LG AP-Z Series Service Manual Download

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Floor Standing Type
Air Conditioner

SERVICE MANUAL

CAUTION

website http://www.lgservice.com
e-mail http://www.lgeservice.com/techsup.html

• BEFORE SERVICING THE UNIT, READ THE SAFETY

PRECAUTIONS IN THIS MANUAL.

• ONLY FOR AUTHORIZED SERVICE PERSONNEL.

MODEL: AP-Z Series

Summary of Contents for AP-Z Series

Page 1: ...itioner SERVICE MANUAL LG CAUTION website http www lgservice com e mail http www lgeservice com techsup html BEFORE SERVICING THE UNIT READ THE SAFETY PRECAUTIONS IN THIS MANUAL ONLY FOR AUTHORIZED SERVICE PERSONNEL MODEL AP Z Series ...

Page 2: ...OF CONTENTS Safety Precautions 3 Functions 7 Product Specifications 10 Wiring Diagram 12 Operation Details 16 Installation of Indoor Outdoor Unit 23 Test running 29 3 way valve 31 Cycle Troubleshooting Guide 37 Electronic Parts Troubleshooting Guide 38 Exploded View and Replacement Parts List 41 ...

Page 3: ...ry or damage to properties only Installation Be sure not to do Be sure to follow the instruction Do not use a defective or under rated circuit breaker Use this appliance on a dedicated circuit There is risk of fire or electric shock Always ground the product There is risk of fire or electric shock Install the panel and the cover of control box securely There is risk of fire or electric shock Alway...

Page 4: ...ective installation stand It may cause injury accident or damage to the product Be sure the installation area does not deteriorate with age If the base collapses the air condi tioner could fall with it causing property damage product failure and personal injury Do not let the air conditioner run for a long time when the humidity is very high and a door or a window is left open Moisture may condens...

Page 5: ...roduct damage Always check for gas refrigerant leakage after installation or repair of product Low refrigerant levels may cause failure of product Install the drain hose to ensure that water is drained away properly A bad connection may cause water leakage Do not store or use flammable gas or com bustibles near the product There is risk of fire or failure of product If strange sounds or small or s...

Page 6: ... fire electric shock or damage to the plastic parts of the product Do not touch the metal parts of the product when removing the air filter They are very sharp There is risk of personal injury Do not step on or put anyting on the product outdoor units There is risk of personal injury and failure of product Do not insert hands or other objects through the air inlet or outlet while the product is op...

Page 7: ...y Control Fan Operation AutoRestart Cooling Heating Soft Dry Fan High Low Speed Cooling operates super high fan speed in cooling mode Cooling Mode only Maintains the room temperature in accordance with the Setting Temp Up up to 30 C Down down to 16 C Heat exchanger temperature sensor Thermistor Intermittent operation of fan at low speed Restarting is inhibited for approx 3 minutes Used to circulat...

Page 8: ...perates super high fan speed in cooling mode Airflow direction Auto swing and Manual Contol Up up to 30 C Down down to 16 C High Low Remote Control Operation ON OFF Cooling Operation Mode Heating Operation Mode Sot Dry Operation Mode Fan Operation Timer Control Jet Cool or Turbo Jet Energy Saving Airflow Direction Control Room Temperature Control Indoor Fan speed control ...

Page 9: ...Service Manual 9 Functions Outdoor Unit Deice Control Outdoor Fan Speed Control Sensing Heat Exchanger Temperature De ice PCB One speed Heat exchanger temperature sensor Thermistor ...

Page 10: ... 50 3 380 415 50 3 380 415 50 28 000 46 000 72 800 2 800 5 300 8 800 13 9 5 15 2 27 800 48 000 88 000 2 800 5 000 8 200 13 9 14 5 5JS330DJSA008 AR061YAB AR061YAB AQ042YAB Matsushita Ele LG Ele LG Ele Rotary Scroll Scroll 28 101 50 800 50 800 35 200 2 915 5 347 5 347 3 608 68 63 63 47 48 46 40 53 51 48 56 58 58 65 17 600 30 28 26 1 060 989 918 57 48 2 013 1 695 58 2 048 104 3 673 150 5 297 Sirroco ...

Page 11: ...nlet Air Outlet Bottom Panel Ground Terminal Refrigerant Pipe Port Antibiotic Filter Plasma Deodorant Air Cleaner Remote Controller Holder Control Panel Top Bottom Airflow Controller Left Right Airflow Controller Air Inlet back side Control Cover Air Intake Vent Rear Air Outlet Vent Piping Air Outlet Vent Remote Signal Receptor Air Intake Vent Indoor Unit Outdoor Unit Indoor Unit Outdoor Unit AP Z...

Page 12: ...BLOCK YL WH 1 6 8 2 4 0 POWER SUPPLY POWER RELAY FUSE 250V 5A DOOR S W1 E HEATER DOOR S W1 HVB ASM A CL UNIT MAIN AC PCB ASM MAIN DC PCB ASM CN 4WAY RY HEATER RY HEATER CN HEATER CN HEATER CN HEATER CN AIRC RY COMP RY LOW CAPACITOR DOOR UPPER SYNC M FMi STEP M PTC1 PTC2 T S FUSE STEP M STEP M STEP M RY MID RY HIGH RY S H RY OPEN RY CLOSE FUSE 250V 3 15A VARISTOR CN FAN M CN LE RI LE RI MOTOR UP DO...

Page 13: ...Service Manual 13 Wiring Diagram INDOOR AP Z286R20 AP Z286R30 OUTDOOR AP Z286RC0 AP Z286R20 AP Z286R30 ...

Page 14: ...BLOCK RY HIGH RY MID RY LOW RY SYNC CN HEAT CN AIRC DOOR S W DOOR S W CN HEAT HEAT PCB ASM H V ASSY AIR CLEANER RD ELECTRIC HEATER DIAGRAM RY 1 PTC HEATER PTC HEATER RY 2 BL BK BK TS TF TS TF BL 1 2 3 4 5 6 P NO 3854A20411A POWER SUPPLY CONNECT CONTACT R N OF OUTDOOR TERMINAL BLOCK TM Outdoor Unit Wiring Diagram R TM POWER SUPPLY 3Ø 380 415V 50Hz TERMINAL 4P S T N BK BK BK BK BK WH WH WH WH RD OR ...

Page 15: ...UPPLY CONNECT CONTACT R N OF OUTDOOR TERMINAL BLOCK TM 3854A20317C OUTDOOR UNIT WIRING DIAGRAM BR BK BK BK BK TNS NC NO NC NO C TH D P WH YL BL BL BL BL BL RD 20SV BR BR TO INDOOR UNIT BR 1 L 2 N 3 4 5 6 BL BK GN YL RD BL 1 2 3 4 5 6 7 8 TB1 TB2 52F1 3 P D R S T A B WH WH RD RD F2 BL YL YL BR BR BK BK OR OR YL YL BR BR BK BK BR BL RD YL WH RD BK OR OR R POWER SUPPLY 3Ø 380 415V 50Hz TERMINAL 4P TM...

Page 16: ... automatically Remote controller 3rd Repress the Airflow Direction Control Button to set the louver as the desired position Remote controller 3 Cooling Mode Operation When selecting the Cooling Mode Operation the unit will operate according to the setting by the controller and the operation diagram is as following Intake Air temp Setting Temp 1 C Compressor ON Setting Temp 1 C Compressor OFF Indoo...

Page 17: ...ing fan speed Selecting fan speed A point The indoor pipe temperature to be less then 35 C Discharge air Temperature to be less than 29 C The indoor fan operates for minimum 10sec even if falls lower than 34 C Low V Stop VI 39 C Discharge Air Temp Indoor Pipe Temp 34 C 28 C 26 C Selecting Fan Speed IV Low II Stop I Hot Start Operating Heating Start Hot Start Release Point Selecting Fan Speed III D...

Page 18: ...ng fan speed A point The indoor pipe temperature to be less than B C The indoor fan operates for minimum 10sec even if the indoor pipe temperature falls lower than B C Low V Stop VI C C Indoor Pipe Temp D C 22 C 20 C Selecting Fan Speed IV Low II Stop I Hot Start Operating Heating Start Hot Start Release Point Selecting Fan Speed III During heating operation the operating procedure of the indoor f...

Page 19: ...ng operation and more than Defrost ends after 10 minutes pass from starting of defrost operation or when the outdoor pipe temperature rises over 12 C even if before 10 minutes The second defrost starts only when the outdoor pipe temperature falls below 6 C after 45 minutes pass from ending of the first defrost and more than INDOOR PIPE TEMP INDOOR FAN SPEED Selecting fan speed OFF OFF LOW 1min Max...

Page 20: ... the setting temperature plus 2 C the compressor OFF temperature is the setting temperature minus 1 C When the room temperature rises over the compressor ON temperature the operation mode is switched to the Cool ing mode When the room temperature falls between the compressor ON temperature and OFF temperature the operation mode is switched to the Soft Dry Operation The operation diagram is shown b...

Page 21: ... During the operation when it stops and runs again setting up is high fan speed on cooling mode set up to 18 C 14 Energy Saving If setting temperature of starting energy saving operation is under 22 C first setting temperature it up to 22 C and perform energy saving operation After energy saving operation starts if adaptation time of the human body pass from the point which room temperature and se...

Page 22: ... temperature 25 C to be set to 26 C c 26 C Room temperature 28 C to be set to 1 C more than room temperature d 29 C Room temperature to be set to 30 C 17 Function for test operation 1 Outline of Operation This is for checking the condition of installation during the installation and it is operated by cooling Fan speed is high comp on and Auto air flow operations without setting temperature 2 Opera...

Page 23: ...ce or other obstacles 2 Outdoor unit If an awning is built over the unit to prevent direct sunlight or rain exposure be careful that heat radiation from the condenser is not restricted There should not be any animals or plants which could be affected by discharged hot air Ensure the space indicated by arrows from the wall ceiling fence or other obstacles A B Indoor unit Outdoor unit 50cm 50cm 50cm...

Page 24: ... nuts If there is any vibration transmitted to the build ing mount the rubber underneath the outdoor unit 4 Refrigerant amount Before shipment this air conditioner is filled with the rated amount of refrigerant including additional amount required for air purging subject to 5m pip ing length The rated amount of refrigerant is indi cated on the name plate But when the piping length exceeds 5 meters...

Page 25: ...e outdoor unit 6 Blowing the pipings To remove dust and scale in working 7 Connecting the pipings of the indoor unit 8 Check a gas leakage of the connecting part of the pipings 9 Air purging of the piping and indoor unit The air which contains moisture and which remains in the refrigeration cycle may cause a malfunction on the compressor 10 Open the 3 way liquid side and 3 way gas side valves 11 F...

Page 26: ...e refrigerant amount 11 Refrigerant Vessel Gas charge Air purge Cleaning the pipe 12 Spanner To tighten the connecting parts of the pipings 13 Monkey spanner 14 Driver 15 Pliers 150mm Cutting the wires 16 Tapeline To measure the length 17 Core drill To make holes through the concrete wall and blocks 18 Voltmeter Amperemeter Clampmeter To measure the current and voltage 19 Insulation resistance tes...

Page 27: ... cause a gas leakage Flaring the pipes Insert the flare nuts mounted on the connection ports of both indoor and outdoor unit onto the copper pipes Some refrigerant gas may leak when the flare nuts are removed from the indoor unit as some gas is charged to prevent the inside of the pipe from rusting Fit the copper pipe end into the Bar of flare tool about 0 0 5mm higher See illustaration Flare the ...

Page 28: ...eed 70mm Refer to Fig 1 Do not repeat the bending process to prevent the tubing from cracking or crushing Keep in mind that the bending part should not be cracked and make the radius R as long as possi ble Refer to Fig 2 PIPE SIZE TORQUE 3 8 4 2 Kg m 1 2 5 5 Kg m 5 8 5 5 Kg m 3 4 6 5 Kg m Indoor unit tubing Flare nut Pipings Torque wrench Spanner Spring R70mm Fig 1 Fig 2 R 2 Connection of piping M...

Page 29: ...vibration and noise operating pressure piping temperature compressive pressure As to the structure and appearance check following items 2 Connection of power supply 1 Connect the power supply cord to the independent power supply Circuit breaker is required 2 Operate the unit for fifteen minutes or more 3 Evaluation of the performance 1 Measure the temperature of the intake and discharge air 2 Ensu...

Page 30: ...ive rise to burn out of the wires 4 Specification of power source 5 Confirm that electrical capacity is sufficient 6 Be sure that the starting voltage is maintained at more than 90 percent of the rated voltage marked on the name plate 7 Confirm that the cable thickness is as specified in the power sources specification Particularly note the relation between cable length and thickness 8 Never fail ...

Page 31: ...ge hose Open the low pressure valve on the charge set slightly to air purge from the charge hose 5 Set the liquid side valve to the closed posi tion 6 Operate the air conditioner in cooling mode and stop it when the gauge indicates 1kg cm2 g 7 Immediately set the 3 way valve to the closed position Do this quickly so that the gauge ends up indi cating 3 to 5kg cm2 g 8 Disconnect the charge set and ...

Page 32: ...e wrench to tighten the flare nut on liquid side valve 4 Check for gas leakage Check the flare connections for gas leakage 5 Discharge the refrigerant Close the valve on the gas cylinder and dis charge the refrigerant until the gauge indicates 3 to 5 kg cm2 g 6 Disconnect the charge set and the gas cylin der and set the 2 way and 3 way valves to the open position Be sure to use a hexagonal wrench ...

Page 33: ...arge set and discharge the refrigerant until the gauge indicates 0 kg cm2 G If there is no air in the refrigerant cycle the pressure when the air conditioner is not run ning is higher than 1 kg cm2 G discharge the refrigerant until the gauge indicates 0 5 to 1 kg cm2 G if this is the case it will not be neces sary to apply a evacuatin Discharge the refrigerant gradually if it is dis charged too su...

Page 34: ...d toward 76 cmHg vacuum of 4 mmHg or less 3 Close the valve Lo side on the charge set turn off the vacuum pump and confirm that the gauge needle does not move approxima tely 5 minutes after turning off the vacuum pump 4 Disconnect the charge hose from the vacuum pump Vacuum pump oil If the vacuum pump oil becomes dirty or depleted replenish as needed Lo Open Open Vacuum pump 3 Way valve Outdoor un...

Page 35: ...ime approximately 150g each time while operating the air conditioner in the cooling cycle however one time is not suffi cient wait approximately 1 minute and then repeat the procedure pumping down pin 4 Immediately disconnect the charge hose from the 3 way valve s service port Stopping partway will allow the gas to be dis charged If the system has been charged with liquid refrigerant while operati...

Page 36: ...system with liquid refrigerant If the system can not be charged with the specified amount of refrigerant it can be charged with a little at a time approximately 150g each time while operating the air conditioner in the cooling cycle however one time is not sufficient wait approxi mately 1 minute and then repeat the procedure pumping down pin 4 Immediately disconnect the charge hose from the 3 way ...

Page 37: ... air humidity When the room air humidity is relativery higher temperature difference is smaller When the room air humidity is relatively lower tem perature difference is larger 2 Check temperature and pressure of refrigeration cycle Notice 1 The suction pressure is usually 4 5 6 0 kg cm2 G at normal condition 2 The temperature can be measured by attaching the thermometer to the low pressure tubing...

Page 38: ...64 of MICOM DC5V Exchange MICOM YES NO Check the main P C B pattern NO NO Check the D02D D05D NO YES Exchange the transformer Is shorted the transformer output NO YES Is the output voltage of IC03D DC5V NO Exchange IC01D Exchange IC03D Is the output voltage of transformer about AC14V Check the 5V P C B pattern Possible Trouble 2 The indoor fan does not operate NO Is IC03M operated normally Check t...

Page 39: ...14 pin of terminal MICOM Is the DC5V at 18 pin of terminal MICOM Is the DC12V at each terminal RY 4WAY COIL Isthe AC220V AC240V betweenconnec tor 4WAY andCN outunit ofMain P C B Is the DC12V at each terminal RY COMP COIL Replacement RY 4WAY Replacement IC02M Replacement RY COMP IstheAC220V AC240V betweenconnector CN outunit and ofMain P C B Check the wiring diagram Replacement MICOM Replacement IC...

Page 40: ...ompressor operating Is the Heat S W of Main PCB ON Heat S W ON Heater S W ON Replacement MICOM Replacement IC02M Replacement RY HEATER Is the heater S W of Main PCB ON Is the DC 5V at 15 pin of MICOM Is the DC 12V at eack terminal RY HEATER COIL Isthe AC220V AC240V between connector HEATER andCN outunit of MainP C B Check the heater wiring Select the heating operation mode Compressor ON ...

Page 41: ...Parts List AP Z286RC0 AP Z286R20 AP Z286R30 1 Indoor Unit 267110 237201 135313 1 135313 2 235811 2 146811 3 146811 1 235811 1 137211 132111 235512 249941 268711 3 268711 2 W0CZZ 268711 4 135310 146811 2 135511 Exploded View and Replacement Parts List ...

Page 42: ...r Exploded View and Replacement Parts List 130911 753010 753000 35211C 354210 W4811 1 354212 336610 W4810 1 730700 346810 359012 W1NF 140570 W1WE 349480 W50400 159830 337000 266000 352150 336600 567480 W4810 2 W4811 2 135515 W52103 35211A ...

Page 43: ...268711 3 PWB PCB ASSEMBLY MAIN DC 6871A20496C 6871A20320E 6871A20489A 1 567480 THERMISTOR ASSEMBLY 6323A20016A 6323A20016A 6323A20016A 1 336600 HOUSING MECH WRAPPER 3660A20023L 3660A20023J 3660A20023J 1 336610 HOUSING ASSEMBLY MECH 3661A20017P 3661A20033A 3661A20033A 1 337000 NET STEEL 3700A30001A 3700A30001A 3700A30001A 1 346810 MOTOR ASSEMBLY INDOOR 4681A20134A 4681A20134A 4681A20134A 1 349480 O...

Page 44: ...oner Exploded View and Replacement Parts List 2 Outdoor Unit C S R 435512 437210 349480 447910 559010 546810 349600 W0CZZ 2 W0CZZ 1 268711 W6920 649950 554030 137213 1 435300 137213 2 435511 552203 1 552203 2 552116 554160 430411 435301 ...

Page 45: ...ASSEMBLY CONTROL OUTDOOR 3551A30071L 1 435512 COVER ASSEMBLY TOP OUTDOOR 3H03266H 1 437210 PANEL ASSY FRONT SUB 1A00197C 1 435300 GRILLE REAR 1A00208D 1 447910 BARRIER ASSEMBLY OUTDOOR 2A01043L 1 546810 MOTOR ASSEMBLY OUTDOOR 4681A10030B 1 552116 TUBE ASSEMBLY REVERSING 5211A20493L 1 552203 1 VALVE SERVICE 5220A20001R 1 552203 2 VALVE SERVICE 5220A20013A 1 554030 CONDENSER ASSEMBLY FIRST 5403A2017...

Page 46: ...Standing Type Air Conditioner Exploded View and Replacement Parts List AP Z488TC0 1 Indoor Unit 668713 268714 W4810 137211 237202 152302 135313 330870 146812 W4810 354210 354210 W4811 267110 753010 753000 135310 ...

Page 47: ...Service Manual 47 Exploded View and Replacement Parts List W4810 359012 W50400 W4810 346810 150170 130400 349480 135317 135500 268715 249941 249951 W0CZZ 336610 135515 130900 349600 ...

Page 48: ...R 4994A10026B 1 249951 CONTROL BOX ASSEMBLY INDOOR 4995A20200P 1 267110 REMOTE CONTROLLER ASSEMBLY 6711A20054R 1 268712 PWB PCB ASSEMBLY MAIN 6871A10054U 1 268714 PWB PCB ASSEMBLY MAIN AC 6871A20268Q 1 330870 DRAIN PAN ASSEMBLY 3087A30001D 1 336600 HOUSING MECH WRAPPER 3660A20024C 1 346810 MOTOR ASSEMBLY INDOOR 4681A20015D 1 349480 ORIFICE 4948A30002A 1 349600 MOUNT MOTOR 4960AP2285F 1 354210 EVAP...

Page 49: ...ded View and Replacement Parts List 2 Outdoor Unit 435512 546810 549610 554031 447910 649950 556001 W0CZZ 268711 137213 147780 150400 430410 435511 437210 135301 437212 552201 552202 552203 552203 554160 559010 W49800 W52120 ...

Page 50: ...B 1 437212 PANEL ASSY REAR 3720AP1202L 1 447910 BARRIER OUTDOOR 4760AP1216C 1 546810 MOTOR ASSEMBLY OUTDOOR 4681A10030B 2 549610 MOUNT MOTOR 4960A10004A 1 552201 VALVE CHECK 3A01020D 1 552202 COIL ASSEMBLY REVERSING VALVE 3A02080B 1 552203 VALVE SERVICE 2A00499L 1 552203 VALVE SERVICE 5220A20001F 1 554031 CONDENSER ASSEMBLY FIRST 5403A21001B 1 554031 CONDENSER ASSEMBLY FIRST 5403A21001D 1 554160 C...

Page 51: ...vice Manual 51 Exploded View and Replacement Parts List AP Z728FA0 1 Indoor Unit 268711 1 235450 336610 359012 135310 237202 147911 W0CZZ 648600 249941 268711 2 135313 159830 135313 268711 4 330720 437210 ...

Page 52: ...52 Floor Standing Type Air Conditioner Exploded View and Replacement Parts List 346810 753010 150170 354210 W4810 2 352114 330870 W4810 1 ...

Page 53: ...1 PWB PCB ASSEMBLY DISPLAY 6871A20157C 1 268711 2 PWB PCB ASSEMBLY MAIN 6871A10150C 1 330720 CUT OFF 4A00085A 2 330870 DRAIN PAN ASSEMBLY 3087AP2381A 1 336610 HOUSING ASSY MECH 3661AP1139A 1 336610 HOUSING ASSY MECH 3661AP1139B 1 346810 MOTOR ASSEMBLY INDOOR 4681AP2411M 1 352114 TUBE ASSEMBLY DISTRIBUTOR 5425AG3363V 1 354210 EVAPORATOR ASSEMBLY FIRST 5420AP2380A 1 359012 FAN ASSY BLOWER 2A00578R 2...

Page 54: ... Conditioner Exploded View and Replacement Parts List 2 Outdoor Unit 435311 349480 559010 437210 1 546810 549610 437210 2 554031 430411 554031 552203 2 548490 552203 1 554160 1 554160 2 649950 W0CZZ W6640 1 W6640 2 566001 268711 ...

Page 55: ...4849A10017H 1 549610 MOUNT ASSEMBLY MOTOR OUTDOOR 3G00789L 1 552203 1 VALVE SERVICE 2A00469K 1 552203 2 VALVE SERVICE 5220A20035A 1 554031 CONDENSER ASSEMBLY BENT 5403A20139A 1 554031 CONDENSER ASSEMBLY BENT 5403A20139B 1 554031 CONDENSER ASSEMBLY BENT 5403A20139C 1 554031 CONDENSER ASSEMBLY BENT 5403A20139D 1 554160 COMPRESSOR SET 2520UBAY2AA 1 554160 COMPRESSOR SET 2520UUCY2AA 1 559010 FAN ASSEM...

Page 56: ...P No 3828A20156G March 2006 Printed in Korea ...

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