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Service Manual

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Outdoor Unit: 9K,18K Btu/h Models

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Summary of Contents for AS-H0966KA2

Page 1: ...NUAL LG MODELS AS H0966KA2 F09AHJ AS H126RKA2 F12AHJ AS H186TKA2 F18AHJ AS H246TKA2 F24AHJ CAUTION website http biz LGservice com BEFORE SERVICING THE UNIT READ THE SAFETY PRECAUTIONS IN THIS MANUAL ONLY FOR AUTHORIZED SERVICE PERSONNEL ...

Page 2: ... Connecting the cable between indoor unit and outdoor unit 22 Connect the Cable to the Indoor Unit 22 Connect the Cable to the Outdoor Unit 23 Checking the drainage and forming the pipings 24 Checking the Drainage 24 Form the Piping 24 AIR PURGING 25 Air purging 25 Air purging with vacuum pump 25 Test Running 27 Operation 28 Function of Controls 28 Display Function 32 Self diagnosis Function 32 Re...

Page 3: ...240V 50Hz E 265V 60Hz 7 110V 50 60Hz F 200V 50 60Hz 8 380 415V 50Hz 9 380 415V 60Hz 7 Chassis A Z Name of Chassis of Unit Ex LSP SP Chassis 8 Look A Z Look Color Artcool Model 9 Function A Z 10 Serial No 1 9 LG Model De ARTCOOL COLOR velopment Serial No Basic A Basic 4Way B Plasma Filter C Plasma Filter 4 Way D Tele LCD E Tele LCD Nano plasma 4Way F Nano Plasma F A changeove A clean Low A G Nano P...

Page 4: ...ision Panel Type Deluxe Fighting Look LG1 LG2 SEMI PANEL OEM1 OEM2 Panel Type Deluxe LG3 50 60Hz 8 380 415V 50Hz 9 380 415V 60Hz 7 Chassis A Z Name of Chassis of Unit Ex LSP SP Chassis 8 Look A Z Look Color Artcool Model 9 Function A Z 10 Serial No 1 9 LG Model De ARTCOOL COLOR velopment Serial No Basic A Basic 4Way B Plasma Filter C Plasma Filter 4 Way D Tele LCD E Tele LCD Nano plasma 4Way F Nan...

Page 5: ...symbol indicates the possibility of death or serious injury This symbol indicates the possibility of injury or damage to properties only Be sure not to do Be sure to follow the instruction Do not use damaged power cords plugs or a loose socket Always use the power plug and socket with the ground terminal There is risk of fire of electric shock There is risk of electric shock Install the panel and ...

Page 6: ... cause injury Be especially care ful of the case edges and the fins on the condenser and evaporator There is risk of fire electric shock explosion or injury Be cautious when unpacking and installing the product For installation always contact the dealer or an Authorized service center For re installation of the installed product always contact a dealer or an authorized ser vice center Do not insta...

Page 7: ...the plug to remove the cord from the outlet Do not touch it with wet hands Do not place a heater or other appliances near the power cable There is risk of fire or electrical shock There is risk of fire and electric shock Do not allow water to run into electrical parts Do not store or use flammable gas or com bustibles near the air conditioner There is risk of fire failure of the product or electri...

Page 8: ...ion may cause water leakage Keep level even when installing the product Use two or more people to lift and transport the air conditioner To avoid vibration or water leakage Avoid personal injury Installation 90 Unplug the unit if strange sounds odors or smoke comes from it Be cautious that water could not enter the product There is risk of electric shock or fire There is risk of fire electric shoc...

Page 9: ... shock or damage to the plastic parts of the product There is risk of personal injury Do not step on or put anyting on the product outdoor units Do not insert hands or other objects through the air inlet or outlet while the air conditioner is plugged in There is risk of personal injury and failure of product There are sharp and moving parts that could cause personal injury Operation Wax Safety Pre...

Page 10: ...85 314 D mm 155 156 172 Model Dimension 9K Btu Series 12K Btu Series 18K 24K Btu Series Indoor Unit This symbol alerts you to the risk of electric shock This symbol alerts you to hazards that could cause harm to the air conditioner This symbol indicates special notes NOTICE Symbols Used in this Manual ...

Page 11: ...L4 L5 Gas side 3 way valve Liquid side 2 way valve MODEL 9K Btu Series 12K Btu Series DIM unit W mm 575 717 H mm 525 481 D mm 260 228 L1 mm 301 270 L2 mm 73 56 L3 mm 392 464 L4 mm 35 17 L5 mm 100 130 Dimensions Outdoor Unit Dimensions ...

Page 12: ...m Air Conditioner Outdoor Unit MODEL DIM W L2 L3 L1 D H L4 L5 Gas side 3 way valve Liquid side 2 way valve W mm 840 H mm 577 D mm 276 L1 mm 337 L2 mm 64 L3 mm 611 L4 mm 16 L5 mm 156 18K But Series Dimensions ...

Page 13: ...tdoor Unit W L7 L6 L8 L9 D L1 L2 L3 L10 L11 L4 L5 H Gas side Liquid side MODEL DIM W mm 870 H mm 655 D mm 320 L1 mm 370 L2 mm 340 L3 mm 25 L4 mm 630 L5 mm 25 L6 mm 546 L7 mm 162 L8 mm 162 L9 mm 54 L10 mm 74 5 L11 mm 79 24K Btu Series ...

Page 14: ...3 52 5 28 6 74 2 56 3 52 5 28 6 74 1 2 1 2 2 2 2 9 1Ø 220 240V 50Hz 1Ø 220 240V 50Hz 1Ø 220 240V 50Hz 1Ø 220 240V 50Hz 5 8 6 6 8 8 9 5 13 4 15 1 20 22 42 42 37 40 40 47 49 52 54 57 950 1270 1900 2350 900 1120 1950 2350 4 2 5 8 8 5 10 5 4 2 5 2 8 7 10 5 2 61 2 77 2 78 2 87 2 84 3 14 2 71 2 87 7 9 5 22 22 18 72 82 9 756x260x155 900x285x156 1090x314x172 1090x314x172 575x525x260 717x481x228 870x577x27...

Page 15: ...not disturb neighbors Rooftop Installations If the outdoor unit is installed on a roof structure be sure to level the unit Ensure the roof structure and anchoring method are adequate for the unit location Consult local codes regarding rooftop mounting More than A More than B More than 2 3m More than B Capacity is based on standard length and maxi mum allowance length is on the basis of reliability...

Page 16: ...the left with the hole slightly slanted to the outdoor side Open the Front Grille Pass Telephone Control Cord Wire through the hole which the power cord goes through Connect Telephone Control Cord Wire to the phone jack of telephone PCB of Control Box Fix Telephone Control Cord Wire inside Control box so as not to disconnect Close the Front Grille Installation Plate Type A screw 5 7mm 3 16 5 16 In...

Page 17: ...rk using flaring tool as shown below Burr removal Completely remove all burrs from the cut cross section of pipe tube Put the end of the copper tube pipe in a downward direc tion as you remove burrs in order to avoid dropping burrs into the tubing Putting nut on Remove flare nuts attached to indoor and outdoor unit then put them on pipe tube having completed burr removal not possible to put them o...

Page 18: ... by moving it left and right Press the lower left and right sides of the unit against the installation plate until the hooks engage into their slots click ing sound Connecting the pipings to the indoor unit and drain hose to drain pipe Align the center of the pipes and sufficiently tighten the flare nut by hand Tighten the flare nut with a wrench When extending the drain hose at the indoor unit in...

Page 19: ...he piping drain hose and the connect ing cable into the piping hole Insert the connecting cable into the indoor unit Don t connect the cable to the indoor unit Make a small loop with the cable for easy connection later Indoor unit installation Hang the indoor unit from the hooks at the top of the instal lation plate Insert the spacer etc between the indoor unit and the installation plate and separ...

Page 20: ... the piping and drain hose together by wrapping them with cloth tape over the range within which they fit into the rear piping housing section Reroute the pipings and the drain hose across the back of the chassis Set the pipings and the drain hose to the back of the chassis with the tubing holder Hook the edge of tubing holder to tap on chassis and push the bottom of tubing holder to be engaged at...

Page 21: ...g the flare nut with torque wrench ensure the direction for tightening follows the arrow on the wrench Bad case Following bending type from right to left could cause problem of pipe damage Connection of the pipes Outdoor mm inch kg m Ø6 35 1 4 1 8 Ø9 52 3 8 4 2 Ø12 7 1 2 5 5 Ø15 88 5 8 6 6 Ø19 05 3 4 6 6 Outside diameter Torque Outdoor unit Gas side piping Bigger diameter Liquid side piping Smalle...

Page 22: ...e A unit should be complied with the following specifications Type B approved by HAR or SAA mm2 The above circuit diagram is subject to change without notice Be sure to connect wires according to the wiring diagram Connect the wires firmly so that not to be pulled out easily Connect the wires according to color codes by referring the wiring diagram If a power plug is not to be used provide a circu...

Page 23: ...om vibrations to which the unit is subjected during the course of transportation Check them and make sure that they are all tightly fastened If they are loose it could cause burn out of the wires 3 Specification of power source 4 Confirm that electrical capacity is sufficient 5 See to that the starting voltage is maintained at more than 90 percent of the rated voltage marked on the name plate 6 Co...

Page 24: ...tapped piping along the exterior wall using sad dle or equivalent To check the drainage Pour a glass of water on the evaporator Ensure the water flows through the drain hose of the indoor unit without any leakage and goes out the drain exit In cases where the Outdoor unit is installed above the Indoor unit perform the following Tape the piping and connecting cable from down to up Secure the taped ...

Page 25: ...de tubes between the indoor and outdoor units have been properly connected and all wiring for the test run has been complet ed Remove the service valve caps from both the gas and the liquid side on the outdoor unit Note that both the liquid and the gas side service valves on the outdoor unit are kept closed at this stage Leak test Connect the manifold valve with pressure gauges and dry nitrogen ga...

Page 26: ... flare nut securely with an adjustable wrench This process is very important to prevent leakage from the system Replace the valve caps at both gas and liquid side service valves and fasten them tight This completes air purging with a vacuum pump The air conditioner is now ready to test run 1 Remove the caps from the 2 way and 3 way valves 2 Remove the service port cap from the 3 way valve 3 To ope...

Page 27: ... minutes then check the system refrigerant charge 1 Measure the pressure of the gas side service valve 2 Measure the temperature of the intake and discharge of air 3 Ensure the difference between the intake temperature and the discharge is more than 8 C 46 F Cooling or Heating 4 For reference the gas side pressure of optimum condition is as below Cooling Bolt Tubing connection Discharge temperatur...

Page 28: ... Cooling Mode Operation When the intake air temperature reaches 0 5 C below the setting temp the compressor and the outdoor fan stop When it reaches 0 5 C above the setting temp they start to operate again Compressor ON Temp Setting Temp 0 5 C Compressor OFF Temp Setting Temp 0 5 C While in compressor running operating with the airflow speed set by the remote control While in compressor not runnin...

Page 29: ... whether to carry out defrost control or not and the time of defrost control are determined according to the following conditions 1 While in heating mode operation the maximum of the indoor pipe temperature is measured and it is com pared with the present indoor pipe temperature to get the difference of the indoor pipe temperatures the maximum temperature of indoor pipe the present temperature of ...

Page 30: ...ntrolled to the setting temperature 18 C When the sleep timer mode is input while in the Jet Cool mode operation the Jet Cool mode has the priority When the Jet Cool key is input the upper lower vanes are reset to those of the initial cooling mode and then operated in order that the air outflow could reach further Jet Cool Mode Operation H P Model While in heating mode or Fuzzy operation the Jet C...

Page 31: ...rom frosting If the indoor pipe temp is below 0 C in 7 min after the compressor operates without any pause while in cool ing cycle operation mode the compressor and the outdoor fan are turned off in order to protect the indoor evaporator pipe from frosting When the indoor pipe temp is 7 C or higher after 3 min pause of the compressor the compressor and the outdoor fan is turned on according to the...

Page 32: ...t Dry Fan Hot start Deice Operation Indicator Deicer Indicator Operation Indicator Compressor on Indicator OUT DOOR 3sec 3sec 3sec once Error Code 1 Error Display LED Indoor body operation LED Error contents Indoor room temperature thermistor open short Indoor pipe temperature thermistor open short Indoor Thermistor assembly check SVC check point ...

Page 33: ...Service Manual 33 Remote Control Operations The remote control transmits the signals to the system Operation ...

Page 34: ... the Grille from the Chassis Set the up and down air discharge louver to open position horizontally by finger pressure Remove the securing screws To remove the Grille pull the lower left and right side of the grille toward you slightly tilted and lift it straight upward 1 Before removing the control box be sure to take out the wire screwed at the other end Earth Conductor ...

Page 35: ... chassis carefully 3 To remove the Discharge Grille Unhook the discharge grille and pull the discharge grille out from the chassis carefully 4 To remove the Evaporator Remove 3 screws securing the evaporator at the left 2EA in the Eva Holder at the right 1EA Caution label When repair do not damage the Caution label ...

Page 36: ...he Motor Cover Remove 2 securing screw Pull the motor cover out from the chassis carefully 6 To remove the Cross Flow Fan Loosen the screw securing the cross flow fan to the fan motor do not remove Lift up the right side of the cross flow fan and the fan motor separate the fan motor from the cross flow fan Remove the left end of the cross flow fan from the self aligning bearing Motor cover ...

Page 37: ...5 4 3 5 4 CN OPTION 2 2 1 1 PIPE TH ROOM TH 3 3 SMW 200 1 2 1 2 1 2 1 2 DC PART CN TH1 SMAW 200 4 4 OR3H 680pF 50V OR1H C11L OR2H 5 OR1H 6H OR5H Q04G OR4H OR6H R26H R25H R24H R23H R22H OPERATION TIMER HIGH MIDDLE LOW OPTION3 OPTION2 103 C01p R05H R04H 6 2K CAT24WC01J EEPROM 5V R21H 5V R02H 12 1K 10K A0 A1 A2 4 3 G 2 1 C02HJ C01H R01H 103 103 R03H 10K 10K OPTION1 PIPE ROOM TH 7 R01P WP SCL SDA 5 6 ...

Page 38: ...KA2 F09AHJ AS H126RKA2 F12AHJ Models AS H186TKA2 F18AHJ Models AS H246TKA2 F24AHJ C S R RD YL YL GN YL GN YL GN YL BR BL BK RD YL YL BR OR BL BK FAN MOTOR BR BL BK RD HEATER RD BR BR WH BK RD BK RD RD T B1 T B3 T B4 T B2 REVERSING VALVE TERMINAL BLOCK TO INDOOR UNIT 3854A20167Q RY S CAPA RY COMP SOFT STARTER PCB COMP START CAPACITOR OPTION PTC CAPACITOR 4 H C F 3 4 3 1 L 2 N 3 4 ...

Page 39: ...1J IC01L R01L RY 4WAY RY FAN D02J C01J C02J C01F NF01J CN U D CN DISP1 C01H OR4H OR2H R21H OR1H OR3H J26 OR5H OR6H R03H C12L R12L R05H D01M J2 C02H R01H R02H R04H CN TH1 FUSE CN 4WAY RY COMP CN MOTOR ZNR01F R04F CN N2 CN N1 FUSE 250V T2A RY COMP PWB 6870A90239A D03J IC01F C03J R02F TR01F R03F NTC D04J CN MOTOR ZNR01F D02J R04F C01F CN N2 NF01J CN N1 3 D01J C02D R02D PWB ASM 6871A20573 C04J 5 R01J ...

Page 40: ...40 Room Air Conditioner Schematic Diagram DISPLAY ASSEMBLY 6871A20575 ...

Page 41: ...GE EVAPORATOR HEAT EXCHANGE CONDENSER HEAT EXCHANGE CONDENSER COMPRESSOR COMPRESSOR ACCUMU LATOR GAS SIDE GAS SIDE 3 WAY VALVE LIQUID SIDE LIQUID SIDE 3 WAY VALVE CAPILLARY TUBE CAPILLARY TUBE CHECK VALVE Heating Model only COOLING HEATING REVERSING VALVE Heating Model Only 1 Cooling Only Models Refrigeration Cycle Diagram 2 Cooling Heating Models ...

Page 42: ...ckwise connected manifold gauge Open Open Open with charging cylinder Open Open Open with charging cylinder Open Open Open Open Works Shipping Air purging Installation Operation Pumping down Transfering Evacuation Servicing Gas charging Servicing Pressure check Servicing Gas releasing Servicing 1 2 3 4 5 6 Valve cap Open position Closed position Pin Service port Service port cap To outdoor unit Fl...

Page 43: ...he closed position 6 Operate the air conditioner at the cooling cycle 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 mount the 2 way and 3 way valve s stem nuts and the ser vice port nut Use torque wrench to tighten the service port nut to a ...

Page 44: ...charge set and discharge the refrigerant until the gauge indi cates 0 kg cm2 G If there is no air in the refrigerant cycle the pressure when the air conditioner is not running is higher than 1 kg cm2 G discharge the refrig erant 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...

Page 45: ...he 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 unit Liquid side Indoor unit Gas side 3 Way valve CLO...

Page 46: ...h 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 operating the air conditioner tur...

Page 47: ... of using graph Find outdoor temperature Find indoor temperature onto the curve of outdoor temperature Read suction pressure at the axis of ordinates The method of using equation Calculate suction pressure after putting indoor and outdoor temperature into the equation 13 At operating the Unit for 10 minutes Suction Pressure Kg cm 2 g Outdoor Temp C Indoor Temp C 12 11 10 9 8 7 6 5 5 10 15 20 25 30...

Page 48: ...ir humidity When the room air humidity is relativery higher temperature difference is smaller When the room air humidity is relatively lower temperature difference is larger 2 Check temperature and pressure of refrigeration cycle 1 The suction pressure is usually 8 5 9 5 kg cm2 G Cooling at normal condition 2 The temperature can be measured by attaching the thermometer to the low pressure tubing a...

Page 49: ... Varistor ZNR01J Check the connection housing for contacting Connector related to CN TAB1 RY COMP NO 3 Connector related to CN MOTOR Connector contacting of Outdoor Fan Compressor Display PCB Assembly Check Check each load Indoor Outdoor Fan Motor Compressor Stepping Motor and contacting condition of related connector Main PCB Board Operation Check Items SMPS Transformer Indoor unit Input Voltage ...

Page 50: ...n LCD screen replace battery Check the contact of CN DISP1 connector When the compressor stopped Indoor Fan is driven by a low speed At this point the wind speed is not controlled by the remote controller When operated in the Sleeping Mode the wind speed is set to the low speed by force Check Display PCB Assembly Voltage between CN DISP1 DC 5V Check the connecting circuit between the remote contro...

Page 51: ...ot engaged Compressor Outdoor Fan is stopped Check the related circuit of RY FAN Check the indoor temperature sensor is disconnected or not About 10kΩ at 25 C Turn off Main Power Check the electrical wiring diagram of outdoor side Check the abnormal condition for the component of Compressor Outdoor Fan Motor Check the open or short of conmecting wires between indoor and outdoor Check Relay RY COMP...

Page 52: ...er Check the related circuit of indoor Fan Motor The pin NO 63 of Micom and the part for driving TRIAC the input and output signal of IC01M PIN NO 7 10 Check the pattern Check the TRIAC TRIAC Open Indoor Fan Motor never operate TRIAC short Indoor Fan Motor always operates in case of ON or OFF When indoor Fan does not operate The voltage of PIN NO 1 orange and 3 yellow of CN MOTOR About AC 180V ove...

Page 53: ...ndition on PWB of CN U D Connector If there are no problems after above checks Confirm the assembly conditions that are catching and interfering parts in the rotation radial of the Vertical Louver When Vertical Louver does not operate Check the operating circuit of the Vertical Louver Confirm that there is DC 12V between pin RED of CN U D and GND Confirm that there is a soldering short at followin...

Page 54: ...ature is disconnected or not about 10KΩ at 25 C Check the indoor pipe temperature is disconnected or not about 5KΩ at 25 C Turn ON Main Power Check the DC voltage on the PWB ASSEMBLY The details of check are as followings Check point Between Micom NO 59 and GND Between IC01M NO 11 and GND Comp ON DC 5V Below DC 1V Comp OFF DC 0V About DC 12V Check point Between Micom NO 51 and GND Between IC02M NO...

Page 55: ... Guide Turn off Main Power Check the electrical wiring diagram of outdoor side Check the abnormal condition for the component of Compressor Outdoor Fan Motor 4 way Check the open or short of connecting wires between indoor and outdoor ...

Page 56: ...56 Room Air Conditioner Exploded View Exploded View 346810 146811 131410 359011 342800 147581 354210 268712 135311 135312 267110 249951 733010 152302 35211B 135516 352150 Indoor Unit ...

Page 57: ...57 Exploded View 554031 437212 435511 W0CZZ 552202 567502 552116 552201 554160 561410 552111 550140 552203 1 552203 2 430410 447910 649950 552102 2 552102 1 437210 435301 559010 546810 Outdoor Unit 9K 18K Btu h Models ...

Page 58: ...oner Exploded View 559010 552202 552111 649950 430410 552203 2 546810 435301 437210 561410 567502 554160 552203 1 552116 447911 W0CZZ 552201 554031 237205 437212 237204 435511 550140 552102 1 Outdoor Unit 12k Btu h Models ...

Page 59: ...ed View 554032 437212 435511 668713 W0CZZ W0CZZ 2 552202 552116 553000 554160 550140 552203 2 552203 1 430410 435301 447910 649950 552111 552201 552102 2 437210 559010 435512 546810 552102 1 567502 Outdoor Unit 24K Btu h Model ...

Page 60: ...1A20013V R 267110 REMOTE CONTROLLER ASSEMBLY 6711A90023C 6711A90023C 6711A90023C 6711A90023C R 268712 PWB PCB ASSEMBLY DISPLAY 6871A20575A 6871A20575A 6871A20573C 6871A20575A R 268714 2 PWB PCB ASSEMBLY MAIN 6871A20573A 6871A20573A 6871A20272K 6871A20573C R 342800 BEARING 4280A20004B 4280A20004B 4280A20004A 4280A20004A R 346810 MOTOR ASSEMBLY INDOOR 4681A20151A 4681A20048A 4681A20003D 4681A20067A ...

Page 61: ...SEMBLY CAPILLARY 5211A21143J 5211A10197X 5211A21471A 5211A10039U R 552116 TUBE ASSEMBLY REVERSING 5211A20188P 5211A29021A 5211A20270P 5211A20529H R 552201 VALVE CHECK 5220A30004A 5220A30004A R 552202 VALVE REVERSING 5220AR3228J 5220AR3228D 5220AR3228E 5220AR3228C R 552203 1 VALVE SERVICE 5220A20005B 5220A20006J 5220A20005B 5220A20001R R 552203 2 VALVE SERVICE 5220A20001Q 5220A20005B 5220A20006J 52...

Page 62: ...P No 3828A20462S July 2005 Printed in Korea ...

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