WANING CAUTION This symbol shows the possibility of death or serious injury. This symbol indicates the possibility of injury or damage to property. Never Do This Always Do This The following items are classified by these symbols. WANING Plug in the power plug properly. Doing so may cause electric shock or fire due to heat generation. Do not modify power cord length or share the outlet with other appliances. Doing so may cause electric shock or fire due to heat generation. Do not allow water to run into electric parts. Doing so may cause failure of machine or electric shock. Do not use the socket if it is loose or damaged. Do not operate or stop the unit by inserting or pulling out the power plug. Doing so may cause electric shock or fire due to heat generation. Do not operate with wet hands or in damp environment. Doing so may cause electric shock. Always install air leakage breaker and a dedicated switching board. Failure to install these may cause fire or electric shock accident. Do not open the entrance during operation. Do not damage or use an unspecified power cord. Doing so may cause electric shock or fire. If the supply cord is damaged, it must be replaced by the manufacturer, the manufacturer's service agent, or a similarly qualified person in order to avoid a hazard. (Y attachment) Always plug into a grounded outlet. No grounding may cause electric shock (See Installation Manual). Unplug the unit if strange sounds, odors, or smoke comes from it. Such a unit may pose a risk of fire or electric shock accident. Keep firearms away. Doing so may cause fire or electric shock. Do not use the power cord close to heating tools. Doing so may cause fire or electric shock. It may cause electric shock. Do not use the power cord near flammable gas or combustibles such as gasoline, benzene, thinner, etc. Doing so may lead to an explosion or fire. Service Manual 3

4 Safety Precautions Ventilate before operating air conditioner when gas goes out. WANING Do not disassemble or modify products randomly. Operating the air conditioner in the presence of gas vapors can lead to explosions and fire. Doing so may cause failure or electric shock. Never touch the metal parts of the unit when removing the filter. They are sharp and may cause injury. When cleaning the unit, first make sure the is off and the cord is unplugged. Since the fan rotates at high speed during operation, it may cause injury if activated while cleaning. Stop operation in storm or hurricanes. Operation with windows opened may cause wetting of indoor and soaking of household furniture. Do not place obstacles around the absorption inlet or output. Doing so may cause failure of appliance or accident. Do not use abrasives or strong detergent such as wax or thinner. Always use a soft cloth. Otherwise, the products appearance may be damaged due to change of product color or scratching of its surface. CAUTION Do not clean the air conditioner with water. Water may enter the unit and degrade the insulation. It also may cause an electric shock. Do not put a pet or house plant where it will be exposed to direct air flow. This could injure the pet or plant. Hold the plug by the head when taking it out. Improper handling may cause electric shock or damage. Ensure that an installation console of the outdoor appliance is not damaged due to extened use. If the previous air conditioner damaged the console, there is a risk of the new unit falling. Do not place heavy object on the power cord and take care so that the cord is not pinched. Treating the power cord carelessly poses a danger of fire or electric shock. Operate only in a well ventilated area when using in the presence of a stove, etc. An oxygen shortage may otherwise occur. Do not use appliance for special purpose such as climate control for animals or vegetables, precision machine, or conservation of art articles. It may cause damage of animals or vegetables or loss of property. Turn off the main power switch when not using it for a long time. Doing so can prolong the life of the product. Always insert filters securely. Clean them every two weeks. Operation without filters will cause failure. Do not drink water drained from air conditioner. It contains contaminants that would make you sick. If water enters the product, turn off the the power switch of the main body of appliance. Contact service center after taking the powerplug out from the socket. Do not direct airflow at room occupants only. This could damage your health. 4 oom Air Conditioner

5 COOL FAN INDOO DY FAN DESIED HEAT DEFOST ENEGY SAVE AI PUYFIE AUTO ESTAT 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 3 490(9 / 8" ) 5 9( / 3" ) 3 6.5(4 / 3" ) unit: mm(inch) (3 / ") 3 3 8( / 3" ) Service Manual 5

6 Specfications Product Specifications MODELS ITEMS POWE SUPPLY COOLING CAPACITY (Btu/h) INPUT (W) UNNING CUENT (A) E.E. (BTU/W. h) OPEATING INDOO ( C) CONDITION OUTDOO ( C) EFIGEANT (-) CHAGE EVAPOATO CONDENSE FAN, INDOO FAN, OUTDOO FAN SPEEDS, FAN/COOLING FAN MOTO OPEATION CONTOL OOM TEMP. CONTOL AI DIECTION CONTOL CONSTUCTION POTECTO COMPESSO FAN MOTO POWE COD DAIN SYSTEM NET WEIGHT (lbs/kg) OUTSIDE DIMENSION (inch) (WxHxD) (mm) HBLG8003 LB8000E ø, 5, 60Hz 8,000 8,00 0, , (DB)* 9.4(WB)** 35(DB)* 3.9(WB)** 300g(0.6oz) 400g(4.oz) g(8.3oz) 50 OW STACKS 3 OW STACKS OW 6STACKS TUBO FAN POPELLE T YPE FAN WITH SLINGE ING 3/3 6POLES EMOTE CONTOLLE THEMISTO VETICAL LOUVE (IGHT & LEFT) HOIZONTAL LOUVE (UP & DOWN) SLIDE IN-OUT CHASSIS OVELOAD POTECTO INTENAL THEMAL POTECTO (3 WIE WITH GOUDING) ATTACHMENT PLUG (COD-CONNECTED TYPE) DAIN PIPE O SPLASHED BY FAN SLINGE 6/8 7/3 0 3 /3 x3 7 /8 x9 3 /8 50 x 353 x 490 LW8000E HBLG003 LWHD006 L006 * DB:Dry Bulb ** WB:Wet Bulb 6 oom Air Conditioner

7 Installation Installation Select the Best Location.To prevent vibration and noise, make sure the unit is installed securely and firmly..install the unit where the sunlight does not shine directly on the unit. 3.The outside of the cabinet must extend outward for at least " and there should be no obstacles, such as a fence or wall, within 0" 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. COOLED AI 30"~60" AWNING HEAT ADIATION ABOUT /" Over 0" FENCE Figure CAUTION: All side louvers of the cabinet must remain exposed on the outdside of the structure. 4.Install the unit a little slanted so the back is slightly lower than the front (about /"). This will help force con-densed water to the outside. 5.Install the unit from the bottom about 30"~60" above the floor level. Installation Check The setting conditions must be checked prior to initial starting. The undermentioned 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.. Connect to a single-outlet 5A circuit. (or 0A 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 BASE PAN Figure BOTTOM HOLE UBBE The air conditioner must be installed horizontally or tilted slightly to the outside for proper water drainage. On exceptionally hot and humid days the air conditioner may overflow condensed water. If the air conditioner is used in hot and a high humidity zone, exchange the HOLE UBBE for the DAIN PIPE.(See figure, figure 3.) BASE PAN Figure 3 BOTTOM HOLE UBBE Service Manual 7

8 COOL INDOO FAN FAN DY HEAT DEFOST DESIED ENEGY SAVE AI PUYFIE AUTO ESTAT COOL INDOO FAN FAN DY HEAT DEFOST DESIED ENEGY SAVE AI PUYFIE AUTO ESTAT Installation How to Install. WHEN USING GASKET A A G B C B IGHT SIDE J H HOIZONTAL LINE 4 D E 3 F. WINDOW (WIDTH-A, HEIGHT-B). GASKET 3. WALL 4. DETAILS 5. x 30 OUND HEAD WOOD SCEWS A B C D E F H J K 535mm 366mm 50mm 30mm 0~5mm OVE 40mm 3 5~0mm 0~5mm ( /") (4 7 /6") (0") ( /6") (0~") (OVE 6 7 /3") ( /4") ( 3 /6"~ 3 /8") (0~ 3 /6"). WHEN USING INSTALLATION KITS A. WINDOW EQUIEMENTS This unit is designed for installation in standard double hung windows with actual opening widths from 5" to 36". The top and bottom window sash must open sufficiently to allow a clear vertical opening of 6" from the bottom of the upper sash to the window stool. B. INSTALLATION KITS CONTENTS 5" min 5" to 36" Stool Interior wall 0 3 /3" min (Without frame curtain) Offset /" to /4" Sill Exterior NAME OF PATS Q'TY FAME CUTAIN SILL SUPPOT 3 BOLT 4 NUT 5 SCEW(TYPE A) 6 6 SCEW(TYPE B) 3 7 SCEW(TYPE C) 5 8 FOAM-STIP 9 FOAM-PE 0 UPPE GUIDE FOAM-PE FAME GUIDE 3 WINDOW LOCKING BACKET 8 oom Air Conditioner

9 COOL FAN FAN ENEGY SAVE AI PUYFIE AUTO ESTAT COOL FAN FAN ENEGY SAVE AI PUYFIE AUTO ESTAT Installation BEFOE INSTALLATION. emove the screws which fasten the cabinet at both sides and at the back.. Slide the unit out from the cabinet by gripping the base pan handle and pulling forward while bracing the cabinet. 3. Cut the window sash seal to the proper length. Peel off the backing and attach the Foam-Pe to the underside of the window sash. 4. emove the backing from the top upper guide Foam PE and attach it to the bottom of the Upper Guide. 5. Attach the upper guide onto the top of the cabinet with 3 type A screws. 6. Insert the Frame Guides into the bottom of the cabinet. 7. Insert the Frame Curtain into the upper guide and Frame Guides. 8. Fasten the curtains to the unit with 4 Type A screws at the both sides. INDOO DESIED DY HEAT DEFOST INDOO DESIED DY HEAT DEFOST Shipping Screws EPS Material W STAT INSTALLATION. Open the window. Mark a line on center of the window stool (or desired air conditioner location). Carefully place the cabinet on the window stool and align the center mark on the front angle with the center line marked in the window stool. (Type A) Pull the bottom window sash down behind the upper guide until it meets. 5 (Type A) TICE Do not pull the window sash down so tightly that the movement of Frame Curtain is restricted. Upper Guide Window stool Front Angle Figure 4 Window Sash Upper guide 9 Foam-pe 3 Cabinet Frame Curtain Foam-pe 0 Figure 5 Service Manual 9

10 Installation 3. Loosely assemble the sill support using the parts in Figure 6. INDOO Bolt 3 OUTDOO Sill Support Nut 4 Figure 6 4. Select the position that will place the sill support near the outer most point on sill (See Figure 6) TICE Be careful when you install the cabinet (frame guides are broken so easily). 5. Attach the sill support to the cabinet track hole in relation to the selected position using Type A screws in each support (See Figure 7). Frame Guide INDOO 5 Screw(Type A) Cabinet OUTDOO About /" Figure 7 6. The cabinet should be installed with a very slight tilt (about /") downward toward the outside (See Figure 8). Adjust the bolt and the nut of Sill Support for balancing the cabinet. Screw(Type B) 6 Screw(Type A) 5 Sill support About /" 7. Attach the cabinet to the window stool by driving the screws (Type B: Length sixteen millimeters and below.) through the front angle into window stool (5/8"). Sash track 8. Pull each Frame Curtain properly to each window sash track, and repeat step. Sill support Screw(Type B) 6 Front Angle Figure 8 9. Attach each Frame Curtain to the window sash by using screws (Type C). (See Figure 9) Type C 7 Figure 9 0 oom Air Conditioner

11 COOL FAN DY INDOO FAN DESIED HEAT DEFOST ENEGY SAVE AI PUYFIE AUTO ESTAT Installation 0. Slide the unit into the cabinet.(see Fig. 0) CAUTION: For security purpose, reinstall screws (Type A) at cabinet's sides. Power cord Screw(Type A) Screw(Type A) Figure 0. Cut the Foam-Strip to the proper length and insert between the upper and lower window sash. (See Fig. ) Foam-Strip 8 Figure. Attach the window Locking Bracket with a type C screw. (See Fig. ) 3 Figure 3. Attach the front grille to the cabinet by inserting the tabs on the grille into the tabs on the front of the cabinet. Push the grille in until it snaps into place.(see Fig. 3) 4. Lift the inlet grille and secure it with a type A screw through the front grille.(see Fig. 4) Figure 3 Figure 4 Figure 5 Service Manual

12 Installation Operation Designed for COOLING ONLY. Powerful and quiet cooling. Slide-in and slide-out chassis for the simple installation and service. Low air-intake, top cooled-air discharge. Built-in adjustable Thermistor Washable one-touch filter Compact size eliable and efficient rotary compressor is equipped. emote Control Operations CAUTION: The emote Controller will not function properly if strong light strikes the sensor window of the air conditioner or if there are obstacles between the emote Controller and the air conditioner. The controls look like this: Controls Cool Energy Saver F LOW F MED F3 HIGH 'F 6 Fan Dry Timer TEMP MODE TIME FAN SPEED POWE Power Temp Fan Speed Timer Mode 4 3 oom Air Conditioner

13 Operation POWE Operation starts when this button is pressed and stops when you press the button again. TEMPEATUE CONTOL The thermostat monitors room temperature to maintain the desired temperature. The thermostat can be set between 60 F~86 F (6 C~30 C). The unit takes an average of 30 minutes to adjust the room temperature by F. OPEATION MODE SELECTO Select cooling mode to cool the room. Select energy saver mode for energy saving operation. Select fan mode for basic ventilating fan operation. Select dry mode for dry operation. FAN SPEED SELECTO For increased power while cooling, select a higher fan speed. 3 steps: High Low Med ON/OFF TIME The timer can be set to start and stop the unit in hourly increments (up to hours). EMOTE CONTOL SENSO How to Insert Batteries 3 Push out the cover on the back of the remote control with your thumb Pay attention to polarity and insert two new AAA.5V batteries. eattach the cover. TICE : Do not use rechargeable batteries. Make sure that both batteries are new. In order to prevent discharge, remove the batteries from the remote control if the air conditioner is not going to be used for an extended period of time Keep the remote control away from extremely hot or humid places. To maintain optimal operation of the remote control, the remote sensor should not be exposed to direct sunlight. Service Manual 3

14 COOL FAN FAN ENEGY SAVE AI PUYFIE AUTO ESTAT Disassembly Disassembly Before the following disassembly, POWE SWITCH set to OFF and disconnect the power cord. Mechanical Parts. FONT GILLE. Open the lnlet grille downward and remove the air filter.. emove the screw which fastens the front grille.(see Figure 6) 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.. CABINET. After disassembling the FONT GILLE, remove the screws which fasten the cabinet at both sides.. emove the screws which fasten the cabinet at back. 3. Pull the base pan forward. (See Figure 7) 4. emove the cabinet. 5. e-install the components by referring to the removal procedure, above. 3. CONTOL BOX. emove the front grille.. emove the cabinet. 3. emove the screws which fasten the power cord. 4. Disconnect the grounding screw from the evaporator channel. 5. emove the screw which fasten the control box cover. 6. emove the housing which connects PCB and motor wire in the control box. 7. Disconnect the housing which connects Plazma Air Purifier.(Optional) 8. emove the screw at left cover of filter case and open the cover to remove inner screw. (Optional) 9. emove the nut which fastens the terminal cover. 0. emove the terminal cover.. emove all the leads from the overload protector.. Discharge the capacitor by placing a 0,000 ohmresistor across the capacitor terminals. 3. aise the control box upward completely. (See Figure 8) 4. e-install the components by referring to the removal procedure, above. (efer to the circuit diagram found on page in this manual and on the control box.) 4 oom Air Conditioner Figure 6 Figure 7 Figure 8 INDOO DESIED DY HEAT DEFOST

15 Disassembly Air Handling Parts 4. AI GUIDE AND TUBO FAN. emove the front grille.. emove the cabinet. 3. emove the control box. 4. emove the 4 screws which fasten the brace. 5. emove the brace. 6. emove the screws which fasten the air guide upper. 7. emove the air guide upper.(see figure 9) 8. emove the screws which fasten the evaporator. 9. Move the evaporator forward and pulling it upward slightly. (See Figure 0) 0. Pull out the hook of orifice by pushing the tabs and remove it. (See Figure ). emove the clamp with a hand plier which secures the turbo fan.. emove the turbo fan. 3. emove the screws which 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. Figure 9 Figure 0 5. FAN. emove the cabinet.. emove the brace. 3. emove the 5 screws which fasten the condenser. 4. Move the condenser to the left carefully. 5. emove the clamp which secures the fan. 6. emove the fan. (See Figure ) 7. e-install by referring to the removal procedure. Figure Figure Service Manual 5

16 Disassembly 6. SHOUD. emove the fan.. emove the shroud. (See Figure 3) 3. e-install the components by referring to the removal procedure, above. Figure 3 Electrical Parts. OVELOAD POTECTO. emove the cabinet.. emove the nut which fastens the terminal cover. 3. emove the terminal cover. (See Figure 4) 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.. COMPESSO. emove the cabinet.. 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. 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 5) 7. e-install the components by referring to the removal procedure, above. Figure 4 Figure 5 6 oom Air Conditioner

17 COOL FAN FAN AI PUYFIE AUTO Disassembly 3. CAPACITO. emove the control box.. Open the top cover from the control box. (See Figure 6) 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. HEAT DEFOST Figure 6 4. POWE COD. emove the control box.. Open the top cover from the control box. 3. Disconnect the front panel from the control box. (See Figure 7) 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.) INDOO DESIED DY HEAT DEFOST ENEGY SAVE ESTAT Figure 7 Service Manual 7

18 Disassembly 5. MOTO. emove the cabinet.. emove the turbo fan. 3. emove the fan. 4. emove the 4 screws which fasten the motor from the air guide. (See Figure 8) 5. emove the motor. 6. e-install the components by referring to the removal procedure, above.(see Figure 8) Figure 8 efrigerating Cycle. CONDENSE 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.. emove the 5 screws which fasten the brace. 3. emove the 5 screws which 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 9) Figure 9. EVAPOATO. emove the control box.. emove the air guide upper. 3. emove the screws which fasten the evaporator. 4. Move the evaporator sideways carefully. 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 30) Figure 30 8 oom Air Conditioner

19 Disassembly 3. CAPILLAY TUBE. emove the cabinet.. 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. TES 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.. 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 3A. ) 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 for 0 to 30 minutes, until 600 microns of vacuum 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 3B. 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. ) Connect the charging cylinder as shown in figure 3B. 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 inches from the pinch-off tool. Use sil-fos solder and solder 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. Service Manual 9

20 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 3A-Pulling Vacuum Figure 3B-Charging 0 oom Air Conditioner

21 Schematic Diagram Schematic Diagram HVB 3 3 OOM-TH CN-TH 5V SMAW H 6.K % 0H.K % OSC0B T8.00MG 0B M 5V C0A V A 0K C0A uf 0V x 05P 0K SDA SCL Digit4 (Scan4) Digit3 (Scan3) Digit (Scan) Digit (Scan) Digit0 (Scan0) SEG-a SEG-b SEG-c 3.6V 5V IC0A S736 06P 0K C0F 0F K C0F 03F K Model Auto estart Non Auto estart EEPOM CAT93C46 A0 Vcc A WP 3 A SCL GND SDA EEPOM 04P O O 04P 5V 0P 03P 0K 0K 04P K Q03G A0S FAN SW0G D0G TIME SW04G D04G Q0G A0S Q0G A0S TEMP DOWN ON/OFF SW0G SW03G D0G 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 Option 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 out LED out LED out0 KEY 5V H H.K.K % % OH OH V IC0M ULN004A 5V C0L 0 0V Vcc 0L K Vout GND ECEIVE 0E 0 0P 0K 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 SW SW CN-TELE SMW V (D) C0T 0. 50V CN-TH SMW50-0 CN-HVB SMW00-03(BL) CN-CONT J5 SMW00-03(YL) CN-V SMW00-03(WH) CN-4WAY YW396-03AV(YL) CN-MOTO YW396-09AV CN-PW YW396-03AV Y-COMP G4A-A-E-LG FUSE 50VT3.5A 5V C0T Q03T 0T 0.00 C04M K x D0T C03T N448 Q04T 0.00 A04M 5V 5V Q0T C04M Tx Q0T A04M 0 J7 V Y-COMP Y-4WAY Y-LOW Y-MED Y-HI Model Y-4WAY J07 CN-4WAY CN-TH Cool Only O Heat Pump O O O Y-4WAY Y-HI Y-MED Y-LOW 5V V C0J 0./75V CN-AC/DC J /W STAIGHT ZN0J SVC7D-4A SVC7D-4A POWE TANS D0D D03D D0D~D05D N4004 D05D IC0D 78 D04D + C0D C0D C03D V 50V 6V BZ0E PKM3EPY C05D C06D V 50V V CN-AC/DC 558-(YEONHO) (MOLEX) ANGLE V 5V IC0D 7805 C04D C05D V 5V 0E K 5V 5V F 0K 5V IC0G ULN004A 6 0G G G G G G G 680 V COOL DEFOST DY/HEAT TIME FAN E/SAVE X 7 4 X X X O I + O I Electronic Control Device 88 SEGMENT Service Manual

22 Schematic Diagram Wiring Diagram 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 50V/TA Y-LOW ZN0J Y-MED POWE TANS CN-AC/DC Y-HI DCV CN-V 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 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 oom Air Conditioner

23 Schematic Diagram Components Location. MAIN P.C.B ASSEMBLY CN-AC/DC J CN-V CN-CON D0D J5 CN-HVB C03T D03D D04D D05D HEAT SINK IC0D Q0T J4 C0D 0T Q0T Q03T J6 C0D D0T C0T J C04D Q04T QIC0DT CN-TELE J3 Y-4WAY Y-LOW Y-MED Y-HI J7 C05D CN-TH PCB:6870A90068D CN-PW ZN0J 0J E03J J8 CN-MOTO E0J E0J CN-4WAY C0J Y-COMP ASSEMBLY:687A047C POWE TANS FUSE 50V/T3.5A E04J E05J. DISPLAY P.C.B. ASSEMBLY PCB:6870A90067C ASSEMBLY:687A048A Service Manual 3

24 Troubleshooting Guide Troubleshooting Guide Piping System CONDENSE COIL FAN MOTO CAPILLAY TUBE COMPESSO TUBO FAN EVAPOATO COIL Figure 3 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 3 LIQUID OUTLET HIGH PESSUE VAPO LIQUID EFIGEANT LOW PESSUE VAPO 4 oom Air Conditioner

25 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) Service Manual 5

26 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) 6 oom Air Conditioner eplacement of compressor (locking of rotor, metal).

27 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 V? eplace D0D~D05D. eplace IC0D. Is output Voltage of IC0D DC 5V? eplace IC0D. Is the reset circuit good? (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.8 of Micom DC 5V? Check the PCB pattern. eplace AC PCB Ass'y. Service Manual 7

28 Troubleshooting Guide Possible Trouble 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 V? 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. 8 oom Air Conditioner

29 Troubleshooting Guide Possible Trouble 4 FAN does not operate. Is the voltage. or or 4 of IC0M DC V? 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. Service Manual 9

30 Troubleshooting Guide Possible Trouble 6 emote controller does not operate. Is the voltage of Battery over.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, Q0G, Q03G for Delux Model) operate normally on DC PCB Ass'y? eplace IC03G (Q0G, Q0G, Q03G for Delux Model). eplace the DC PCB Ass'y. 30 oom Air Conditioner

31 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 V? eplace D0D~D05D. eplace IC0D. Is output Voltage of IC0D DC 5V? eplace IC0D. 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. Service Manual 3

32 Troubleshooting Guide Possible Trouble 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 V? 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. 3 oom Air Conditioner

33 Troubleshooting Guide Possible Trouble 4 FAN does not operate. Is the voltage. or 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.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. Service Manual 33

34 Troubleshooting Guide Possible Trouble 6 It displays abnormally on DC PCB Ass y. Are IC0G and IC0G OK? Is the connection of CN-AC/DC OK? eplace IC0G, IC0G. 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. 34 oom Air Conditioner

35 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. Service Manual 35

36 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. 36 oom Air Conditioner

37 Exploded View Exploded View W W W0CZZ A 353 Service Manual 37

38 eplacement Parts List eplacement Parts List LOCATION. DESCIPTION PAT. HBLG8003 LB8000E LW8000E HBLG003 EMAK A W0CZZ W4860 BASE ASSEMBLY,SINGLE CABINET ASSEMBLY,SINGLE GILLE ASSEMBLY,FONT(SINGLE) GILLE ASSEMBLY,INLET COVE,CONTOL(INDOO) LOUVE,HOIZONTAL LOUVE,VETICAL BACE SHOUD FILTE(MECH),A/C PANEL,CONTOL ESCUTCHEON CONTOL BOX ASSEMBLY,SINGLE TANSFOME,POWE THEMISTO ASSEMBLY POWE COD ASSEMBLY EMOTE CONTOLLE PWB(PCB) ASSEMBLY,DISPLAY PWB(PCB) ASSEMBLY,MAIN MOTO ASSEMBLY,SINGLE DAMPE,VENTILATION OIFICE TUBE ASSEMBLY,SUCTION SINGLE TUBE ASSEMBLY,DISCHAGE SINGLE TUBE ASSEMBLY,EVAPOATO IN AI GUIDE ASSEMBLY AI GUIDE ASSEMBLY EVAPOATO ASSEMBLY,FIST FAN,TUBO ISOLATO,COMP CONDENSE ASSEMBLY,FIST CONDENSE ASSEMBLY,BENT COMPESSO FAN ASSEMBLY,AXIAL O.L.P CAPACITO CLAMP,SPING 304A00V 309A37M 353A060A 3530A0075A 4998A003A 383A00E 4995A078 64A00F 67A0056S 468A0069G 5A0708B 5A0559K 5A08 54A006E 5403A009B A00N 309A37N 309A37M 353A0097A 353A060A 3530A0038A 3530A0075A 3550A304A 4758A009A 4758A0040A 4800A3000C 4998A00A 53A0006A 370A0C 383A00L 4995A078U 670A30003C 633A0004P 67A0034G 687A048A 687A047C 468A007X 4900A0003A 4948A004A 5A0074D 5A0470B 5A08F 539A0005B 539A00A 54A006J 5900A000A 4830A4335A 5403A0043L 5403A0043M 546A90007A 5900A67B 6750A3000N 0CZZA0005B 3H093B 383A00E 4995A078S 64A00 67A0056S 468A0069H 5A0074J 5A0470F 5A08S 54A006G 50UCDK U-L03A 0CZZA000N 38 oom Air Conditioner

39 eplacement Parts List eplacement Parts List LOCATION. DESCIPTION LWHD006 PAT. L006 EMAK A W4860 BASE ASSEMBLY,WELD[SINGLE] CABINET ASSEMBLY,SINGLE GILLE ASSEMBLY,FONT(SINGLE) GILLE,INLET COVE LOUVE,HOIZONTAL LOUVE,VETICAL LOUVE,VETICAL BACE SHOUD FILTE ASSEMBLY,AI CLEANE PANEL,CONTOL CONTOL BOX ASSEMBLY,SINGLE PWB(PCB) ASSEMBLY,MAIN(AC) ESCUTCHEON PWB(PCB) ASSEMBLY,MAIN(DC) THEMISTO ASSEMBLY POWE COD ASSEMBLY MOTO ASSEMBLY,SINGLE DAMPE,VENTILATION DAMPE,VENTILATION OIFICE TUBE ASSEMBLY,EVAPOATO IN TUBE ASSEMBLY,SUCTION SINGLE TUBE ASSEMBLY,DISCHAGE SINGLE TUBE ASSEMBLY,CONDENSE OUT TUBE ASSEMBLY,CAPILLAY AI GUIDE ASSEMBLY EVAPOATO ASSEMBLY,FIST CONDENSE ASSEMBLY,FIST ANTI-VIBATION BUSH COMPESSO SET FAN, AXIAL FAN, TUBO EMOTE CONTOLLE ASSEMBLY CLAMP, SPING 304A00N 309A37M 353A060A 3530A0075A 3550A306A 4758A009A 4758A0040A 4758A0040B 4800A3000C 4998A00A 53A0006A 370A0C 4995A078S 687A047C 383A00E 687A048A 633A0004P 64A0056F 468A0069H 4900A0003A 4948A004A 5A0470L 5A786A 5A0074J 5A3075M 539A00A 54A006P 5403A0043M 5040A495A 50UCDK A67B 5900A000A 67A0034G 3H093B 304A00N 309A37M 353A0097A 3530A038A 3550A306A 4758A009A 4758A0040A 4758A0040B 4800A3000C 4998A00A 53A0006A 370A0C 4995A03T 687A047C 383A00L 687A048A 633A0004P 64A0056F 468A0069H 4900A0003A 4948A004A 5A0470L 5A786A 5A0074J 5A3075M 539A00A 54A006P 5403A0043M 5040A495A 50UCDK A67B 5900A000A 67A0034G 3H093B W0CZZ CAPACITO, DAWING 0CZZA000N 0CZZA000N Service Manual 39

40 P/:388A0439B February, 004 Printed in China