website http://www.lgservice.com LG LG Room Air Conditioner SERVICE MANUAL MODEL: LWHD200R CAUTION BEFORE SERVICING THE UNIT, READ THE SAFETY PRECAUTIONS IN THIS MANUAL. ONLY FOR AUTHORIZED SERVICE PERSONNEL.
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 Suggested Tool Requirements...9 Operation...2 Function of Controls...2 Disassembly...3 Mechanical Parts...3 Air handling Parts...4 Electrical Parts...5 Refrigerating Cycle...7 Schematic Diagram...20 Electronic Control Device....20 Wiring Diagram...2 Components Location...22 Troubleshooting Guide...23 Pipeing System...23 Troubleshooting Guide...23 Electrical Parts Troubleshooting Guide...26 Electrical Parts...30 Exploded View...36 Replacement Parts List...37 2 Room Air Conditioner
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. WARNING 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. Installation WARNING Do not use damaged power cord plugs, or a loose socket. Always use the power plug and socket with the ground terminal. There is risk of fire or electric shock. There is risk of electric shock. Service Manual 3
Safety Precautions Do not modify or extend the power cord. Do not install, remove, or re-install the unit by yourself(customer). There is risk or fire or electric shock. There is risk of fire, electric shock, explosion, or injury. Be cautious when unpacking and installing the product. Do not store or use flammable gas or combustibles near the air conditioner. Sharp edges could cause injury. Be especially careful of the case edges and the fins on the condenser and evaporator. Sharp edges There is risk of fire or failure of product. Gasolin Be sure the installation area does not deteriorate with age. If the base collapses, the air conditioner could fall with it, causing property damage, product failure, and personal injury. 4 Room Air Conditioner
Cool Energy Saver Fan Dry MODE Timer TIMER F LOW F2 MED F3 HIGH TEMP SPEED C POWER 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 D W H Dimension Model HBLG203R / R200E W mm(inch) 600(23 5 /8) H mm(inch) 380(4 3 /32) D mm(inch) 567(22 5 /6) Service Manual 5
Specfications Product Specifications ITEMS POWER SUPPLY COOLING CAPACITY INPUT RUNNING CURRENT MODELS (Btu/h) (W) (A) LWHD200R ø, 5, 60Hz 2,000,220.0 E.E.R (BTU/W. h) OPERATING INDOOR ( C) CONDITION OUTDOOR ( C) REFRIGERANT (R-22) CHARGE EVAPORATOR CONDENSER, INDOOR, OUTDOOR SPEEDS, /COOLING MOTOR OPERATION CONTROL ROOM TEMP. CONTROL AIR DIRECTION CONTROL CONSTRUCTION 9.8 9.4(WB)** 23.9(WB)** 490(7.3 oz) 2 ROW 2 STACKS 2 ROW7 STACKS TURBO PROPELLER TYPE WITH SLINGER RING 3/3 6 POLES REMOTE CONTROLLER THERMISTOR VERTICAL LOUVER (RIGHT & LEFT) HORIZONTAL LOUVER (UP & DOWN) SLIDE IN-OUT CHASSIS PROTECTOR POWER CORD DRAIN SYSTEM NET WEIGHT COMPRESSOR MOTOR (lbs/kg) OVERLOAD PROTECTOR INTERNAL THERMAL PROTECTOR (3 WIRE WITH GROUDING) ATTACHMENT PLUG (CORD-CONNECTED TYPE) DRAIN PIPE OR SPLASHED BY SLINGER 79/36 OUTSIDE DIMENSION (inch) 23 5 /8 x 4 3 /32 x 22 5 /6 (W x H x D) (mm) 600 x 380 x 567 * DB:Dry Bulb ** WB:Wet Bulb 6 Room Air Conditioner
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 sunlight 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. Restriction of outside air will greatly reduce the cooling efficiency of the air conditioner. CAUTION: All side louvers of the cabinet must remain exposed to the outside of the structure. COOLED AIR 30"~60" AWNING HEAT RADIATION ABOUT /2" Over 20" FENCE Figure 4.Install the unit a little slanted so the back is slightly lower than the front (about /2"). 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 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. Press the drain pipe into the hole by pushing down and away from the fins to avoid injury. Drain pipe Drain cap Optional. Install the drain pan over the corner of the cabinet where you removed the plug with 4 (or 2) screws. 2. Connect the drain hose to the outlet located at the bottom of the drain pan. You can purchase the drain hose or tubing locally to satisfy your particular needs. (Drain hose is not supplied). 3. Select the most appropriate connection from among the following figures (by considering the hole of the unit) to fit drain pan to your own unit. CABINET DRAIN PAN SCREW Fig. DRAIN HOSE Fig. 3 Fig. 2 Fig. 4 Service Manual 7
Cool C F LOW F2 MED Energy F3 HIGH Saver Fan Dry Timer TEMP MODE TIMER POWER SPEED Cool C F LOW F2 MED Energy F3 HIGH Saver Fan Dry Timer TEMP MODE TIMER POWER SPEED Installation How to Install When Using Gasket A 2 2 A B B RIGHT SIDE 4 3 D E F H HORIZONTAL LINE. WINDOW (WIDTH-A, HEIGHT-B) 2. GASKET 3. WALL 4. DETAILS 5. x 30 ROUND HEAD WOOD SCREWS A B C D E F H I 625mm 392mm 280mm 30mm 0~25mm OVER 420mm 5~0mm -5~5mm (24 5 /8") (5 7 /6") ( /32") ( /6") (0~") (OVER 6 7 /32") ( 3 /6"~ 3 /8") (- 3 /6"~ 3 /6") When Using Installation Kits. Window Requirements This unit is designed for installation in standard double hung windows with actual opening widths from 27" to 39". 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. 2. Installation Kits Contents 6" min 27" to 39" Stool Interior wall 23 5 /8" min (Without frame curtain) Offset /2" to /4" Sill Exterior 3 2 3 4 5 6 7 8 0 2 9. NAME OF PARTS Q'TY FRAME CURTAIN 2 2 SILL SUPPORT 2 3 BOLT 2 4 NUT 2 5 SCREW(TYPE A) (0mm( 2 /5")) 6 6 SCREW(TYPE B) D5.mm(0.2")/6mm(0.63") 3 7 SCREW(TYPE C) D4.mm(0.7")/6mm(0.63") 5 8 FOAM-STRIP 9 FOAM-PE (600mm x 25mm x 2mm) 0 WINDOW LOCKING BRACKET FOAM-PE (920mm x 30mm x 2mm) 2 DRAIN PIPE 3 FRAME GUIDE 2 Top retainer bar is in the product package. 8 Room Air Conditioner
Cool Energy Saver MODE F LOW F2 MED F3 HIGH TEMP SPEED C Cool Energy Saver MODE C Cool F LOW F2 MED F3 HIGH TEMP SPEED Energy Saver MODE F LOW F2 MED F3 HIGH TEMP SPEED C Installation Suggested Tool Requirements SCREWDRIVER (+, -), RULER, KNIFE, HAMMER, PENCIL, LEVEL Preparation of Chassis. Remove the screws that fasten the cabinet at both sides and at the back. 2. 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. Remove 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. Fan Dry Timer TIMER POWER Fan Dry Timer TIMER POWER Fan Dry Timer TIMER POWER 9 Shipping Screws EPS Material Cabinet 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. 3 (Type A) 5 5 9 0 2. 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 2 Window Sash Upper guide 9 Foam-pe 3 Cabinet Frame Curtain Foam-pe 0 Figure 3 Service Manual 9
Installation 3. Loosely assemble the sill support using the parts in Figure 4. INDOOR Bolt 3 OUTDOOR Sill Support 2 Nut 4 Figure 4 4. Select the position that will place the sill support near the outer most point on sill (See Figure 4) TICE Be careful when you install the cabinet (Frame Guides are broken easily). 5. Attach the sill support to the cabinet track hole in relation to the selected position using 2 Type A screws in each support (See Figure 5). 2 Frame Guide INDOOR 5 Screw(Type A) Cabinet OUTDOOR About /2" Figure 5 6. The cabinet should be installed with a very slight tilt (about /2") downward toward the outside (See Figure 6). Adjust the bolt and the nut of Sill Support for balancing the cabinet. Screw(Type B) 6 Screw(Type A) 5 Sill support About /2" 2 7. Attach the cabinet to the window stool by driving the screws (Type B) 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 2. Sill support 2 Screw(Type B) 6 Front Angle Figure 6 9. Attach each Frame Curtain to the window sash by using screws (Type C). (See Figure 7) Type C 7 Figure 7 0 Room Air Conditioner
Cool Energy Saver Fan Dry Timer MODE F LOW F2 MED F3 HIGH TEMP SPEED C MODE TIMER F LOW F2 MED F3 HIGH Cool Energy Saver Fan Dry Timer TEMP SPEED C POWER Cool Energy Saver MODE F LOW F2 MED F3 HIGH TEMP SPEED C Installation 0. Slide the unit into the cabinet.(see Fig. 8) CAUTION: For security purpose, reinstall screws (Type A) at the cabinet's sides. TIMER POWER Power cord Screw(Type A) Screw(Type A) Figure 8. Cut the Foam-Strip to the proper length and insert between the upper and lower window sash. (See Fig. 9) Foam-Strip 8 Figure 9 2. Attach the window Locking Bracket with a type C screw. (See Fig. 0) 3 Figure 0 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. ) Fan Dry Timer TIMER POWER Figure Figure 2 4. Lift the inlet grille and secure it with a type A screw through the front grille.(see Fig. 2) Figure 3 Service Manual
Operation Operation Function of Controls Designed for COOLING ONLY. Powerful and whispering 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 Reliable and efficient rotary compressor DISPLAY REMOTE CONTROL F LOW F2 MED F3 HIGH C 6 Power Cool Energy Saver Fan Dry Timer TEMP 2 Temp 2 MODE TIMER SPEED 3 5 4 POWER 5 Fan Speed Timer Mode 4 3 PRECAUTION: The Remote Control unit will not function properly if bright light strikes the sensor window of the air conditioner or if there are obstacles between the Remote Control unit and the air conditioner. 6 POWER 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. ROOM TEMPERATURE 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. OPERATION MODE SELECTION BUTTON Every time you push this button, it will shift among COOL, ENERGY SAVER, and DRY. - 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. SPEED SELECTOR Every time you push this button, it is set as follows. (Hi [F3] Low [F] Med [F2] Hi [F3] Low [F]...) ON/OFF TIMER 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... ) REMOCON SIGNAL RECEIVER 2 Room Air Conditioner
Cool Energy Saver Fan F LOW F2 MED F3 HIGH C Cool Energy Saver Fan F LOW F2 MED F3 HIGH C Cool F LOW F2 MED F3 HIGH C Disassembly Disassembly Before the following disassembly, set the CONTROL BOX to OFF and disconnect the power cord. Mechanical Parts. Front Grille. Open the lnlet grille downward and remove the air filter. 2. Remove the screw that fastens the front grille.(see Figure 4) 3. Pull the front grille from the right side. 4. Remove the front grille.(there are 4 hooks.) 5. Re-install the components by referring to the removal procedure, above. 2. Cabinet. After disassembling the FRONT GRILLE, remove the 2 screws that fasten the cabinet at both sides. 2. Remove the 2 screws that fasten the cabinet at back. 3. Pull the base pan forward. (See Figure 5) 4. Remove the cabinet. 5. Re-install the components by referring to the removal procedure, above. 3. Control Box. Remove the front grille. (Refer to section ) 2. Remove the cabinet. (Refer to section 2) 3. Remove the 2 screws that fasten the power cord. 4. Disconnect the grounding screw from the evaporator channel. 5. Remove the screw that fasten the control box cover. 6. Remove the housing which connects PCB and motor wire in the control box. 7. Disconnect the housing that connects Plazma Air Purifier.(Optional) 8. Remove the screw at left cover of filter case and open the cover to remove inner screw. (Optional) 9. Remove the nut that fastens the terminal cover. 0. Remove the terminal cover.. Remove all the leads from the overload protector. 2. Discharge the capacitor by placing a 20,000 ohmresistor across the capacitor terminals. 3. Raise the control box upward completely. (See Figure 6) 4. Re-install the components by referring to the removal procedure, above. (Refer to the circuit diagram found on page 32 in this manual and on the control box.) Dry Timer MODE TEMP TIMER POWER Dry Timer MODE SPEED TEMP TIMER POWER SPEED Energy Saver Fan Dry Timer MODE TEMP SPEED TIMER POWER Figure 4 Figure 5 Figure 6 Service Manual 3
Disassembly Air Handling Parts 4. Air Guide and Turbo Fan. Remove the front grille. (Refer to section ) 2. Remove the cabinet. (Refer to section 2) 3. Remove the control box. (Refer to section 3) 4. Remove the 4 screws that fasten the brace. 5. Remove the brace. 6. Remove the 2 screws that fasten the air guide upper. 7. Remove the air guide upper.(see Figure 7) 8. Remove the 2 screws that fasten the evaporator. 9. Move the evaporator forward and pulling it upward slightly. (See Figure 8) 0. Pull out the hook of orifice by pushing the tabs and remove it. (See Figure 9). Remove the clamp with hand pliers which secures the turbo fan. 2. Remove the turbo fan. 3. Remove 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. Re-install the components by referring to the removal procedure, above. Figure 7 Figure 8 5.. Remove the cabinet. (Refer to section 2) 2. Remove the brace (Refer to section 4) 3. Remove the 5 screws which fasten the condenser. 4. Move the condenser to the left carefully. 5. Remove the clamp that secures the fan. 6. Remove the fan. (See Figure 20) 7. Re-install by referring to the removal procedure. Figure 9 Figure 20 4 Room Air Conditioner
Disassembly 6. Shroud. Remove the fan. (Refer to section 2.2.2) 2. Remove the shroud. (See Figure 8) 3. Re-install the components by referring to the removal procedure, above. Figure 2 Electrical Parts 7. Overload Protector. Remove the cabinet. (Refer to section 2) 2. Remove the nut that fastens the terminal cover. 3. Remove the terminal cover. (See Figure 22) 4. Remove all the leads from the overload protector. 5. Remove the overload protector. 6. Re-install the components by referring to the removal procedure, above. 8. Compressor. Remove the cabinet. (Refer to section 2) 2. 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. 3. Remove the overload protector. (Refer to section 7) 4. After purging the unit completely, unbraze the suction and discharge tubes at the compressor connections. 5. Remove the 3 nuts and the 3 washers which fasten the compressor. 6. Remove the compressor. (See Figure 23) 7. Re-install the components by referring to the removal procedure, above. Figure 22 Figure 23 Service Manual 5
Cool Fan F LOW F2 MED F3 HIGH C Disassembly 9. Capacitor. Remove the control box. (Refer to section 3) 2. Open the top cover from the control box. (See Figure 24) 3. Pull out the capacitor from the control box. 4. Disconnect all the leads of capacitor terminals. 5. Re-install the components by referring to the removal procedure, above. Cool Energy Saver Fan Dry Timer MODE F LOW F2 MED F3 HIGH TEMP TIMER POWER SPEED C Figure 24 0. Power Cord. Remove the control box. (Refer to section 3) 2. Open the top cover from the control box. (Refer to section 9) 3. Disconnect the front panel from the control box. (See Figure 25) 4. Disconnect two leads from the capacitor and relay. 5. Pull out the power cord. 6. Re-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.) Energy Saver Dry Timer MODE TEMP TIMER POWER SPEED Figure 25 6 Room Air Conditioner
Disassembly. Motor. Remove the cabinet. (Refer to section 2) 2. Remove the turbo fan. (Refer to section 4) 3. Remove the fan. (Refer to section 5) 4. Remove the 4 screws that fasten the motor from the air guide. (See Figure 26) 5. Remove the motor. 6. Re-install the components by referring to the removal procedure, above.(see Figure 26) Figure 26 Refrigerating Cycle 2. Condenser CAUTION: 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.. Remove the cabinet. (Refer to section 2) 2. Remove the 4 screws that fasten the brace.(refer to section 4) 3. Remove the 5 screws that fasten the condenser and shroud. 4. After discharging the refrigerant completely, unbraze the interconnecting tube at the condenser connections. 5. Remove the condenser. 6. Re-install the components by referring to notes. (See Figure 27) Figure 27 3. Evaporator. Remove the control box.(refer to section 3) 2. Remove the air guide upper. (Refer to section 4) 3. Remove the 2 screws that fasten the evaporator. 4. Move the evaporator sideways carefully. (Refer to section 4) 5. After discharging the refrigerant completely, unbraze the interconnecting tube at the evaporator connections. 6. Remove the evaporator. 7. Re-install the components by referring to notes. (See Figure 28) Figure 28 Service Manual 7
Disassembly 4. Capillary Tube. Remove the cabinet. (Refer to section s2) 2. After discharging the refrigerant completely, unbraze the interconnecting tube at the capillary tube.(see caution above) 3. Remove the capillary tube. 4. Re-install the components by referring to notes. TICE Replacement 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 29A. 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) Remove the hose from the vacuum pump and place it on the charging cylinder. See figure 29B. Open valve C. Discharge the line at the manifold connection. 5) The system is now ready for final charging. 6. Recharge as follows : ) Refrigeration 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 29B. 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. Repeat 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 Room Air Conditioner
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. CONDENSER (HIGH PRESSURE SIDE) COMPOUND GAUGE MANIFOLD GAUGE B A CAPILLARY TUBE SEE INSETS BELOW EVAPORATOR (LOW PRESSURE SIDE) COMPRESSOR LOW HI B A B A EXTERNAL VACUUM PUMP CHARGING CYLINDER C Figure 29A-Pulling Vacuum Figure 29B-Charging Service Manual 9
Schematic Diagram HVB 3 3 2 2 ROOM-TH CN-TH 5V SMAW200-02 R04H 6.2K % R02H 2.K % OSC0B RT8.00MG R0B M 5V C0A 0.0 50V 4 3 2 0 R0A 20K C02A uf 0V Rx R05P 0K SDA SCL Digit4 (Scan4) Digit3 (Scan3) Digit2 (Scan2) Digit (Scan) Digit0 (Scan0) SEG-a SEG-b SEG-c 3.6V 5V IC0A S736 R06P 0K C0F R0F 0.00 0K C02F R03F 0.00 0K Model Auto Restart Non Auto Restart EEPROM CAT93C46 A0 Vcc A WP 3 A2 SCL GND SDA EEPROM R04P O O R04P 5V R02P R03P 20K 20K R04P K Q03G A0S SW0G D0G TIMER SW04G D04G Q02G A0S Q0G A0S TEMP DOWN ON/OFF SW02G SW03G D02G D03G MODE TEMP UP SW05G SW06G D05G D06G 5V 2 2 2 9 8 + 3 2 2 4 8 7 6 5 X X b c VAref VSS Osc out Osc in /Reset TEST 5V COMP SYNC 4WAY LOW 22 2 20 9 8 7 6 5 Option2 Option Pipe TH Room TH 23 24 25 26 MICOM TMP87CH47U 27 28 29 30 3 32 33 42 43 44 7 6 5 4 3 2 VDD SEG-f SEG-e SEG-d 37 38 39 40 4 KEY0 SLIDE SW SEG-g ION MED HI Receiver Buzzer LED out3 34 35 36 LED out2 LED out LED out0 KEY 5V R2H R22H 2.K 2.K % % ORH OR2H 0 2 3 4 3 5 6 9 8 2V IC0M ULN2004A 5V C02L 220 0V Vcc R0L K Vout GND RECEIVER R02E 20 R0P 20K C0L 680pF 50V HVB 0 Digit Digit0 3 9 8 7 6 5 4 + 7 6 5 4 2 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 MOTOR CAPACITOR C HERM MAIN POWER COMP PIPE-TH SW2 SW 2 2 3 3 2 2 2 2 3 3 3 3 CN-TELE SMW200-03 5V (RD) C0T 0. 50V CN-TH2 SMW250-02 CN-HVB SMW200-03(BL) CN-CONT J5 SMW200-03(YL) CN-2V SMW200-03(WH) CN-4WAY YW396-03AV(YL) CN-MOTOR YW396-09AV CN-PWR YW396-03AV RY-COMP G4A-A-E-LG FUSE 250V/T2A 5V C02T Q03T R0T 0.00 C04M K Rx 2 D0T C03T N448 Q04T 0.00 A04M 25V 5V Q0T C04M Tx Q02T A04M 0 J7 2V RY-COMP RY-4WAY RY-LOW RY-MED RY-HI Model RY-4WAY J07 CN-4WAY CN-TH2 Cool Only O Heat Pump O O O RY-4WAY RY-HI RY-MED RY-LOW 5V 2V C0J 0./275V CN-AC/DC 5580-2 R0J 52045-245 20 /2W STRAIGHT ZNR0J SVC27D-4A SVC27D-4A POWER TRANS D02D D03D D02D~D05D N4004 D05D IC0D 782 D04D + C0D C02D C03D 000 0. 000 35V 50V 6V BZ0E PKM3EPY -4002 0 C05D C06D 220 0.0 0V 50V 2V 2 CN-AC/DC 558-2(YEONHO) 52044-245(MOLEX) ANGLE 2V 5V IC02D 7805 C04D C05D 0.0 0.0 25V 25V R0E K 5V 5V R2F 0K 5V IC0G ULN2004A 6 R0G 680 5 R02G 680 4 R03G 680 3 R04G 680 2 R05G 680 R06G 680 0 R07G 680 2V COOL DEFROST DRY/HEAT TIMER E/SAVER 3 2 3 3 5 7 9 3 2 3 3 5 7 9 2 X 7 4 X X X O 4 5 6 7 8 9 3 2 I + O I + 2 3 4 5 6 7 8 9 Schematic Diagram Electronic Control Device 88 SEGMENT 20 Room Air Conditioner
Schematic Diagram Wiring Diagram 2 3 4 GN/YL (GN) GN/YL (GN) MOTOR CAPACITOR F C H WH(BL) (Ribbed) BK(BR) (Plain) COMP. R C S YL BK BL RD YL OR OR(BR) BK OLP RD BL WIRING DIAGRAM CN-MOTOR CN-PWR FUSE 250V/T2A (5V/T2A) 3 4 RY-LOW ZNR0J RY-COMP RY-MED POWER TRANS AC PCB ASSEMBLY 3854AR3563N CN-AC/DC RY-HI DC2V CN-2V CN-HVB CN-AC/DC DC PCB ASSEMBLY THERMISTOR SWITCH H.V. ASSEMBLY BK CN-TH RD AIR FILTER ASSEMBLY 5 7 6 8 S: Service Parts N: Non Service Parts LOCATION. DESCRIPTION Q'TY PER SET REMARKS MOTOR ASSY S 2 CAPACITOR S 3 COMPRESSOR S 4 OVERLOAD PROTECTOR S 5 DC PCB ASSEMBLY S 6 AC PCB ASSEMBLY S 7 THERMISTOR S 8 PLASMA FILTER ASSY S Service Manual 2
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 R0T Q0T Q03T J6 C02D D0T C02T J2 Q04T QIC02DT C04D CN-TELE J3 RY-4WAY RY-LOW RY-MED RY-HI J7 C05D CN-TH2 PCB:6870A90068A CN-PWR ZNR0J R0J E03J J8 CN-MOTOR E02J E0J CN-4WAY C0J RY-COMP ASSEMBLY:687A2067 POWER TRANS FUSE 250V/T2A E04J E05J 2. DISPLAY P.C.B. ASSEMBLY 22 Room Air Conditioner
Troubleshooting Guide Troubleshooting Guide Piping System CONDENSER COIL MOTOR CAPILLARY TUBE COMPRESSOR TURBO EVAPORATOR COIL Figure 30 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 AIR EVAPORATOR COILS COMPLETE LIQUID BOIL OFF POINT ROOM AIR HEAT LOAD ROOM AIR CONITIONER CYCLE OF REFRIGERATION SUCTION LINE COOL LOW PRESSURE VAPOR VAPOR INLET CONDENSER COILS HOT DISCHARGED AIR MOTOR OUTSIDE COOLING AIR FOR REFRIGERANT PASS THROUGH COMPRESSOR LIQUID PRESSURE DROP OIL (LIQUID REFRIGERANT) CAPILLARY TUBE Figure 30 LIQUID OUTLET HIGH PRESSURE VAPOR LIQUID REFRIGERANT LOW PRESSURE VAPOR Service Manual 23
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 Repair gas leak. Not on separate circuit. Clogged of air filter. Replacement 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. Replacement of compressor. Repair clogging in refrigeration circuit. Satisfactory operation with temperature difference of inlet & outlet air ; 44~50 F(7~0 C) 24 Room Air Conditioner
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. Replacement Improper thermostat setting. Loose terminal connection. Improper wiring. Improper wiring. Defect of fan motor capacitor. Irregular motor resistance ( ). Irregular motor insulation ( ). Replacement of fan motor. Irregular motor resistance ( ) Regular but fails to start. Irregular motor insulation ( ) Replacement of compressor (Motor damaged) Replacement of compressor (locking of rotor, metal). Service Manual 25
Troubleshooting Guide Electrical Parts Troubleshooting Guide Possible Trouble The unit does not operate. Is the Trans input power AC 5V? (208/230V for LWL230WAL) 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. Replace the Trans. Is output Voltage of IC0D DC 2V? Replace D02D~D05D. Replace IC0D. Is output Voltage of IC02D DC 5V? Replace IC02D. Is the reset circuit good? (The No.4 of Micom is 5V.) Replace 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. Replace AC PCB Ass'y. 26 Room Air Conditioner
Troubleshooting Guide Possible Trouble 2 The compressor does not operate. Is setting Temp. set lower than Room 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 RY-COMP. Check the wiring Diagram. Replace IC0M. Wait 3 Minutes. Replace MAIN PCB Ass'y. Possible Trouble 3 The compressor always operate. Is the wire connection of RY-COMP OK? Connect LEAD Wire to RY-COMP again. Check the RY-COMP. Service Manual 27
Troubleshooting Guide Possible Trouble 4 does not operate. Is the voltage. or 2 or 4 of IC0M DC 2V? Replace IC0M. Is the voltage.6 or 5 or 3 of IC0M 0V? Replace IC0M. Check the RY-Hi or RY-Med or RY-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? Reference to OWNER'S MANUAL. Check the Energy Saver mode key. Check the pattern of AC & DC PCB. 28 Room Air Conditioner
Troubleshooting Guide Possible Trouble 6 Remote controller does not operate. Is the voltage of Battery over 2.3V? Replace 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. Replace Receiver Ass'y. Possible Trouble 7 It displays abnormally on DC PCB Ass y. Is IC0G good? Replace 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? Replace IC03G (Q0G, Q02G, Q03G for Delux Model). Replace the DC PCB Ass'y. Service Manual 29
Troubleshooting Guide Electrical Parts Possible Trouble The unit does not operate. Is the Trans input power AC 5V? (208/230V for LWL230WAL) 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. Replace the Trans. Is output Voltage of IC0D DC 2V? Replace D02D~D05D. Replace IC0D. Is output Voltage of IC02D DC 5V? Replace IC02D. Is the reset circuit OK? (The No.4 of Micom is 5V.) Replace 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. Replace AC PCB Ass'y. 30 Room Air Conditioner
Troubleshooting Guide Possible Trouble 2 The compressor does not operate. Is desired Temp. set lower than Room 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 RY-COMP. Check the wiring Diagram. Replace IC0M. Wait 3 Minutes. Replace AC PCB Ass'y. Possible Trouble 3 The compressor always operate. Is the wire connection of RY-COMP OK? Connect LEAD Wire to RY-COMP again. Check the RY-COMP. Service Manual 3
Troubleshooting Guide Possible Trouble 4 does not operate. Is the voltage. or 2 or 4 of IC0M DC 5V? Replace IC0M. Is the voltage.6 or 5 or 3 of IC0M 0V? Replace IC0M. Check the RY-Hi or RY-Med or RY-Lo. Check the wiring diagram. Possible Trouble 5 Remote controller does not operate. Is the voltage of Battery over 2.3V? Replace 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. Replace Receiver Ass'y. 32 Room Air Conditioner
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? Replace IC0G, IC02G. Connect connector to CN-AC/DC exactly. Does the IC03G operate normally on AC PCB Ass'y? Replace IC03G. Replace the DC PCB Ass'y. Service Manual 33
Troubleshooting Guide COMPLAINT CAUSE REMEDY 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 Revolves 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. Replace cord if circuit is open. Connect wire. Refer to wiring diagram for terminal identification. Repair or replace loose terminal. Test capacitor. Replace if not within ±0% of manufacturer's rating. Replace if shorted, open, or damaged. Fan blade hitting shroud or blower wheel hitting scroll. Realign 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 Room Air Conditioner
Troubleshooting Guide COMPLAINT CAUSE REMEDY 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 Refrigerating 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. Replace the thermistor if the circuit is open. Check the capacitor. Replace if not within ±0% of manufacturers rating. Replace 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. Replace 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. Replace if open. (If the compressor temperature is high, remove the overload, cool, and retest.) If not running, determine the cause. Replace if required. Remove 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. Remove the cabinet carefully and rearrange tubing not to contact cabinet, compressor, shroud, and barrier. Service Manual 35
Exploded View Exploded View 73373 49980 3090 48000 W48602 3468 55902 55900 W48602 35422 352390-2 2670 352390-4758 47582 5232 3532 34900 567502 52302 55460 3040 3533 55040 26872 26874 W0CZZ 35500 249950 3525 552 237200 23830 Cool Energy Saver Fan Dry Timer MODE F LOW F2 MED F3 HIGH TEMP C TIMER POWER SPEED 263230 2640 352A 3523 36 Room Air Conditioner
Replacement Parts List Replacement Parts List LOCATION. DESCRIPTION PART. HBLG203R / R200E 3040 BASE PAN WELD ASS'Y 304A20020X R 3090 CABINET ASS'Y 309A007B R 3532 FRONT GRILL ASS'Y 353A206D R 3533 INLET GRILLE 3530A20076A R 35500 COVER, CONTROL BOX 3550A304A R 4758 HORIZONTAL LOUVER 4758A2008A R 47582 VERTICAL LOUVER 4758A2004A/B R 48000 BRACE 4800A30002D R 49980 SHROUD 4998A006A R 52302 AIR FILTER ASS'Y 523A20007A R 237200 CONTROL PANEL 3720A0C R 249950 CONTROL BOX ASS'Y 4995A20484A R 26872 DISPLAY PCB ASS'Y 687A2048A R 23830 ESCUTCHEON 383A002E R 26874 MAIN PCB ASS'Y 687A2047C R 263230 THERMISTOR ASS'Y 6323A20004P R 2640 POWER CORD ASS'Y 64A20048U R 2670 REMOTE CONTROLLER ASSEMBLY 67A20034G R 3468 MOTOR ASS'Y 468A20069J R 34900 VENTILATION DAMPER 4900A20002A R 349480 ORIFICE 4948A005A R 352 TUBE ASS'Y CAPILLARY 52A32004A R 3523 DISCHARGE TUBE 52A0074S R 3525 TUBE FORMED, EVAPORATOR 520A2099J R 352A SUCTION TUBE ASS'Y 52A2044J R 352390- AIR GUIDE ASSEMBLY 5239A20004A R 35422 EVAPORATOR ASS'Y 542A2008C R 567502 OVERLOAD PROTECTOR 6750U-L029A R 55040 ISOLATOR, COMP 4830AR4335A R 554030 CONDENSER ASS'Y 5403AR292P R 55460 COMPRESSOR 2520UCBK05 R 55900, AXIAL 5900A0009B R 55902 TURBO 5900A2009C R W0CZZ CAPACITOR, DRAWING 0CZZA2000N R W48602 CLAMP, SPRING 3H02932B R 73273 INSTALL PART ASSEMBLY 327A005G R 352390-2 AIR GUIDE ASSEMBLY 5238A20008C R REMARK Service Manual 37
P/No.: 3828A29003B January, 2005 Printed in China