LG AS-W0964DH0 Service Manual Download Page 67

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72 Room Air Conditioner

C16Z

SPM3:6002EC2005C
SPM3:6002EC2005D

R01P

R12P

R11P

R03P

R13P

R14Z

C12Z

R15Z

D03Z

R21Z

R22Z

R16Z

C08Z

C10Z

R13Z

D02Z

D01Z

IC02S

IC01S

R06S

C19Z

SPM3

R20Z

IGBT

C05S

R05S

C06S

D01S

R02S

R01S

C09S

PCB : 6870A90055M_1(040221)
Assy : 6871A10128

R03S

2004.02.21.

BD02S

R02F

R02D

R21P

R14P

C05D

R02P

R17P

R16P

R15P

C02D

CN-LEV

C05H

IC01D

CN-S/VALVE2

CN-TEST

CN-S/VALVE1

WCN-NOISE2

C09J

D03K

WCN-NOISE3

C01J

C02J

C10J

ZD01K

IC02K

IC01K

CN-D_PIPE

C02F

R04P

BL-V

R23Z

C06D

RD-U

C03D

ZD01F

R01D

C01D

D01D

CN-FAN2

POWER MODULE

C07D

YL-W

C02S

C03F

R01Y

LED01M

MICOM

R02Y

R03Y

C01Y

D01Y

OJ01

EEPROM

C04D

R05F

C01C

RXD

TXD

C02A

IC02M

OSC01B

CN-TH2

GND

C01H

C04H

CN-TH1

C03H

C02H

R07C

15V

D02N

GND

R05C

C01S

IC01A

CN-PC

J09~12(JAPAN)

J13~15(EUROPE)

J01~04(EUROPE)

J01

J02

J03

J04

C03S

J09

J10

J11

J12

J13

J14

J15

J16

CN-COIL1

CN-COIL2

BD01S

J05~08(JAPAN)

C01M

J08

J07

J05

J06

R03C

D01N

BD01N

R01N

D01C

C03C

R02N

C01N

RY-PUMP

CN-4WAY

CN-FAN1/PUMP

RY-H/PUMP

RY-4WAY

CN-PUMP

J24

C04J

C05J

R09K

NF01J

ZNR01J

D01K

R05K

R07K

R06K

R08K

FUSE

C03K

ZD03K

ZNR02J

R01J

R06C

D02C

D02K

R10K

C04K

ZD02K

J23

J22

J21

J20

J19

J18

J17

WCN-NOISE1

SURGE

J26

J25

R02J

R03J

N/F02J

RY_PWR

R04C

R01C

Q01C

BD01C

C02C

R02C

C08J

C06J

C07J

J33

J34

J32

J31

PTC

J28

J27

J29

J30

J27~34(JAPAN)

C10J

WCN-NOISE3

C01J

C02J

NF01J

SURGE

R01J

ZNR02J

WCN-NOISE1

R03J

J22

N/F02J

J24

J23

C04J

C05J

J21

R02J

J26

J25

C06J

C08J

C07J

J27

J30

J28

R12Z

R10Z

C08P

C06P

C01K

C01F

C02K

R01F

C15Z

R10P

D03K

C09J

WCN-NOISE2

R02F

CN-TEST

IC02M

CN-S/VALVE1

R08Z

Q01F

R09Z

R07Z

R11Z

Q03F

C05H

CN-LEV

R19P

R18P

R20P

CN-S/VALVE2

R17P

R16P

R15P

C02D

IC01D

R08P

C05D

C05P

IC01P

R06P

C04Z

R04Z

C01P

R05P

C02P

R07P

C03P

R09P

C03Z

C02Z

R02Z

C06Z

C05Z

R05Z

C16Z

R06Z

R03Z

D02N

R01A

R03A

R01M

IC01K

D01K

R07K

R09K

R08K

FUSE

R06K

C03K

ZD03K

R05K

ZNR01J

R02M

OSC01B

C01A

C04C

R01X

C01X

R02X

R07S

IC01M

R01K

C08S

R02K

R04K

IC02K

C18Z

C07S

R08S

D02C

J17

D02K

ZD02K

J19

J20

J18

R02A

C02A

R07C

R05C

R06C

LED01M

R10K

ZD01K

C04K

IC01A

CN-PC

R04M

R03M

R08H

R06H

R05H

R03H

OJ01

R02L

Q02F

Q04F

R03F

R03Y

C01Y

R03N

EEPROM

R01L

R02Y

C02N

D01Y

1 1

C07P

C01T

C01B

R17H

C01C

MICOM

POWER MODULE

C01D

D01D

C01L

C03D

C04D

ZD01F

R05F

R01D

CN-D_PIPE

CN-TH1

C04H

C03H

R04H

CN-TH2

C01H

C02H

R02H

R01H

CN-FAN2

C03F

R01Y

R07H

R04F

C02F

R01C

RY_PWR

R08C

Q01C

R04C

R02C

D01N

R01N

R02N

C01N

BD01C

C03C

R03C

D01C

C02C

BD01N

J33

J32

J31

J29

J34

CN-OXY2

RY-H/PUMP

RY-OXY

RY-4WAY

C01S

J09

J10

J11

J12

J13

J16

J15

J14

CN-FAN1/PUMP

CN-4WAY

C01M

J08

J07

J06

CN-COIL1

SPM3

R04P

R23Z

C04P

R02D

C06D

BL-V

RD-U

R21P

R14P

R13P

R01P

R12P

R02P

R21Z

R22Z

R16Z

R03P

R11P

C19Z

C07D

YL-W

R20Z

R14Z

SPM3

D03Z

R15Z

R19Z

C01Z

R01Z

C13Z

C11Z

C12Z

R18Z

C14Z

C17Z

R17Z

R06S

D01Z

R13Z

D02Z

IC01S

C10Z

C09Z

C08Z

C07Z

J01

J03

J02

J04

C02S

R01S

C03S

CN-COIL2

BD01S

J05

BD02S

IC02S

C06S

R02S

IGBT

R05S

D01S

C05S

R03S

C09S

• TOP VIEW

Schematic Diagram

• BOTTOM VIEW

Outdoor Unit

Models: AS-W0964DH0, AS-W1264DH0, AS-W0964GH0, AS-W1264GH0, AS-W1224DH0, AS-W1424DH0

Summary of Contents for AS-W0964DH0

Page 1: ... AS W0964DH0 GH0 AS W1264DH0 GH0 AS W1865DH0 AS W1224DH0 AS W1424DH0 AS W1825DH0 AS W096E1G0 AS W126E1G0 CAUTION website http www lgservice com BEFORE SERVICING THE UNIT READ THE SAFETY PRECAUTIONS IN THIS MANUAL ONLY FOR AUTHORIZED SERVICE PERSONNEL ...

Page 2: ...ns 10 Installation 14 Connecting the cable between indoor unit and outdoor unit 24 Checking the drainage and forming the pipings 26 Air purging 27 Test running 29 Functions 30 Operation 33 Disassembly 44 Troubleshooting Guide 47 Schematic Diagram 67 Product Specifications 76 Exploded View 79 Replacement Parts List 83 ...

Page 3: ...65V 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 4 S4 Chassis 8 Look A Z Look Color Artcool Model 9 Function A Z 10 Serial No 0 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 Plasma F A chang...

Page 4: ...Grille Type 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 4 S4 Chassis 8 Look A Z Look Color Artcool Model 9 Function A Z 10 Serial No 0 9 LG Model De ARTCOOL COLOR velopment Serial No R Mirror W White B Blue D Wood M Metal C Cherry S4 S5 SD SE S6 SQ SR ST Basic A Basic 4Way B Plas...

Page 5: ...sions W mm 840 895 H mm 270 282 D mm 153 165 Model Dimension 7k 9k 12k 14k 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 6: ...Service Manual 11 Dimensions D H W Installation plate Installation plate Type 1 Type 2 W mm 1090 H mm 300 D mm 178 Model Dimension 18k 24k Btu Series ...

Page 7: ...onditioner W L2 L3 L1 D H L4 L5 Gas side 3 way valve Liquid side 2 way valve MODEL DIM unit W mm 770 H mm 540 D mm 245 L1 mm 285 L2 mm 65 L3 mm 518 L4 mm 10 L5 mm 100 Dimensions Outdoor Unit 7k 9k 12k 14k Btu Series ...

Page 8: ...3 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 18k 24k Btu Series ...

Page 9: ... is built over the unit to prevent direct sunlight or rain exposure make sure that heat radia tion from the condenser is not restricted 2 Ensure that the space around the back and sides is more than 10cm The front of the unit should have more than 70cm of space 3 Do not place animals and plants in the path of the warm air 4 Take the weight of the air conditioner into account and select a place whe...

Page 10: ...8 4 or 7 5 15 30 30 Pipe Size Capacity Btu h GAS LIQUID Max Length A m Additional Refrigerant g m Max Elevation B m Standard Length m Outdoor unit Indoor unit A B Outdoor unit Indoor unit A B A Oil trap Outdoor unit Indoor unit B If the piping length is more 10 Meters and the outdoor Capacity is based on standard length and maximum allowance length is on the basis of reliability Oil trap should be...

Page 11: ... typically Drilling the hole through the wall for piping connections must be done safely Fixing Installation Plate Installation Plate Type A screw Chassis Hook Installation plate Left rear piping Right rear piping Ø70mm Ø70mm D B A C Drill the piping hole with a ø70mm hole core drill Drill the piping hole at either the right or the left with the hole slightly slanted to the outdoor side Drill a Ho...

Page 12: ... 2 Put the end of the copper tube pipe in a downward direction 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 on after flaring work Flaring work 1 Firmly hold copper pipe in a die in the dimension shown in the table below 2 Car...

Page 13: ... unit through the piping hole Do not connect the cable to the indoor unit Make a small loop with the cable for easy connec tion later 3 Tape the tubing drain hose and the connecting cable Be sure that the drain hose is located at the lowest side of the bundle Locating at the uper side can cause drain pan to overflow inside the unit If the drain hose is routed inside the room insulate the hose with...

Page 14: ...pipe Wrap the insulation material around the connecting portion 1 Overlap the connection pipe insulation material and the indoor unit pipe insulation material Bind them together with vinyl tape so that there may be no gap 2 Wrap the area which accommodates the rear piping housing section with vinyl tape 3 Bundle the piping and drain hose together by wrap ping them with vinyl tape for enough to cov...

Page 15: ...en the indoor unit and the installation plate and separate the bottom of the indoor unit from the wall Connecting the piping to the indoor unit and the drain hose to drain pipe 1 Align the center of the pipes and sufficiently tighten the flare nut by hand 2 Tighten the flare nut with a wrench 3 When extending the drain hose at the indoor unit install the drain pipe For left rear piping Drain pipe ...

Page 16: ...the rear piping housing section Reroute the pipings and the drain hose across the back of the chassis Indoor unit installation 1 Remove the spacer 2 Ensure that the hooks are properly seated on the installation plate by moving it left and right 3 Press the lower left and right sides of the unit against the installation plate until the hooks engage into their slots clicking sound Plastic bands Insu...

Page 17: ...n Installation Information For left piping Follow the instruction below Good case Press on the upper side of clamp and unfold the tubing to downward slowly Bad case Following bending type from right to left may cause damage to the tubing ...

Page 18: ...rque wrench until the wrench clicks When tightening the flare nut with torque wrench ensure the direction for tightening follows the arrow on the wrench 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 Liquid side piping Smaller diameter Gas side piping Bigger diameter Torque wrench ...

Page 19: ... wires according to color codes referring to the wiring diagram If a power plug is not used provide a circuit breaker between power source and the unit as shown by The power cord connected to the A unit should be selected according to the following specifications Type B approved by HAR or SAA The power connecting cable connecting the indoor and outdoor unit should be selected according to the foll...

Page 20: ...urse 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 Confirm that the cable thickness is as specified in the powe...

Page 21: ...ction louvers up and down to the position horizontally by hand Remove the securing screws that retain the front panel Pull the lower left and right sides of the grille toward you and lift it off 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 piping along the exterior wall Form a trap to ...

Page 22: ...e 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 gas...

Page 23: ...ecurely 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 open the 2 way ...

Page 24: ...unit for 15 20 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 Discha...

Page 25: ... Lights up in Preheat Mode or Defrost Mode Lights up in Plasma Air Clean Mode Lights up in during Energy Saving Cooling Mode Operation Optional Indoor Unit Operation ON OFF by Remote controller Sensing the Room Temperature Room temperature control Starting the Current Control Time Delay Safety Control Indoor Fan Speed Control Operation indication Lamps LED Cooling Mode Operation Healty dehumidific...

Page 26: ...ter 1 2 3 4 5 6 7 hours The fan is switched to intermittent or irregular operation The fan speed is automatically switched from high to low speed The louver can be set at the desired position or swing up and down automatically Sleep Mode Auto Control Natural Air Control by CHAOS Logic Airflow Direction Control The function will be operated while in any operation mode with selecting the function Th...

Page 27: ...peed Although fan motor speed is middle it will change high speed in case of below AC193V over 40 C Cooling Mode of outdoor temp below 4 C Heating Mode of outdoor temp and over fc fh of comp Freq Middle speed Nomal mode Low speed Although fan motor speed is middle it will change Low speed in case of over AC 270V over 21 C Heating Mode of outdoor temp below 24 C Cooling Mode of outdoor temp When th...

Page 28: ...iance pause Flashing while in disconnection or short in Thermistor 3 sec off 0 5 sec on Timer Indicator ON while in timer mode on off OFF when timer mode is completed or canceled Defrost Indicator OFF except when hot start during heating mode operation or while in defrost control If the indoor pipe temperaure is below 0 C in 7 min after the compressor operates without pause while in cooling cycle ...

Page 29: ... comp The targeting operating freq of comp each model Model AS W0964DH0 GH0 35 39 43 47 52 57 62 AS W1264DH0 GH0 20 35 47 56 63 70 78 AS W1865DH0 16 32 58 64 70 75 85 AS W1224DH0 20 35 47 54 65 70 74 AS W1424DH0 20 35 47 54 72 74 78 AS W1825DH0 16 32 53 62 72 75 85 AS W096E1G0 25 35 40 52 56 74 82 AS W126E1G0 25 35 40 52 66 74 82 Comp Operating frequency Step 1 Step 2 Step 3 Step 4 Step 5 Fc Step ...

Page 30: ...rgeting operating freq of comp each model Heating mode operation Model AS W0964DH0 GH0 35 44 53 62 69 74 80 AS W1264DH0 GH0 20 38 53 63 72 79 86 AS W1865DH0 16 38 47 65 79 87 96 AS W1224DH0 20 35 53 63 70 79 86 AS W1424DH0 20 35 53 63 77 79 86 AS W1825DH0 16 38 47 62 79 87 90 AS W096E1G0 35 40 48 56 65 90 94 AS W126E1G0 35 40 48 56 80 90 94 Comp Operating frequency Step 1 Step 2 Step 3 Step 4 Step...

Page 31: ...er vane is reset to those of the initial Jet heating mode and then operated in order that the air outflow could reach under flow 1 New Chaos swing mode By the Chaos swing key input the upper lower vane automatically operates with the Chaos swing or it is fixed to the desired direction Mode2 Mode3 Mode4 Mode5 Mode6 Mode7 Mode8 Mode9 OPEN CLOSED 8 Cooling Operation 120 Mode2 Mode3 Mode4 Mode5 Mode6 ...

Page 32: ...he setting temperature decrease by 1 C After another 60min elapse it decreases by 1 C again Setting temp C 1 0 C up 1 0 C up Cooling ON temp Setting temp 0 5 C Cooling OFF temp Setting temp 0 5 C 0 5 1 Sleep time hr Setting temp C Heating ON temp Setting temp Heating OFF temp Setting temp 3 0 C 1 2 Sleep time hr 1 0 C down 1 0 C down When the sleep time is reached after 1 2 3 4 5 6 7hr is input by...

Page 33: ...ol is lost the forced operation selection switch is on the main unit of the appliance to operate the appliance in the standard conditions The operation condition is set according to the outdoor temp and intake air temperature as follows The unit select before operating mode in 3 hours Press the Tact Switch for compulsory operation of the main body for 3 seconds in order to operate in the trial ope...

Page 34: ... DC Peak Current Error by a fault signal of IPM If the operating current of IPM reaches 35A 3A the compressor stop instantly If DC PEAK occurs 5 times within 1 hour the appliance turns off and display ERROR CODE 6 DC Peak Current Error by the compressor lock If the DC LINK voltage below DC 140V occurs 5 times within 1 hour while the compressor is operating the appliance turns off and display ERROR...

Page 35: ...e by COMP SPEC varies by 10 C Portection from overheating of power module Portection from overheating of compressor T off C T2 C Heat Sink Temp T1 C T on C COMP Freq Free OFF Free Fc 1 Fc 1 Fc 2 Fc 2 T T off T on T1 T on T T2 T on 2 T D Pipe Temp COMP Freq Free Free Fh min OFF Fc 1 Fc 1 Fc 2 Fc 2 T T off T2 2 T1 T2 2 T T3 T2 T T off C T2 C T3 C T1 C 13 C 1 AS W0964DH0 GH0 95 105 2 AS W1264DH0 GH0 ...

Page 36: ...able 50 minutes later since heating cycle started and the pipe temperature of out door unit reaches below 6 C Setting Freq Operating Freq of Comp 4 Way EEV Open step Outdoor FAN Indoor FAN Pre Heat LED Deice STEP Fh min Minimum Time of Heating Main Deice time Fh min Fh min ON OFF Setting Speed ON Hot Start OFF Hot Starting ON OFF OFF 0 1 2 3 4 5 6 Setting Starting step Setting Freq Setting Speed S...

Page 37: ...eration mode automatically to keep indoor tempera ture When room temperature vary over 2 C with respect to setting temperature air condition er keeps the room temperature in 2 C with respect to setting temperature by auto change mode If outdoor temperature drops below certain temperature liquid back is prevented by reducing fan speed It can prevent frosting of evaporator and keep cooling operation...

Page 38: ...G BUTTONS Used to adjust the time 9 TIMER SET CANCEL BUTTON Used to set the timer when the desired time is obtained and to cancel the Timer operation 10 SLEEP MODE AUTO BUTTON Used to set Sleep Mode Auto operation 11 ENERGY SAVING COOLING MODE BUTTON OPTIONAL Used to set Energy Save in cooling mode 12 ROOM TEMPERATURE CHECKING BUTTON Used to check the room temperature 13 PLASMA OPTIONAL Used to st...

Page 39: ...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 Disassembly ...

Page 40: ... the 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 Screw When repair do not damage the Caution label ...

Page 41: ... 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 Bearing Cross flow fan Disasse...

Page 42: ...UMU LATOR GAS SIDE 3 WAY VALVE LIQUID SIDE 3 WAY VALVE COOLING HEATING REVERSING VALVE INDOOR UNIT OUTDOOR UNIT HEAT EXCHANGE EVAPORATOR HEAT EXCHANGE CONDENSER COMPRESSOR ACCUMU LATOR GAS SIDE 3 WAY VALVE LIQUID SIDE 3 WAY VALVE COOLING HEATING REVERSING VALVE 1 Model Capillary Tube Refrigeration Cycle Diagram 2 Model Adopted Electronic Expansion Valve ...

Page 43: ...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 44: ...sing the hexagonal wrench to press the valve core pin discharge for three seconds and then wait for one minute Repeat this three times 5 Use torque wrench to tighten the service port nut to a torque of 1 8kg cm 6 Set the 3 way valve to the back seat 7 Mount the valve stem nuts to the 2 way and 3 way valves 8 Check for gas leakage At this time especially check for gas leakage from the 2 way and 3 w...

Page 45: ... the charge hose Open the low pressure valve on the charge set slightly to air purge from the charge hose 5 Set the 2 way valve to the 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 s...

Page 46: ...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 Liquid side and Gas side valves to the open position Be sure to use a hexagonal wrench ...

Page 47: ...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 48: ...d 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 unit Liqu...

Page 49: ... 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 valve s service port Stopping partway will allow the gas to be dis charged If the system has been charged with liquid refrigerant while ...

Page 50: ...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 1 The suction pressure is usually 8 5 9 5kg cm2 G Cooling at normal condition 2 The temperature can be measured by attaching the thermometer to the low pressure tubing and ...

Page 51: ...O O O O O O O O O O O Indoor Temp sensor error Sensor open or short Heat Sink sensor error Sensor open or short Heat Sink temp is over 95 Communication error Outdoor Temp sensor error Sensor open or short DC Peak error Over current error CT2 ON ON ON OFF SHUT DOWN SHUT DOWN 9times 9times 3 sec 10times 10times 3 sec 3 sec 3 sec 3 sec 3 sec 2times 10 ON Outdoor fan lock error D Pipe TH is short or o...

Page 52: ... function Check the self diagnosis table Check the condition of connectors The condition of P C B pattern Check the condition of connectors The condition of P C B pattern The electronic components Indoor Outdoor 1 Error indicator of air conditioner 1 Indoor Operating LED Outdoor LED01M Red on the outdoor PCB 2 2 more errors occur at same time Air conditioner Off condition Display the error code of...

Page 53: ... power AC220V AC240V 50Hz The voltage of main power The voltage applied to the unit The connecting method of Indoor Outdoor connecting cable each color The P C B Ass y Fuse Noise Filter Power Module Bridge Diode etc Trouble 1 NO YES The operation check of the Indoor P C B Ass y Procedure 1 The input voltage of power mod ule 2 The output voltage of power mod ule 4 IC04D 7805 5 IC01A KIA7036 Specifi...

Page 54: ...y the remote controller When operated in the Sleeping Mode the wind speed is set to the low speed as force Caused by the remote controller Caused by other parts except the remote controller When the mark is displayed in LCD screen replace battery Check the contact of CN DISP 1 2 connector Check DISP P C B Ass y Voltage between CN DISP1 DC 5V Check point Check the connecting circuit between MICOM P...

Page 55: ...resistance of TH air about 10k Ω at 25 C pipe about 5k Ω at 25 C YES No Check soldering state of R01H R04H C01H C02H Check flow 2 Outdoor TH sensor is short or open Outdoor TH sensor is not connected to the outdoorpcb assembly Damage or defect on the sensing circuit of outdoorpcb assembly R03H R06H C02H C03H Outdoor TH is short or open Description Error code Error code Cause of error Outdoor TH is...

Page 56: ...oor PCB assembly No Check soldering state of R01H R02H C01H Check flow Cause of error 4 Heat sink TH in outdoor pcb is open or short Heat sink Temp is over 95 C Damage or defect on the sensing circuit of outdoorpcb assembly R01H R02H C01H Heat sink Temp is over 95 C Heat sink TH in outdoor pcb is open or short Heat sink TH in outdoor pcb is Right Sensing circuit of outdoor pcb is right YES No Chec...

Page 57: ...ck in outdoor about AC 220 240V YES No Indoor Outdoor 1 BR 1 BR 2 BL 2 BL 3 GN YL 3 GN YL 4 RD 4 RD No Check power connector Is not connected to the T Block in indoor unit Check flow Is the voltage of GND DC5V in Outdoor pcb about DC 5V YES No Check FUSE NF01 02J PTC Power Module BD 01S in Outdoor pcb assembly Communication circuit of indoor outdoor pcb Is right YES No Check IC01K IC02K D01K D03K ...

Page 58: ...t YES No Check refrigerant pressure and adjust Is the compressor right YES No Check resistance Between U V V W U W port Short Open circuit Comp motor coil error normal 1 2 Ω Between U V W and Body Ê normal over10M Ω Inverter components in outdoor pcb assembly are right YES No 9 K 12K Model Check Short of SPM3 pins GND P U V W pin Direction of D01Z D03Z C08Z 10Z 12Z 16Z Assembling state of R01P R21...

Page 59: ...ormally YES No Check power source No Check indoor outdoor fan and adjust Check flow Refrigerant pressure is right YES No Check refrigerant pressure and adjust Current sensing circuit is right YES No Check current sensing circuit check CT is damaged in outdoor pcb output wire is disconnected to pin or not BD01N is inserted in right position refer marking on pcb and component Spec of R01N 1kΩ R02N 1...

Page 60: ...ving circuit Soldering state Direction R01F R09F C01F C03F IC01F IC03F Q01F Q02F ZD01F 9 Outdoor fan is locked by an obstacle ex branch of tree bar etc Fan connector is not connected to outdoor pcb assembly Defective in DC fan driving circuit Outdoor fan is locked BLDC fan model only Outdoor fan is rotating 1 Outdoor fan is rotating 2 YES No Check outdoor unit remove obstacles in outdoor unit No C...

Page 61: ...t of outdoor pcb assembly D Pipe TH is short or open D_PIPE TH is connected to Outdoor pcb assembly D_PIPE TH is right YES No Connect to CN D_PIPE in outdoor pcb assembly Sensing circuit of outdoor pcb is right No Check D_PIPE TH Measure resistance of TH about 200kΩ at 25 C YES No Check soldering state of R07H R08H C04H Check flow Description Cause of error Error code ...

Page 62: ...e Manual 67 Wiring Diagram Schematic Diagram Indoor Unit Models AS W0964DH0 AS W0964GH0 Models AS W1264DH0 AS W1865DH0 AS W1264GH0 AS W1224DH0 AS W1424DH0 AS W1825DH0 AS W096E1G0 AS W126E1G0 Schematic Diagram ...

Page 63: ...68 Room Air Conditioner Schematic Diagram Outdoor Unit Models AS W0964DH0 AS W0964GH0 Models AS W1264DH0 AS W1264GH0 AS W1224DH0 AS W1424DH0 ...

Page 64: ...Service Manual 69 Schematic Diagram Models AS W1865DH0 AS W1825DH0 Models AS W096E1G0 AS W126E1G0 ...

Page 65: ...70 Room Air Conditioner Schematic Diagram Components Location TOP VIEW BOTTOM VIEW Indoor Unit Models AS W1264DH0 AS W1865DH0 AS W1264GH0 AS W1224DH0 AS W1424DH0 AS W1825DH0 AS W096E1G0 AS W126E1G0 ...

Page 66: ...Service Manual 71 BOTTOM VIEW TOP VIEW Schematic Diagram Models AS W0964DH0 AS W0964GH0 ...

Page 67: ... 0 4 Z R 0 4 Z C 0 1 P R 0 5 P C 0 2 P R 0 7 P C 0 3 P R 0 9 P C 0 3 Z C 0 2 Z R 0 2 Z C 0 6 Z C 0 5 Z R 0 5 Z C 1 6 Z R 0 6 Z R 0 3 Z D 0 2 N R 0 1 A 1 7 R 0 3 A R 0 1 M I C 0 1 K D 0 1 K R 0 7 K R09K R 0 8 K F U S E R 0 6 K C 0 3 K Z D 0 3 K R 0 5 K ZNR01J R 0 2 M O S C 0 1 B C 0 1 A C 0 4 C R 0 1 X C 0 1 X R 0 2 X R 0 7 S 1 I C 0 1 M 1 6 R 0 1 K C 0 8 S R 0 2 K R 0 4 K I C 0 2 K C 1 8 Z C 0 7 S...

Page 68: ... D02N C01C C03K D02C R07C R06C R02N D01N C03C BD01N NF01J C04J R03J C05J BD01S R03S C09S BD02S CN COIL1 CN 4AWY CN COIL2 JS21 23 WCN CAP1 RY 4WAY WCN CAP2 RY L RY H CN FAN1 R04J CT T1 PTC C07J C08J C09J NF02J CN FAN2 CN LEV PWB P NO 6870A90148A 030509 10 R15Z 9 8 7 6 5 4 3 2 1 R16Z R17Z C16Z SPM2 IC01S 23 22 21 20 19 18 17 16 15 14 13 12 11 R14Z R13Z C12Z C10Z C10S R05S R06S C08Z C05S C06S IPM R01...

Page 69: ...01S J15 J14 RY 4WAY RY H PUMP RY PUMP CN COIL1 C03S R03S CN COIL2 J08 J07 J06 J01 J04 J03 J02 J05 CN PUMP CN FAN1 PUMP C01M HEATSINK R12Z R22Z R21Z R20Z C04Z C05Z C06Z R03Z R02Z R01Z C16Z C15Z C10Z R08Z C12Z C01Z C11Z D03Z R09Z C13Z C14Z C03Z C17Z C02Z R11Z C08Z C07Z C09Z C08S D01Z R07Z D02Z C05S R04S C06S R01S C07S C09S R05S C04S R02S BL WH D02N C03F D01Y 7 6 SPM3 6002EC2005 1 SPM3 C16Z C02D C03D...

Page 70: ...Service Manual 75 Schematic Diagram DISPLAY ASSEMBLY 6871A20574A 6871A20624A ...

Page 71: ...oor mm Dimension inch W H D Outdoor mm inch Net Weight Indoor kg lbs Outdoor kg lbs 1 758 1 143 2 755 1 512 983 2 369 6 000 3 100 9 400 2 637 3 516 5 274 2 268 3 024 4 536 9 000 12 000 18 000 3 033 4 043 6 096 2 608 3 478 5 242 10 350 13 800 20 800 1 465 879 1 406 1 260 756 1 210 5 000 3 000 4 800 3 296 4 043 6 065 2 835 3 478 5 216 11 250 13 800 20 700 3 810 4 659 6 651 3 276 4 007 5 720 13 000 1...

Page 72: ... 3 Refrigerant R410A Charge Power Cord AWG P mm2 Connecting Cable AWG P mm2 Connecting Tube Liquid Side mm in Ø Socket Flare Gas Side mm in Length std m in Drain Hose O D I D mm in Indoor mm Dimension inch W H D Outdoor mm inch Net Weight Indoor kg lbs Outdoor kg lbs 900 900 770 770 3 070 3 070 2 630 3 510 2 260 3 020 9 000 12 000 3 700 4 040 3 180 3 470 12 620 13 800 900 900 770 770 3 070 3 070 3...

Page 73: ...mm inch 980 1 140 989 1 150 1 548 1 800 3 890 6 142 3 024 3 517 3 528 4 102 4 536 5 274 12 000 14 000 18 000 3 474 4 040 3 732 4 340 4 987 5 800 13 800 14 810 19 790 757 880 765 892 1 204 1 400 3 003 3039 4 777 3 478 4 043 3 780 4 396 5 242 6 096 13 800 15 000 20 800 4 007 4 660 4 119 4 790 5 761 6 700 15 900 16 344 22 861 1 100 1 320 1 600 1 120 1 300 1 685 5 0 5 9 7 0 5 1 5 8 8 0 5 0 6 7 5 5 5 7...

Page 74: ...w 152302 342800 264110 263230 1 359011 131410 733010 135316 135313 135311 147581 268711 1 146811 346810 266090 135516 35211B 352150 354210 249951 268711 3 267110 152313 159830 Option Parts Part for Plasma Models Part for Plasma Models Indoor Unit ...

Page 75: ...s AS W0964DH0 AS W1264DH0AS W0964GH0 AS W1264GH0 AS W1224DH0 AS W1424DH0 UL Chassis 554031 435511 552202 552116 554160 561410 552111 550140 552203 2 552203 1 430410 649950 437211 435301 559010 546810 349600 447910 263230 2 268711 3 Part for H P Models 437212 ...

Page 76: ... W096E1G0 AS W126E1G0 UL Chassis 554031 435511 552202 552116 554160 552560 561410 550140 552203 1 552203 2 430410 649950 437210 561411 437212 435301 559010 546810 349600 658740 447910 263230 2 263230 3 268714 55211G 552200 Part for H P Models ...

Page 77: ...4031 437212 263230 1 435511 552202 567502 552116 554160 561410 435512 550140 552203 1 552203 2 430410 649950 552111 559010 546810 349600 447910 263230 2 Part for H P Models Models AS W1865DH0 AS W1825DH0 UE Chassis Exploded View ...

Page 78: ...14Z 266090 H V ASSEMBLY 6609A10003Z 6609A10003Z 267110 REMOTE CONTROLLER 6711A20077Y 6711A20077Y 6711A90032Y 268712 PWB PCB ASSEMBLY DISPLAY 6871A20574A 6871A20574A 6871A20624A 268714 PWB PCB ASSEMBLY 6871A20675A 6871A20156A 6871A20156B 342800 BEARING 4280A20004B 4280A20004B 4280A20004A 346810 MOTOR ASSEMBLY INDOOR 4681A20151B 4681A20091J 4681A20091J 354210 EVAPORATOR ASSEMBLY FIRST 5421A20218A 54...

Page 79: ...64110 POWER CORD ASSEMBLY 6411A20013E 6411A20013E 6410A20007E 6410A20007E 6410A20007F 266090 H V ASSEMBLY 6609A10003Z 6609A10003Z 6609A10003Z 6609A10003Z 6609A10003Z 267110 REMOTE CONTROLLER ASSEMBLY 6711A20077Y 6711A20077Y 6711A20124A 6711A20124A 6711A20124A 268712 PWB PCB ASSEMBLY DISPLAY 6871A20574A 6871A20574A 6871A20574A 6871A20574A 6871A20624A 268714 PWB PCB ASSEMBLY MAIN 6871A20675A 6871A20...

Page 80: ...0156Q 6871A20156P R 264110 Power Cord 6411A20013E 6411A20013E R 263230 1 Thermistor NTC 6323A20004A 6323A20004A R 266090 HVPS DC DC 6609A10003Z 6609A10003Z R 354210 Evaporator Assembly First 5421A20258B 5421A20258B R 35211B Tube Assembly Tubing 5211A29044A 5211A29044A R 359011 Fan Assembly Cross Flow 5901A20017H 5901A20017H R 342800 Bearing 4280A20004B 4280A20004A R 135516 Cover Assembly Motor 355...

Page 81: ...11A21393C 5211A21393B 55211G TUBE ASSEMBLY EXPANSION 5211A21459A 5211A21459A 5211A21459A 552116 TUBE ASSEMBLY REVERSING 5211A10466B 5211A10466C 5211A21140B 552201 VALVE CHECK 3H01552F 3H01552F 552202 VALVE REVERSING 5220AR3228D 5220AR3228D 5220AR3228E 554031 CONDENSER ASSEMBLY 5403A20019V 5403A20019V 5403A21012B 554160 COMPRESSOR 5416A90045A 5416A90029A 5416A90024A 559010 FAN ASSEMBLY PROPELLER 59...

Page 82: ...2111 TUBE ASSEMBLY CAPILLARY 5211A21393C 5211A21393B 5211A21393B 5211A21393E 552116 TUBE ASSEMBLY REVERSING 5211A10466B 5211A10466C 5211A10466C 5211A10466D 5211A21140B 552201 VALVE CHECK 3H01552F 3H01552F 3H01552F 3H01552F 5220A30004A 552202 VALVE REVERSING 5220AR3228D 5220AR3228D 5220AR3228D 5220AR3228D 5220AR3228E 554031 CONDENSER ASSEMBLY BENT 5403A20019V 5403A20019V 5403A20019V 5403A20019V 540...

Page 83: ...or 4H00982E 4H00982E R 554160 Compressor 5416A90029C 5416A90029C R 437210 Panel Assembly Front Outdoor 3721A20027S 3721A20027S R 435301 Grille Discharge 3530A20006G 3530A20006G R 437212 Panel Assembly Rear Outdoor 3721A20026Z 3721A20026Z R 559010 Fan Assembly Propeller 5901A10033A 5901A10033A R 549610 Bracket Assembly Motor Outdoor 4961A10015B 4961A10015B R 546810 AC Motor Assembly 4681A20122A 468...

Page 84: ...P No 3828A20462G October 2006 Printed in Korea ...

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