LG AP-Z Series Svc Manual Download Page 1

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Floor Standing Type Air Conditioner

SVC MANUAL

MODEL : AP-Z Series

CAUTION

Before Servicing the unit, read the safety precautions in General SVC manual.
Only for authorized service personnel.

Internal Use Only

http://biz.lgservice.com

Summary of Contents for AP-Z Series

Page 1: ...g Type Air Conditioner SVC MANUAL MODEL AP Z Series CAUTION Before Servicing the unit read the safety precautions in General SVC manual Only for authorized service personnel Internal Use Only http biz lgservice com ...

Page 2: ...r Standing Type Air Conditioner Service Manual TABLE 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 41 ...

Page 3: ...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 Always install a dedicated cir cuit and breaker Improper wiring or inst...

Page 4: ...ury Do not install the product on a defective 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 w...

Page 5: ...lation 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 smoke comes from product Turn the breaker off or discon nect the pow...

Page 6: ...detergents solvents etc There is risk of 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...

Page 7: ...ed 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 circulate room air without cooling The power comes on again after a power failure Fun...

Page 8: ...g OFF Timer 1 2 3 7 hour Speed cooling operates 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 ...

Page 9: ...cs Inc All right reserved Only for training and service purposes LGE Internal Use Only Outdoor Unit Deice Control Outdoor Fan Speed Control Sensing Heat Exchanger Temperature De ice PCB One speed Heat exchanger temperature sensor Thermistor ...

Page 10: ...0 AP Z728FA0 HEAT PUMP MODELS 1 220 240 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 69...

Page 11: ...or Display Panel Antibiotic Filter Air Inlet Air Inlet 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 Indo...

Page 12: ...CITOR COMP THERMISTOR COND TH TERMINAL 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 VARIS...

Page 13: ...Wiring Diagram 13 Copyright 2010 LG Electronics Inc All right reserved Only for training and service purposes LGE Internal Use Only INDOOR AP Z286R20 AP Z286R30 OUTDOOR AP Z286RC0 AP Z286R20 AP Z286R30 ...

Page 14: ...LLOW GREEN YELLOW ROOM SENSOR TERMINAL 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 ...

Page 15: ... RY 2 TMi BL BR BR TS TF TS TF BL 3 4 5 6 POWER SUPPLY 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 ...

Page 16: ...tton to swing the louver left and right 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 O...

Page 17: ... LOW Setting Temp 1 C Compressor OFF Selecting 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 St...

Page 18: ...or OFF Selecting fan speed Selecting 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 o...

Page 19: ... C after 45 minutes passed from starting of heating 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 F...

Page 20: ... the compressor ON temperature is 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...

Page 21: ...e in high Fan speed on Cooling mode set up to 18 C 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...

Page 22: ...ature 20 C to be set to 23 C b 21 C Room 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 operat...

Page 23: ...ces indicated by arrows from the wall ceiling fence 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 radi ation 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 obs...

Page 24: ...ally by securing it with bolts Ø12mm and nuts If there is any vibration transmitted to the building 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 piping length The rated amount of refrigerant is indicated on the name plate But wh...

Page 25: ...he flare nut outdoor Connecting the pipings of the 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...

Page 26: ...0 Charge cylinder balance To measure the 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 a...

Page 27: ...e pipe Caution If burrs are not removed they may cause a gas leakage Flaring the pipes Insert the flare nuts mounted on the connection ports of both indoor and outdoor unit onto the cop per 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 ...

Page 28: ...member that the radius R should not exceed 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...

Page 29: ... wind volume voltage current presence of abnormal 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 ...

Page 30: ...y fastened If they are loose it could give 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 c...

Page 31: ...ose to the service port 4 Air purging of the charge 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 catin...

Page 32: ...times After purging the air use a torque 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 posi...

Page 33: ...e service port 3 Open the valve Lo side on the charge 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 ...

Page 34: ... Confirm that the gauge needle has moved 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 ...

Page 35: ...efrigerant 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 suffi cient wait approximately 1 minute and then repeat the procedure pumping down pin 4 Immediately disconnect the charge hose from the 3 way valveʼs service port Stopping partway will allow the gas to be dis charged If the system has b...

Page 36: ... side on the charge set and charge the 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 dis...

Page 37: ...e between intake and discharge air depends on room 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 at...

Page 38: ...t voltage of IC01D DC12V Is the PIN 55 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 operat...

Page 39: ...it heating mode Room temp Set temp Is the DC5V at 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 t...

Page 40: ...ES NO Is the heating operating Is the Compressor 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 ...

Page 41: ...LGE Internal Use Only AP Z286RC0 AP Z286R20 AP Z286R30 1 Indoor Unit 146811E 146811C 146811C 268711A 135303A 135313B 135303B 267110 146811A 137211 235512 W0CZZA 268711B 268711C 249951 146811B 135310 437210A 249941 146811D 147582B 147581B 135313A 237201 147582A 147581A W0FZZ 159830C W6640A W6640B Exploded View ...

Page 42: ...rved Only for training and service purposes LGE Internal Use Only W4810A 354210 354212 W4810B 336600 159830B W4811B 349480A 359012 266000 266090 266000 346810 730700 W50400 140570 336610 567480B 130911 567480A 552111 35211C 352150 135515 159830A W4811A 349600 W4811C ...

Page 43: ...ZZC W0CZZB 135500A W6920 649950 554030 137213A 435300 137213B 435511 268711F 567480 552203A 552203B 554160 435301 W49810 135500B 430410 152503 552112 552113 552202 552560 552116 561410 43 Copyright 2010 LG Electronics Inc All right reserved Only for training and service purposes LGE Internal Use Only ...

Page 44: ...l right reserved Only for training and service purposes LGE Internal Use Only Exploded View AP Z488TC0 1 Indoor Unit 668713 268714 W4810 137211 237202 152302 135313 330870 263230 1 146812 W4810 354210 354210 W4811 267110 753010 753000 135310 ...

Page 45: ...tronics Inc All right reserved Only for training and service purposes LGE Internal Use Only Exploded View W4810 359012 W50400 W4810 346810 150170 130400 349480 135317 135500 268715 249941 249951 W0CZZ 336610 135515 130900 349600 ...

Page 46: ...aining and service purposes LGE Internal Use Only Exploded View 2 Outdoor Unit 435512 546810 549610 554031 554031 2 447910 649950 556001 W0CZZ 268711 137213 147780 150400 430410 435511 437210 135301 437212 552201 552202 552203 552203 554160 559010 W49800 W52120 554031 1 ...

Page 47: ...0A 147582 135310 149400B 149410 237202 147911 W0CZZA 249941A 135316 147901B 268711B 249941B 268711D 135313A 159830 336610B 359012 249951 135313B 330720 135080A 437210 149400A 149400D 149400C 330720 47 Copyright 2010 LG Electronics Inc All right reserved Only for training and service purposes LGE Internal Use Only ...

Page 48: ... All right reserved Only for training and service purposes LGE Internal Use Only Exploded View 753010 135515 137213F 330871 W4810 W4811 346810 730700 150170 354210 352118 137213C 137213A 137213B 437212 352115 130400 137213D 137213G 137213E ...

Page 49: ... 552117 552203A W52107A W52107B 554160B W6631A 554031B 554031A 435511A 552115C 552115D W49810C 430411 554031C 552115B 552115A W49810C 554031D 49 Copyright 2010 LG Electronics Inc All right reserved Only for training and service purposes LGE Internal Use Only Model Classiﬁcation Description Part Number Location Number Remark Compressor 2520UUCY2AA 554160A Barrier Side APUZ728FA0 Heating Harness Mul...

Page 50: ...P NO 3828A20156G FEBRUARY 2010 ...

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