Room Air Conditioner - ApplianceAssistant.com...Service Manual 5 Close all doors, windows and other outside openings to the room. • The air conditioner must be operated in a enclosed

LG RoomAir ConditionerSERVICE MANUAL

LG

CAUTION

website http://www.lgservice.com

• BEFORE SERVICING THE UNIT, READ THE SAFETY PRECAUTIONS IN THIS MANUAL.

• ONLY FOR AUTHORIZED SERVICE PERSONNEL.

MODEL: L5004R

2 Room Air Conditioner

Air Conditioner Service Manual

TABLE OF CONTENTSSafety Precautions..........................................................................................................................................3Dimensions .....................................................................................................................................................7

Outside Dimensions ...................................................................................................................................7Product Specifications ..................................................................................................................................8Installation .......................................................................................................................................................9

Select the Best Location ............................................................................................................................9How to Install ..............................................................................................................................................9Installation Kits Contents .........................................................................................................................10How to Secure the Drain Pipe....................................................................................................................11

Operation ......................................................................................................................................................12Feature ....................................................................................................................................................12About the Controls of the Air Conditioner ................................................................................................13

Disassembly ..................................................................................................................................................14Mechanical Parts......................................................................................................................................14Air Handling Parts ....................................................................................................................................15Electrical Parts .........................................................................................................................................16Refrigerating Cycle...................................................................................................................................17

Schematic Diagram .......................................................................................................................................20Circuit Diagram.........................................................................................................................................20Electronic Control Device .........................................................................................................................21Components Location(For Main P.W.B ASM)...........................................................................................22

Troubleshooting Guide .................................................................................................................................23Piping System ........................................................................................................................................23Troubleshooting Guide .............................................................................................................................24

Exploded View ..............................................................................................................................................32Replacement Parts List ................................................................................................................................33

Service Manual 3

Safety Precautions

Safety PrecautionsTo prevent injury to the user or other people and property damage, the following instructions mustbe followed.� Incorrect operation due to ignoring instruction will cause harm or damage. The seriousness is

classified by the following indications.

� Meanings of symbols used in this manual are as shown below.

Service Manual 3

Safety Precautions




Service Manual 3

Safety Precautions




Service Manual 3

Safety Precautions




WARNING This symbol indicates the possibility of death or serious injury.

This symbol indicates the possibility of injury or damage to property only.

This symbol indicates the possibility of death or serious injury.






WARNING� InstallationAlways install the expansion panel(s).

• Improper assembly or installation may cause incorrectoperation, including injury, fire, and electric shock haz-ards.

Do not place the power cord near a heater.• It may cause fire and electric shock.

Be sure not to do.

Be sure to follow the instruction.

� InstallationAlways install the expansion panel(s).



Be sure not to do.





Be sure not to do.





Be sure not to do.


Do not use the power cord near flammable gasor 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.

GasolinGasolinGasolinGasolinGasolinGasolinGasolinGasolin

CAUTION


Safety Precautions

Plug in the power plug prop-erly.

• Otherwise, it will cause electricshock or fire.

Do not operate or stop theunit by inserting or pullingout the power plug.

• It will cause electric shock or fire.

Do not damage or use anunspecified power cord.



Safety Precautions








Safety Precautions








Safety Precautions







Do not modify power cordlength.

• It will cause electric shock or fire

Use the air conditioner on asingle outlet circuit.(See page7.) Do not share the outletwith other appliances.

Always plug into a groundedoutlet.

• No grounding may cause electric

Unplug the unit if strangesounds, odors, or smokecome from it.

• Otherwise it will cause fire andelectric shock accident.

Do not use the socket if it isloose or damaged.

• It may cause fire and electric

Do not operate with wethands or in damp environ-ment.

• It ma cause electric shock.

� Operation� Operation� Operation� Operation

ON

• It will cause electric shock or fire.shock.

shock.

Service Manual 5Service Manual 5Service Manual 5Service Manual 5

Close all doors, windows and other outsideopenings to the room.

• The air conditioner must be operated in a enclosedarea to be most effective.

Ventilate before operating air conditionerwhen gas goes out.

• It may cause explosion, fire, and burn.

��

Do not clean the air conditioner with water.If water enters the product, turn off the powerswitch of the main body of appliance. Contactservice center after taking the power plug utfrom the socket.

• Water may enter the unit and degrage the insulation. It may cause an electric shock.

CAUTIONInstallation

• There is risk of fire or electric shock.

Never touch the metal partsof the unit when removingthe filter.

• They are sharp and may causeinjury.

Do not block the inlet or out-let.

• It may cause failure of appliance orperformance deteriorate.

Ensure that the outer case isnot damaged by age or wear.

• If the outer case is damaged, itmust be repaired or replacedimmediately. Leaving it damagedcould result in the air conditionerfalling out of the window, creatinga safety hazard.

• Since the fan rotates at high speedduring operation, it may causeinjury.

• This could injury the pet or plant. • It is an air conditioner, not a preci-sion refrigeration system.

6 Room Air Conditioner6 Room Air Conditioner6 Room Air Conditioner6 Room Air Conditioner

Unplug the air conditionerbefore cleaning it.

Do not put a pet or nouseplant where it will be exposedto direct air flow

Do not use this appliance forspecial purposes such aspets, foods, precisionmachinery, or objucts of art.

Be cautious not to touch thesharp edges when installing

• It may cause injury.

Hold the plug by the headwhen taking it out.

• It may cause electric shock anddamage.

Unplug the air conditioner ifit will not be used for a longperiod.

• It will waste power consumption invain and it may cause accident.

Sharp edges

Always insert the filtersecurely. Clean it every twoweeks.

• Operation without filters will causefailure.

Use a soft cloth to clean. Donot use wax, thinner, or astrong detergent.

• The appearance of the air condi-tioner may deteriorate, changecolor, or develop surface flaws.

Do not drink water drainedfrom air conditioner. Do notdirect airflow at room occu-pants only.

• It is not sanitary and could causeillness or personal injury hazard.

Wax ThinnerWax Thinner

� Operation� Operation

Service Manual 7

Dimensions

Dimensions

H

DW

W mm(inch) 439(17 5/16")

H mm(inch) 283(11 1/8")

D mm(inch) 326(12 13/16")

Model

DimensionAll Model

Outside Dimensions

This symbol alerts you to the risk of electric shock.

This symbol alerts you to hazards that could cause harm to theair conditioner.

This symbol indicates special notes.NOTICE

Symbols Used in this Manual


Product Specifications


SPECIFICATIONS ARE SUBJECT TO MINOR CHANGE WITHOUT NOTICE FOR FURTHERIMPROVEMENT.













NOTICE

COOLING CAPACITY (BTU/h) 5,050

POWER SUPPLY (Phase, V, Hz) 1ø, 115V, 60HZ

INPUT (W) 520

OPERATING CURRENT (AMP.) 4.8

REFRIGERANT CONTROL CAPILLARY TUBE

REFRIGERANT CHARGE (R-22) 205g(7.2 Oz)

INSIDE FAN TURBO

OUTSIDE FAN ROPELLER FAN WITH SLINGER RING

AIR DISCHARGE 2-WAY (RIGHT AND LEFT)

CHASSIS TOP-DOWN

PROTECTOR

TEMPERATURE CONTROL THERMISTOR

• OVERLOAD PROTECTOR FOR COMPRESSOR• INTERNAL PROTECTOR FOR FAN MOTOR

GL5004MODELS

ITEMS



INPUT (W) 520




INSIDE FAN TURBO



CHASSIS TOP-DOWN

PROTECTOR



MODELS

ITEMS



INPUT (W) 520




INSIDE FAN TURBO



CHASSIS TOP-DOWN

PROTECTOR



MODELS

ITEMS



INPUT (W) 520




INSIDE FAN TURBO



CHASSIS TOP-DOWN

PROTECTOR



MODELS

ITEMS

Service Manual 9

Window Requirements

All supporting parts should be secured to firmwood, masonry, or metal.

1. This unit is designed for installation in standard doublehung windows with actual opening widths of 21" to 35".The upper and lower sash must open sufficiently to allowa clear vertical opening of 12" from the bottom of thesash to the window stool.

2. If storm window presents interference, fasten a 2" widewood strip to the inner window sill across the full width ofthe sill. The wood strip should be thick enough to raisethe height of the window sill so that the unit can beinstalled without interference by the storm window frame.See Figure. 3. Top of wood strip should be approximately3/4" higher than the storm window frame (STORM WIN-DOW FRAME) or wood strip (OUTDOORS) to help con-densation to drain properly to the outside.

3. Install a second wood strip (approximately 6" long by11/2" wide and same thickness as first strip) in the centerof the outer sill flush against the back off the inner sill.This will raise the L bracket as shown Figure. 3.

4. If the distance between STORM WINDOW FRAME andWOOD STRIP MOUNTED ON TOP OF INNER SILL ismore than 1", two of wood strip are not necessary.

NOTICE

Installation

Installation

Select the Best Location

How to Install

This air conditioner is designed with a button-down chassis so it can be easily installed in a window.

1. To prevent vibration and noise, make sure the unit isinstalled securely and firmly.

2. Install the unit where the sun does not shine directly onthe unit.

3. The outside of the cabinet must extend outward for atleast 10" and there should be no obstacles, such as afence or wall, within 20" from the back of the cabinetbecause it will prevent heat radiation of the condenser.Restriction of outside air will greatly reduce the coolingefficiency of the air conditioner.

CAUTION: All side louvers of the cabinetmust remain exposed on the outdside ofthe structure.

4. Install the unit slanted slightly so the back is slightlylower than the front (about 1/4"). This will force con-densed water to the outside.

5. Install the unit with the bottom about 30"~60" above thefloor level.

ABOUT / "

Over 20"

HEATRADIATION

FENCEAWNING

OUTSIDE INSIDE

COOLED AIR

30"-6

0" 12

OUTDOORSINDOORS

INNER SILL

OUTERSILL

INNERSILL

WOOD STRIP MOUNTEDON TOP OF INNER SILL

WOOD STRIPFOR L BRACKET

3/4"CLEARANCE

1" MAX.

STORMWINDOWFRAME

OUTDOORSINDOORS

OUTERSILL

Figure 1

Figure 2

Figure 3


Installation

Installation Kits Contents(some Models)

Before Installation (Some Models IncludingInstallation Kit)1. Insert the guide panels into the guides of the air conditioner.

Fasten the curtains to the unit with screws (TYPE A), as shownFigure. 4.

2. Cut the adhesive-backed seal strip (TYPE E) to the windowwidth.Remove the backing from the seal strip and attach the seal stripto the underside of the bottom window. (Figure. 5)

Start Installation (Some Models IncludingInstallation Kit)1. Locating Unit in Window

Open the window and mark center line with pencil on the centerof the inner sill, as shown in Figure. 6.

2. Attach L Bracketa. 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 toplace bracket edge flush against back of inner sill. SeeFigure.7.

HARDWARE

TYPE F: 1EA(SASH SEAL)

(Not adhesive backed)

TYPE E: 1EA(SEAL STRIP)

(Adhesive backed)

TYPE G: 2EA(GUIDE PANEL)

TYPE D: 3EA(L BACKET)

TYPE A: 14EA(SHORT SCREW)

10m

m

TYPE B: 2EA(WOOD SCREW)

16m

m

TYPE H: 1EA(UPPER GUIDE)

16m

m

TYPE C: 2EA(WOOD SCREW)

ROOM SIDE

CENTER LINE

INNER SILL

SEAL STRIP(TYPE E)

OUTSIDE

INSIDE

L BRACKET

OUTER SILLINNER SILL

TYPE A

7.5"7.5"

CENTER LINE

TYPE A

TYPE A

TYPE AFigure 4

Figure 5

Figure 6

Figure 7

Service Manual 11

CAUTION: During the following step, holdunit firmly until window sash is lowered totop channel behind side panel frames.Personal injury or property damage mayresult if unit falls from window.

3. Install the Air Conditioner in the Windowa. Carefully lift the air conditioner and slide it into the open win-

dow. Make sure the bottom guide of the air conditioner dropsinto the notches of the L bracket.

IMPORTANT :When the air conditioner drops into the L bracket, the airconditioner will be centered in window opening as shown inFigure. 8.

b. While steadying the air conditioner, carefully bring thewindow sash down behind the upper guide of the airconditioner, as shown in Figure. 9.

4. Secure the Guide PanelsExtend the guide panels (TYPE G) to fill the windowopening using 2 screws (TYPE B), 2 screws(TYPE C) tosecure them as shown in Figure. 10.

5. Install the Sash Seal and Sash Locka. Cut the sash seal (TYPE F) to the window width.

Stuff the sash seal between the glass and the windowto prevent air and insects from getting into the room,as shown in Figure. 10.

b. Fasten the L bracket using a (TYPE A) screw, asshown in Figure. 10.

6. Window installation of room air conditioner is nowcompleted. See ELECTRICAL DATA for attachingpower cord to electrical outlet.

In humid weather, excess water may cause the BASE PANto overflow. To drain the water, remove the DRAIN CAPand secure the DRAIN PIPE to the rear hole of the BASEPAN. (Figure. 11)

Press the drain pipe into the hole by pushing down andaway from the fins to avoid injury.

Installation

How to Secure the Drain pipe

hang push1 2

DRAIN PIPEDRAIN CAP

CENTER LINE

SEALWINDOW FRAME

BOTTOMGUIDE

ABOUT 1/4"

UPPER GUIDE

L BRACKET

L BRACKET

FOAM SEAL(TYPE F)

TYPE A

TYPE B

TYPE C

Figure 8

Figure 9

Figure 10

Figure 11


Operation

Feature

Insulation Resistance Test

About the Controls of the Air Conditioner

• DESIGNED FOR COOLING ONLY • POWERFUL AND INCREDIBLE COOLING• TOP-DOWN CHASSIS FOR THE SIMPLE INSTALLATION AND SERVICE• BUILT-IN ADJUSTABLE THERMOSTAT• WASHABLE ONE-TOUCH FILTER• COMPACT SIZE

1. Unplug the power cord and connect a jumper between 2 pins (black and white).

2. The grounding conductor (green or green and yellow) is to be open.

3. Measure the resistance value with an ohm meter between the jumpered lead and each exposed metallic parton the equipment at all positions [except Off] of the ROCKER SWITCH.

4. The value should be over 1 MΩ.

Operation

AutoSwing

Power

Temp

Fan Speed

Timer Mode

CAUTION: The Remote Controller will not function properly if stronglight strikes the sensor window of the air conditioner or if there areobstacles between the Remote Controller and the air conditioner.

1. FRONT GRILLE

1. Disconnect the unit from source of power.2. Using a screwdriver, remove the screw from the front

grille. (See Figure 13)3. Push the front grille up from the bottom.

Pull the top of the front grille away from the cabinet as thetop tabs lift out of their slots. (See Figure 14)

4. Replace the grille by placing the tabs in the slots andpush the grille until it snaps into place.

2. CABINET

1. Disconnect the unit from the power source.2. Remove the front grille. (Refer to section 1)3. Remove 10 screws that secure the cabinet to the base

pan and condenser. (See Figure 15)4. Lift the cabinet from the unit.5. Re-install by referring to the procedures above.

3. CONTROL PANEL

1. Disconnect the unit from the power source.2. Remove the front grille. (Refer to Section 1)3. Remove the cabinet. (Refer to Section 2)4. Remove 2 screws that secure the control panel to control

box and base pan. (See Figure 16)5. Pull the control board toward yourself.

Controls, wires, and capacitor are now accessi-ble for servicing. Discharge the capacitor beforeservicing.

6. Disconnect one housing terminal and 3 wires for the fanmotor and compressor. (See Figure 17)

7. Re-install components by referring to procedures above.(Refer to wiring diagram on page 19 in this manual or oncontrol box.)

NOTICE

NOTICE

Disassemblyly

Mechanical Parts

Disassembly

NOTICE


4. AIR GUIDE UPPER

1. Disconnect the unit from the power source.2. Remove the front grille. (Refer to Section 1)3. Remove the cabinet. (Refer to Section 2)4. Remove the control board. (Refer to Section 3)5. Remove tape that attached the air guide upper and

lower.6. Lift air guide upper upward. (See Figure 18)7. Re-install by referring to the procedures above.

5. ORIFICE, TURBO FAN AND FAN

1. Disconnect the unit from the power source.2. Remove the front grille. (Refer to Section 1)3. Remove the cabinet. (Refer to Section 2)4. Remove the control panel. (Refer to Section 3)5. Remove the air guide upper. (Refer to Section 4)6. Remove 2 screws that secure the condenser to the

base pan.7. Remove the screw that secures the shroud to channel

of condenser.8. Press the snap area of shroud with your thumbs. This

allows you to remove it from the condenser.9. Remove 1 screw that secure the evaporator to the base

pan. (See Figure 19)10. Remove the orifice by pushing the snap area of the air

guide blower. (See Figure 20)11. Remove the clamp springs which are clamped to the

boss of fan and turbo fan by hand plier.(See Figure 21)

12. Pull the fan and turbo fan outward. 13. Re-install by referring to the procedures above.

Disassembly

Air Handling Parts

Figure 19

Figure 18

Figure 20

Figure 21

Service Manual 15

Disassembly

6. MOTOR1. Disconnect the unit from the power source.2. Remove the front grille. (Refer to Section 1)3. Remove the cabinet. (Refer to Section 2)4. Remove the control panel. (Refer to Section 3)5. Remove the air guide upper. (Refer to Section 4)6. Remove the compressor, turbo fan, axial fan and

shroud. (Refer to Section 5)7. Remove 4 screws that secure the motor to the mount

motor of shroud. (See Figure 22)8. Remove the motor. 9. Re-install by referring to the procedures above.

7. AIR GUIDE LOWER AND SHROUD1. Disconnect the unit from the power source.2. Remove the front grille. (Refer to Section 1)3. Remove the cabinet. (Refer to Section 2)4. Remove the control panel. (Refer to Section 3)5. Remove the air guide upper. (Refer to Section 4)6. Remove the compressor, turbo fan, axial fan.

(Refer to Section 5)7. Remove the motor. (Refer to Section 6)8. Remove 2 screws that secure the shroud to the base

pan. (See Figure 23)9. Lift air guide lower and shroud upward.

(See Figure 23)10. Re-install by referring to the procedures above.

8. OVERLOAD PROTECTOR 1. Remove the front grille and cabinet.

(Refer to Section 1, 2)2. Remove the nut which fastens the terminal cover.3. Remove the terminal cover.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. (See Figure 24)

9. COMPRESSOR1. Remove the front grille and cabinet.

(Refer to Section 1, 2) 2. Discharge the refrigerant by using a refrigerant

recovery system.3. Remove the overload protector.

(Refer to Section 8)4. After discharging the unit completely, unbrace the

suction and discharge pipes at the compressor con-nections.

5. Remove 3 nuts which fasten the compressor.6. Remove the compressor.7. Re-install by referring to the removal procedure

above. (See Figure 25)

Electrical Parts

Figure 22

Figure 23

Figure 24

Figure 25


Disassembly Disassembly Disassembly Disassembly

le

le

R erating CycRefrigerating Cycle

10. CAPACITOR1. Remove the cabinet. (Refer to Section 2)2. Remove the control panel. (Refer to Section 3)3. Discharge the capacitor by placing a 20 K� resistor

across the capacitor terminals.4. Remove all the leads of capacitor terminals.5. Re-install the components by referring to the removal

procedure above. (See Figure 26)

11. THERMISTOR1. Remove the cabinet. (Refer to Section 2)2. Remove the control panel. (Refer to Section 3)3. Remove the main PCB inside the control box.4. Remove the thermostat.5. Re-install the components by referrig to the � temoval procedure above.

12. POWER CORD1. Disconnect the unit from source of power.2. Remove the front grille. (Refer to Section 1)3. Remove the cabinet. (Refer to Section .2)4.

box. (Refer to Section 3)5. Pull the power cord. (See Figure 29)6. Re-install by referring to procedures above.

1. Remove the cabinet. (Refer to Section 2)2. Discharge the refrigerant by using a refrigerant recovery

system.3. Remove 2 screws which fasten the condenser.

(See Figure 30)4. After discharging the refrigerant completely, unbraze the

interconnecting tube at the condenser connections.5. Remove the condenser.

6. Re-install by referring to the procedures above.





1. Disconnect the unit from source of power.2. Remove the front grille. (Refer to Section 1)3. Remove the cabinet. (Refer to Section .2)4.











1. Disconnect the unit from source of power.2. Remove the front grille. (Refer to Section 1)3. Remove the cabinet. (Refer to Section .2)4.











1. Disconnect the unit from source of power.2. Remove the front grille. (Refer to Section 1)3. Remove the cabinet. (Refer to Section .2)4. Remove a screw that secures control panel to control


13. CONDENSER1. Remove the cabinet. (Refer to Section 2)2. Discharge the refrigerant by using a refrigerant recovery





Figure 26

Figure 27

Figure 29

Figure 30

Service Manual 17

Disassembly

15. EVAPORATOR1. Remove the cabinet. (Refer to Section 2)2. Discharge the refrigerant by using a refrigerant

recovery system. 3. Remove the air guide upper.

(Refer to Section 4)4. After discharging the refrigerant completely,

unbraze the interconnecting tube at the evapo-rator connections.

5. Remove the evaporator.6. Re-install by referring to the procedures above.

16. CAPILLARY TUBE1. Remove the cabinet. (Refer to Section 2)2. Discharge the refrigerant by using a refrigerant

recovery system.3. Remove the air guide upper.

(Refer to Section 4)4. After discharging the refrigerant completely,

unbraze the interconnecting tube of the capil-lary tube.

5. Remove the capillary tube.6. Re-install by referring to the procedures above.

Replacement of the refrigeration cycle.

1. When replacing the refrigerating cycle, be sure todischarge the refrigerant by using a refrigerantrecovery system.

2. After discharging the unit completely, remove thedesired components, and unbraze the pinch-offtubes.

3. Solder service valves into the pinch-off tube ports,leaving the valves open.

4. Solder the pinch-off tubes with service valves. 5. After completing the above procedures, the valve

must be closed and left in place on the system forany subsequent procedures.

6. Evacuate as follows: 6-1. Connect the vacuum pump, as illustrated in

figure 31A. 6-2. Start the vacuum pump. Slowly open manifold

valves A and B with two full turns counter-clockwise and leave the valves closed. The vacuum pump is now pulling throughvalves A and B up to valve C by means ofmanifold and the entire system.

CAUTION: If high vacuum equip-ment is used, just crack valves Aand B for a few minutes, then open

slowly with the two full turnscounter-clockwise. This will keep oilfrom foaming and being drawn intothe vacuum pump.

6-3. Operate the vacuum pump for 20 to 30 minutes,until 600 micron vacuum is obtained. Close valves A and B and observe vacuumgauge for a few minutes. A rise in pressure would indicate a possible leakor moisture remaining in the system. With valves A and B closed, stop the vacuumpump.

6-4. Remove the hose from the vacuum pump andplace it on the charging cylinder. See figure 20B.Open valve C. Discharge the line at the manifold connection.

6-5. The system is now ready for final charging.

7. Recharge as follows: 7-1. Rotary compressor systems are charged from

the high-side. If the total charge cannot be putin the high-side, the balance will be put in thesuction line through the access valve which isinstalled as the system is opened.

7-2. Connect the charging cylinder as shown in fig-ure 31B. With valve C open, discharge thehose at the manifold connection.

7-3. Open valve A and allow the proper charge toenter the system. Valve B is still closed.

7-4. If more charge is required, the high-side willnot take it. Close valve A.

7-5. With the unit running, open valve B and addthe balance of the charge. a. Do not add the liquid refrigerant to the low-

side. b. Watch the low-side gauge, allow pressure to

rise to 30 lbs(0.2MP). c. Turn off valve B and allow the pressure to

drop. d. Repeat steps B and C until the balance of

the charge is in the system. 7-6. When the unit is operating correctly, use the

pinch-off tool with the unit still running and theclamp on the pinch-off tube. Using a tube cut-ter, cut the pinch-off tube about 2 inches fromthe pinch-off tool. Use sil-fos solder and solderthe pinch-off tube closed. Turn off the unit,allow setting for a while and then test the leak-age of the pinch-off connection.

NOTICE


Disassembly

Equipment needed: Vacuum pump, charging cylinder, manifold gauge, brazing equipment, pinch-off tool capableof making a vapor proof seal, leak detector, tubing cutter, hand tools to remove components and service valve.

BA

B A

B A

COMPOUND GAUGE

SEE INSETSBELOW

CAPILLARY TUBE

EVAPORATOR(LOW PRESSURE SIDE)

COMPRESSOR

CONDENSER(HIGH PRESSURE SIDE)

EXTERNAL VACUUM PUMP

LO HI CHARGING CYLINDER

MANIFOLDGAUGE

C

Figure 31A-Pulling Vacuum Figure 31B-Charging

Service Manual 19

Schematic Diagram

Schematic DiagramCircuit Diagram

DESCRIPTION & NAME

FAN MOTOR

MAIN PCB

DISPLAY

TERMITOR

COMPRESSOR

POWER CORD ASSY

CAPACITOR

OVERLOAD PROTECTOR

Q'TY

1

1

1

1

1

1

1

1

REF. NO

1

2

3

4

5

6

7

8


WP

Vcc

Dig

it3 (S

can3

)

Dig

it4 (S

can4

)

Dig

it1 (S

can1

)

Dig

it2 (S

can2

)

Dig

it0 (S

can0

)

MA

IN P

OW

ER

CO

MP

HE

RM

FAN

C

CA

PA

CIT

ORM

OTO

RFA

N

120

1/2W

ZNR

01J

SV

C27

1D-1

4A

250V

/T2A

FUS

E

G4A

-1A

-E-L

GR

Y-C

OM

P

1000

D02

D~D

05D

1N40

0435

V

D03

D

D02

D

PO

WE

R T

RA

NS

1 2

7 4

D05

D

+D

04D C01

D

R01

J

CN

-WO

R

C01

J0.

1/27

5V

CN

-BK

CN

-BL

CN

-RD

RY

-HI

RY

-LO

W

RY

-ME

D

C06

D5V

0.01

0.1

50V

16V

1000

10V

0.01

50V

50V

C04

D

12V

IC01

D C03

DC

02D78

12O

I

+22

0C

05D

OIC

02D

7805

+

IC

01L

680p

F

1K

ULN

2004

AIC

01G

R01

L

5V

1KR

01E

20R

02E

20K

R12

F

10K

R02

F0.

001

C02

FR

01F

10K

C01

F0.

001

RO

OM

-TH

PIP

E-T

H

SY

NC

S/V

-4W

AY

MO

TOR

314

RY

-SY

NC

RY

-4W

AY

CN

-4W

AY

11

331

1

CN

-SY

NC

33

12V

RY

-HI

RY

-ME

D

ULN

2004

AIC

01M

915 16

82 1

12V

443

2

OR

1H

RY

-SY

NC

RY

-LO

W

RY

-4W

AY

RY

-CO

MP

11 12 13

6 5 4

107

OR

2H

5V

12.1

KR

21H

R03

H0K

12.1

K1%

1%R22

H

HV

B

KEY1

LED out2

LED out1

LED out0

3435

36

LED

out

3

Rec

eive

r30

Buz

zer

333231

HI

ME

D

ION

292827

SLIDE SW

40

KEY0

3738

39

VDD

SEG-g4142

43

SEG-f

SEG-e

44 SEG-d

TMP

87C

H47

UM

ICO

M

4

SE

G-b

SE

G-a

SE

G-c

3 2 17 6 5

Room TH

Option2

Option1

Pipe TH

23 262524S

YN

C

LOW

4WA

Y

CO

MP

2021

22

/Reset

Osc out

Osc in

16

VAref

VSS

1819

1713

1415

TEST

11

SC

L

SD

A10 9 8

Tx

12R

x

5VA

13 4

GN

DS

DA

SC

LA

2

A0

1 2

EE

PR

OM

CA

T93C

46

SM

W25

0-02

11 2

2

CN

-TH

1

5V

R01

B

R02

HR

01H

1%6.2K

1%12.1

KR

T8.0

0MG

1M

OS

C01

B

50V

C01

A0.

01+

C02

A1u

F10

V

3

20K

R01

A

610

AIR

PU

RIF

IER

220

R07

G7

108

912

V

162

12 1536

220

220

220

220

220

R03

G3

14

512

611

413

R05

G

R06

G

220

R04

G

116

215

R01

G

R02

G

1110

78

98

910A

/RE

STA

RT

126 7

11

1413

45

A/S

WIN

G

gE

/SA

VE

R

+88 S

EG

ME

NT

GN

D

RE

CE

IVE

R

BZ0

1E

-400

2P

KM

13E

PY

Vou

t

Vcc

8

10V

5V

220

C22

L

dd

DE

FRO

ST

fc

FAN

DR

Y/H

EA

T

TIM

ER

71e

fe23

d

CO

OL

45bD

igit1

a

bf

b cc

e

gg

aa

Dig

it0

5V

5V17 1

171

D03

F5V

EN

ER

GY

SA

VE

RS

W3

D07

F

TEM

P U

P SW7

1KR04

P

6 5

20K

20K

R02

P8 7

R03

P5V

A10

1S

D02

F

TIM

ER

SW

2

D01

F

FAN

SW

1

TEM

P D

OW

N

D05

F

SW

5

MO

DE

D04

F

SW

4

D08

F

AU

TO S

WIN

G

SW

8

SW

6

ON

/OFF

D06

F

1442 16

3 15

A10

1SQ

03G

A10

1SQ

02G

5 13

Q01

GA

101S

1

IC01

AS

7136

2

3.6V

5V

Q04

G

CN

-DIS

PC

N-D

ISP

Electronic Control Device

Schematic Diagram

Service Manual 21

Components Location (For Main P.W.B ASM)

Trouleshooting Glwide


Troubleshooting Guide

Troubleshooting GuidePiping System

Following is a brief description of the important components and their function in what is called the refrigerationsystem. Reference should be made to Figure 32 to follow the refrigerating cycle and the flow of the refrigerant inthe cooling cycle.

COOLEDAIR

HOTDISCHARGEDAIR

MOTOR

COMPRESSOR

ROOM AIR HEAT LOAD

CAPILLARY TUBE

(LIQUID REFRIGERANT)

LIQUID OUTLET

VAPOR INLETCOMPLETE LIQUIDBOIL OFF POINT

SUCTION LINECOOL LOW PRESSURE VAPOR

LIQUID PRESSUREDROP

DISCHARGELINE

NOT HIGH PRESSUREVAPOR

OUTSIDE COOLINGAIR FOR REFRIGERANTPASS THROUGH

EVAPORATOR COILS CONDENSER COILS

ROOM AIR CONDITIONERCYCLE OF REFRIGERATION

HIGH PRESSURE VAPOR

LIQUID REFRIGERANT

LOW PRESSURE VAPOR

OIL

CONDENSER COILS

FAN

MOTORCAPILLARY TUBE

TURBO FAN

EVAPORATORCOILS

Figure 32

Service Manual 23


Troubleshooting GuideIn general, possible trouble is classified in two kinds. The one is called Starting Failure which is caused by an electrical defect. The other is Ineffective Air Conditioningcaused by a defect in the refrigeration circuit and improper application.

Unit is running but cooling is ineffective.

Ineffective Cooling

Satisfactory operationwith temperature difference of inlet & outletair; 44~50°F (7~10°C)

Replacement of unit if the unit is beyond repair.

Check outdoor coil (heat exchanger) andfan operation.

Check heat load increase.

Check cold air circulation for smooth flow.

Check gas leakage. Clean condenser.

Not on separate circuit

Check inside gas pressure.

Adjust refrigerant charge.

Malfunction of compressor.

Replacement of compressor.

Check clogging in refrigera-tion circuit.

Repair clogging in refrigeration circuit.

Dirty indoor coil (heat exchanger)

Repair gas leak. Malfunction of fan.

Clogging of air filter.

Obstruction at air outlet.

Remove obstruction.



Fails to Start

Improper thermostat setting

Loose terminal connection

Improper wiring

Check of power source.

Drop of power voltage.

Capacitor check.

Replacement.

Check of control switch setting.

Compressor fails only to start.

Defect of compressor capacitor.

Replacement of compressor (Motor damaged).

Irregular motor insulation (Ω)

Irregular motor resistance (Ω)

Check of circuit breaker and fuse.

Gas leakage of feeler bulb of thermostat.

Check control switch.

Fan only fails to start.

Improper wiring.

Defect of fan motor capacitor.

Replacement of fan motor.

Regular but fails to start.

Replacement of compressor. (Locking of piston, metal.)

Irregular motor resistance (Ω)Irregular motor insulation (Ω)

Service Manual 25


ELECTRIC PARTS TROUBLESHOOTING GUIDE:

Possible Trouble 1 • The unit does not operate.

Is the Trans input powerAC 115V?

Is the Trans output powerabout AC 14V?

Is shorted the Trans. output?

Is output Voltage of IC01DDC 12V?

Is output Voltage of IC02DDC 5V?

Is the voltage No.18 of MicomDC 5V?

Exchange Main P.W.B Ass'y.

Is the connection between

Main and Display all right?

Is the reset circuit all right?(The No.14 of Micom

is 5V.)

• Check the Fuse.• Check the wiring diagram.

• Check the Main P.W.B pattern.

• Exchange the Trans.

• Exchange D02D~D05D.• Exchange IC01D.

• Exchange IC02D.

• Exchange IC01A.

• Connect connector exactly.

• Check the P.W.B pattern.

NO

NO

NO

NO

NO

NO

NO

YES

YES

YES

YES

YES

YES

YES

NO

YES



Is Temp.setting set lower than Room

Temp.-0.5°C?

Is the voltage No.10of IC01M 0V?

• Exchange IC01M.

• Set the Temp. setting to lower Temp.

• Wait 3 Minutes

Is the Unit for 3 minutesdelay?

• Exchange MAIN P.W.B Ass'y.

Is the voltage N0.7 of IC01M DC 5V?

• Check the RY-COMP.• Check the wiring Diagram.

NO

NO

NO NO

YES YES

YES

YES

Possible Trouble 2 • The compressor does not operate.

Is the wire connection of RY-COMP all right?

• Check the RY-COMP.

• Connect LEAD Wire to RY-COMP again.

NO

YES

Possible Trouble 3 • The compressor always operate.

• Exchange IC01M.

• Exchange IC01M.

Is the voltage NO.1 or 4of IC01M DC 5V?

Is the voltage NO.13 or 16of IC01M 0V?

• Check the RY-Hi orRY-Lo.

• Check the wiring diagram.

NO

NO

YES

YES

Possible Trouble 4 • Fan does not operate.

Service Manual 27


Is the voltage of Batteryabout over 2.3V?

• Exchange Receiver Ass'y.

Is the connection of CN-DISP1 all right?

Is the voltage No.16 of CN-DISP1 on Main P.W.B

Ass'y DC 5V?

• Exchange the battery.

• Check the P.W.B pattern.

• Connect connector to CN-DISP1 exactly.

NO

NO

NO

YES

YES

YES

Possible Trouble 5 • Romote controller does not operate.

NO

NO

NO

NO

YES

YES

YES

Is the IC01G all right?

Is the connection of CN-DISP1 all right?

• Exchange the display P.W.B Ass'y.

• Exchange IC01G.

• Exchange Q01G, Q02G, Q03G, Q04G

• Connect connector to CN-DISP1 exactly.

Does the Q01G,Q02G, Q03G Q04G operate normally

on main P.W.B Ass'y?

Possible Trouble 6 • It displays abnormally on Display P.W.B Ass'y.



Room Air Conditioner Voltage Limits

NAME PLATE RATING MINIMUM MAXIMUM

115V ± 10% 103.5V 126.5V

COMPLAINT CAUSE REMEDY

Fan motor will not run. No power Check voltage at outlet. Correct if none.

Power supply cord Check voltage to rotary switch. If none, check power supply cord. Replace cord if circuit is open.

Rocker switch Check switch continuity. Refer to wiring diagram for terminal identification. Replace switch if defective.

Wire disconnected or Connect wire. Refer to wiring diagram for connection loose terminal identification. Repair or replace loose

terminal.

Capacitor (Discharge Test capacitor. capacitor before testing.) Replace if not within ±10% of manufacturer's

rating. Replace if shorted, open, or damaged.

Will not rotate Fan blade hitting shroud or blower wheel hitting scroll. Re-align assembly.

Units using slinger ring condenser fans must have 0.22~0.25 inch clearance to the base. If necessary, 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.

Fan motor runs. Revolves on overload Check voltage. See limits on this page.

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.

Service Manual 29



Fan motor noise. Tubo Fan If cracked, out of balance, or partially missing, replace it.

Axial Fan If cracked, out of balance, or partially missing, replace it.

Loose set screw Tighten it.

Worn bearings 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.

Compressor will not run, Voltage Check voltage. See the limits on the preceding fan motor runs. page. If not within limits, call an electrician.

Wiring Check the wire connections; if loose, repair or replace the terminal. If the wires are discon-nected, refer to wiring diagram for identification, and replace the wires. Check the wire connections; If not according to the wiring diagram, correct the connections.

Rocker Switch Check for continuity, refer to the wiring diagram for terminal identification. Replace the switch if the circuit is open.

Thermostat Check the position of knob. If not at the coldest setting, advance the knob to this setting and restart the unit.

Check the continuity of the thermostat. Replace the thermostat if the circuit is open.

Capacitor (discharge Check the capacitor. capacitor before Replace if not within ±10% of manufacturer’s servicing.) rating, replace if shorted, open, or damaged.

Compressor Check the compressor for open circuit or ground. If open or grounded, replace the compressor.

Overload Check the compressor overload if externally mounted.Replace if open. (If the compressor temperature is high, remove the overload, cool, and retest.)

Compressor cycles on Voltage Check the voltage. See the limits on the overload. preceding page. If voltage is not within these limits,

call an electrician.

Overload Check overload, if externally mounted. Replace if open. (If the compressor temperature is high, remove the overload, cool, and retest.)




Compressor cycles on Fan motor If not running, determine the cause. Replace if overload. required.

Condenser air flow Remove the cabinet, inspect the interior surface restriction of the condenser. If restricted, clean carefully

with a vacuum cleaner (do not damage fins) or brush. Clean the interior base before re-assembling.

Condenser fins If the condenser fins are closed over a large (damaged) area on the coil surface, head pressures will

increase, causing the compressor to cycle. Straighten the fins or replace the coil.

Capacitor Test the capacitor.

Wiring Check the terminals. If loose, repair or replace.

Refrigeration system Check the system for a restriction.

Insufficient cooling Air filter If restricted, clean or replace.

Unit undersized Determine if the unit is properly sized for the area to be cooled.

Excessive noise Turbo Fan or Axial Fan Check the set screw, or clamp. If loose or miss-ing, correct. If the tubo fan or axial fan is hitting scroll or barrier, rearrange the air handling parts.

Copper tubing Remove the cabinet and carefully rearrange the tubing not to contact the cabinet,compressor, shroud, and barrier.

Service Manual 31

Exploded View

Exploded View

B A E

C

D

352115

349480

352113

35211A

567502

554160

550140

352410

130410

W48602

148000

130910

559010

552113

554030

152302

159900-1

159900-1159900-2

352380-1

352380-2

135312

249950

359012

149980

346811

731373

W48602

AutoSwing

Power

Temp

Fan Speed

Timer Mode


Replacement Parts ListReplacement Parts List

130410 BASE ASSEMBLY, SINGLE 3 0 4 1 A 1 0 0 4 0 A130910 CABINET ASSEMBLY, SINGLE 3 0 9 1 A 1 0 0 5 5 A135312 GRILLE ASSEMBLY, FRONT(SINGLE) 3 5 3 1 A 1 1 0 1 0 A

148000 BRACE 4 8 0 0 A 3 0 0 1 2 A149980 SHROUD 4 9 9 8 A 1 0 0 2 8 A152302 FILTER(MECH), A/C 5 2 3 1 A R 9 0 0 1 B

159900-1 VANE, VERTICAL 4 7 5 8 A 3 0 0 4 1 A159900-2 VANE, VERTICAL 4 7 5 8 A 3 0 0 4 1 B

249950 CONTROL BOX ASSEMBLY 4 9 9 5 A 2 0 3 7 8 B

237200 PANEL,CONTROL 3 7 2 0 A 3 0 0 7 6 A238210 ESCUTCHEON 3 8 3 1 A 1 0 0 3 8 C

263230 THERMISTOR ASSEMBLY 6 3 2 3 A 2 0 0 0 4 R

264110 POWER CODE ASSEMBLY 6 4 1 1 A 2 0 0 3 8 A267110 REMOTE CONTROLLER 6 7 2 7 A Q 9 1 4 2 P238712 PWB(PCB)ASEMBLY,DISPLAY 6 8 7 1 A 2 0 4 4 9 A268714 PWB(PCB)ASSEMBLY,MAIN 6 8 7 1 A 1 0 1 2 9 A

346811 MOTOR ASSEMBLY, SINGLE 4 6 8 1 A 2 0 1 1 6 E349480 ORIFICE 4 9 4 8 A 2 0 0 3 1 B352113 TUBE ASSEMBLY, DISCHARGE 5 2 1 1 A 2 1 1 3 6 A352115 TUBE ASSEMBLY, EVAPORATOR IN 5 2 1 1 A 2 5 0 1 9 A35211A TUBE ASSEMBLY, SUCTION SINGLE 5 2 1 1 A 2 1 2 2 8 B

352380-1 AIR GUIDE 5 2 3 8 A 1 0 0 2 6 A352380-2 AIR GUIDE 5 2 3 8 A 1 0 0 2 5 A352410 EVAPORATOR ASSEMBLY, FIRST 5 4 2 1 A 2 0 1 7 6 C359012 FAN TURBO 5 9 0 0 A 2 0 0 4 0 B550140 ISOLATOR, COMPRESSOR 5 0 4 0 A R 4 1 9 5 A554030 CONDESER ASSEMBLY, FIRST 5 4 0 3 A 2 0 1 7 4 A554160 COMPRESSOR 2 5 2 0 U C A A 0 1 1559010 FAN, AXIAL 5 9 0 0 A 2 0 0 4 2 A567502 O.L.P 6 7 5 0 U - L 0 5 0 AW0CZZ CAPACITOR, DRAWING 0 C Z Z A 2 0 0 0 5 BW48602 CLAMP, SPRING 3 H 0 2 9 3 2 B

LOCATIONNO.

P A R T N O .W G 5 0 0 4 R

REMARKDESCRIPTION

Service Manual 33

P/No.: 3828A20472DFebruary, 2004

Printed in China

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