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LG AS-W096QGG1, Service Manual

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2 Room Air Conditioner

Air Conditioner Service Manual

TABLE OF CONTENTS

LG Model Name ...............................................................................................................................................3
Safety Precautions..........................................................................................................................................5
Dimensions .....................................................................................................................................................9

Symbols Used in this Manual .....................................................................................................................9
Indoor Unit..................................................................................................................................................9
Outdoor Unit .............................................................................................................................................10

Product Specifications  ................................................................................................................................12
Installation .....................................................................................................................................................14

Select the Best Location  .........................................................................................................................14
Piping Length and Elevation.....................................................................................................................14
How to Fix Installation Plate .....................................................................................................................15
Drill a Hole in the Wall ..............................................................................................................................15
Installation Instructions of Telephone Control(Optional)...........................................................................15
Flaring Work .............................................................................................................................................16
Connection of Piping Indoor .....................................................................................................................17
Connection of the Pipes-Outdoor .............................................................................................................20
Connect the Cable to the Indoor Unit .......................................................................................................21
Connect the Cable to the Outdoor Unit ....................................................................................................22
Checking the Drainage.............................................................................................................................23
Form the Piping ........................................................................................................................................23
Air Purging ...............................................................................................................................................24
Air Purging with Vacuum Pump................................................................................................................24
Test Running ............................................................................................................................................26

Functions  ......................................................................................................................................................27
Operation  ......................................................................................................................................................30
Disassembly ..................................................................................................................................................45

Indoor Unit................................................................................................................................................45

Schematic Diagram.......................................................................................................................................48

Electric Control device..............................................................................................................................48
Wiring Diagram.........................................................................................................................................51
Components Location ..............................................................................................................................53

Troubleshooting Guide .................................................................................................................................57

Refrigeration Cycle Diagram ....................................................................................................................57
Pipe Length and the Elevation .................................................................................................................58
2-way, 3-way Valve ...................................................................................................................................59
Cycle Parts ...............................................................................................................................................66
Self-diagnosis Function ............................................................................................................................67
Electronic Parts ........................................................................................................................................69

Exploded View ..............................................................................................................................................80

Indoor Unit................................................................................................................................................80
Outdoor Unit .............................................................................................................................................81

Replacement Parts List ................................................................................................................................82

Indoor .......................................................................................................................................................82
Outdoor ....................................................................................................................................................83

Summary of Contents for AS-W096QGG1

Page 1: ...RVICE MANUAL LG MODELS AS W096QGG1 AS W126RGH1 AS W186TGH1 AS W246TGH1 AS W246TLG1 CAUTION website http www lgservice com BEFORE SERVICING THE UNIT READ THE SAFETY PRECAUTIONS IN THIS MANUAL ONLY FOR AUTHORIZED SERVICE PERSONNEL ...

Page 2: ...ndoor 17 Connection of the Pipes Outdoor 20 Connect the Cable to the Indoor Unit 21 Connect the Cable to the Outdoor Unit 22 Checking the Drainage 23 Form the Piping 23 Air Purging 24 Air Purging with Vacuum Pump 24 Test Running 26 Functions 27 Operation 30 Disassembly 45 Indoor Unit 45 Schematic Diagram 48 Electric Control device 48 Wiring Diagram 51 Components Location 53 Troubleshooting Guide 5...

Page 3: ... Look Color Artcool Model 9 Function A Z 10 Serial No 1 9 LG Model Development Serial No ARTCOOL COLOR 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 changeove A clean 4way Low A H Tele LED 4way I Internet J Plasma F 4Way Oxy generator K Nano Plasma F A changeove A clean L Nano Plasma F A c...

Page 4: ... 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 Plasma F A...

Page 5: ...erties only Be sure not to do Be sure to follow the instruction Do not use damaged power cords plugs or a loose socket There is risk of fire or electric shock Always use the power plug and socket with the ground terminal There is risk of electric shock Install the panel and the cover of control box securely There is risk of fire or electric shock Installation Do not modify or extend the power cord...

Page 6: ...he air conditioner run for a long time when the humidity is very high and a door or a window is left open Moisture may condense and wet or damage furnishings Always install a dedicated circuit and breaker Improper wiring or installation may cause fire or electric shock Use the correctly rated break er or fuse There is risk of fire or electric shock Operation Do not turn the air conditioner ON or O...

Page 7: ... heater or other appliances near the power cable There is risk of fire failure of the product and or electric shock Do not allow water to run into electric part There is risk of fire failure of the product and or electric shock Do not store of use flammable gas or combustibles near the air conditioner There is risk of fire or failure of product Wax Thinner Always check for gas refriger ant leakage...

Page 8: ...ge 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 anything on the product outdoor unit 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 air conditioner is plugged in There are s...

Page 9: ...14 D mm 155 156 172 Model Dimension AS W096QGG1 AS W126RGH1 AS W186TGH1 AS W246TGH1 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 10: ...onditioner Outdoor Unit Dimensions 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 AS W096QGG1 AS W126RGH1 ...

Page 11: ...r Unit W L7 L6 L8 L9 D L1 L2 L3 L10 L4 L5 H Gas side Liquid side AS W186TGH1 AS W246TGH1 AS W246TLG1 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 MODEL DIM ...

Page 12: ... 654 5 400 7 200 6 000 14 500 2 640 3 520 5 280 7 032 2 270 3 027 4 540 6 048 9 010 12 014 18 016 24 000 2 901 3 868 5 801 7 735 2 495 3 326 4 990 6 653 9 900 13 200 19 800 26 400 1 978 2 532 1 406 3 604 1 701 2 177 1 210 3 100 6 750 8 640 4 800 12 300 3 170 3 960 6 070 7 735 2 726 3 405 5 219 6 653 10 819 13 512 20 711 26 400 3 481 4 351 6 651 8 497 2 994 3 742 5 720 7 308 11 880 14 850 22 700 29...

Page 13: ...ir Circulation Indoor Max m3 min CFM Outdoor Max m3 min CFM Moisture Removal l h pts h Noise Level Indoor High dB A 3 Sound Med dB A 3 Pressure 1m Low dB A 3 Outdoor Max dB A 3 Refrigerant R410A Charge g 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 i...

Page 14: ...ce where noise and vibration are mini mum Select a place so that the warm air and noise from the air conditioner do not disturb neighbors More than A More than B More than 2 3m More than B More than 10cm More than 10cm More than 60cm More than 60cm More than 70cm CAUTION Install the indoor unit on the wall where the height from the floors more than 2 3 meters CAUTION Capacity is based on standard ...

Page 15: ...he 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 Indoor WALL Outdoor Answering telephone Normal telephone Not packed ...

Page 16: ...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 Firmly hold copper pipe in a die in the dimension shown in the table above Carry out flaring work using flaring tool as shown below Check Compare the flared work with figure below If flare is noted to be defective ...

Page 17: ... with an insula tion material so that dripping from sweating condensation will not dam age furniture or floors Foamed polyethylene or equivalent is recom mended 4 Indoor unit installation Hook the indoor unit onto the upper portion of the installation plate Engage the two hooks of the rear top of the indoor unit with the upper edge of the installation plate Ensure that the hooks are prop erly seat...

Page 18: ...vinyl tape for enough to cover where they fit into the rear piping housing section For left rear piping 1 Route the indoor tubing and the drain hose to the required piping hole position 2 Insert the piping drain hose and the connecting cable into the piping hole 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 Wrench Indoor unit tubing Op...

Page 19: ...nut with a wrench When extending the drain hose at the indoor unit install the drain pipe 7 Wrap the insulation material around the con necting portion Overlap the connection pipe heat insulation and the indoor unit pipe heat insulation material Bind them together with vinyl tape so that there is no gap Wrap the area which accommodates the rear pip ing housing section with vinyl tape mm inch kg m ...

Page 20: ... left and right Press the lower left and right sides of the unit against the installation plate until the hooks engage into their slots clicking sound 1 Align the center of the pipings and sufficiently tighten the flare nut by hand 2 Finally tighten the flare nut with torque wrench until the wrench clicks When tightening the flare nut with torque wrench ensure the direction for tightening follows ...

Page 21: ...rd connected to the A unit should be complied with the following specifications Type B approved by HAR or SAA 7k 9k 12k 18k 1 0 1 5 2 5 NORMAL CROSS SECTIONAL AREA Grade 7k 9k 12k 18k 1 0 1 5 2 5 NORMAL CROSS SECTIONAL AREA Grade mm2 mm2 CAUTION 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 no...

Page 22: ...s 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 Confirm that t...

Page 23: ...d be routed above the ground Secure the drain hose appropriately 2 In cases where the outdoor unit is installed below the indoor unit perform the following Tape the piping drain hose and connecting cable from down to up Secure the tapped piping along the exterior wall using saddle or equivalent 3 In cases where the Outdoor unit is installed above the Indoor unit perform the following Tape the pipi...

Page 24: ...quid 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 2 Leak test Connect the manifold valve with pressure gauges and dry nitrogen gas cylinder to this service port with charge hoses Pressurize the system to no more than 150 P S I G with dry nitrogen gas and close the cylin der valve when the gauge reading reached ...

Page 25: ... 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 26: ...eating 4 For reference the gas side pressure of optimum condition is as below Cooling If the actual pressure is higher than shown the system is most likely over charged and charge should be removed If the actual pres sure are lower than shown the system is most likely undercharged and charge should be added The air conditioner is now ready for use NOTICE NOTICE Bolt Tubing connection Discharge tem...

Page 27: ... can be set at the desired position or swing up and down automatically 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 Soft Dry Operation Mode Both the indoor and outdoor fan stops during defrosting The indoor fan stops until the eva...

Page 28: ...ccording to operating frequency It is only operated in the heating operation mode except defrosting operation High speed Although fan motor speed is middle it will change high speed in case of below AC193V over 45 C 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...

Page 29: ...E LOW HIGH Cooling Operation Mode Heating Operation Mode Auto Operation Mode Horizontal Airflow Direction Control Button Optional Room Temperature Display Setting the Time or Timer PLASMA Optional ON OFF SET PLASMA CANCEL Heater Optional Optional Auto Clean Fan Speed Selection Low Med High CHAOS Power Save Cooling Button AUTO CLEAN High 39 C Low 11 C OFF ON OFF ON Cancel Sleep Mode Timer ON or Tim...

Page 30: ... appliance operation pause On while in plasma mode off when plasma mode cancel On while in timer mode on off off when timer mode is completed or canceled Off except when hot start during heating mode operation or while in defrost control Cooling heating dehumidification mode setting temperature from remote control Fuzzy operation mode fuzzy key data 5sec on AI Operation Indicator Power Saving Indi...

Page 31: ...trolled to depend on indoor and outdoor conditions It is displayed as below Heat mode operation Power level 1 below Step 2 of COMP operating frequency Power level 2 below Step 4 of COMP operating frequency Power level 3 Equal Step 5 of COMP operating frequency Power level 4 below Step 7 of COMP operating frequency Power Level 1 Power Level 2 Power Level 3 Power Level 4 Power Level 1 Power Level 2 ...

Page 32: ...room temperature Control condition The system operates standard operation without this condition as follows Setting temperature 25 C Indoor fan speed low speed Outdoor temperature 30 C Control method In operation for 5 20 minutes in conditions return to the previous COMP STEP after operation for 5 40 minutes at the COMP STEP 3 Comp free Comp Step 4 Comp Step 2 Comp off 0 C 3 C 6 C 7 C Indoor pipe ...

Page 33: ...temp 1 0 C for 3 minutes continuously When intake air temperature reaches below the temperature of setting temp 1 0 C Compressor 2 minutes delay The compressor can restart minimum 2 minutes later after compressor off Temp differences Comp Operating frequency over 3 0 C Step 7 over 2 5 C Step 6 2 0 2 49 C Step 5 1 5 1 99 C Step 4 1 0 1 49 C Step 3 0 5 0 99 C Step 2 0 0 0 49 C Step 1 The operating f...

Page 34: ...n intake air temp reaches above the temp of setting 1 0 C condition of compressor same as cooling mode operation When intake air temperature reaches bolow the temp of setting 1 0 C compressor operate step1 step3 and indoor fan speed repeatly operate low or stop Intake air Temp 32 C intake air temp 26 C intake air temp 32 C 24 C intake air temp 26 C 18 C intake air temp 24 C intake air temp 18 C Se...

Page 35: ...on indoor pipe temp 30 C While in defrost control between the indoor and outdoor fans are turned off Compressor 2minutes delay After compressor off the compressor can restart minimum 2 minutes later Temp differences over 3 0 C 2 5 3 0 C 2 0 2 49 C 1 5 1 99 C 1 0 1 49 C 0 5 0 99 C 0 0 0 49 C Comp Operating frequency Step 7 Step 6 Step 5 Step 4 Step 3 Step 2 Step 1 The operating freq step of comp Th...

Page 36: ...the operating frequency of compressor is deter mined like cooling mode operation At the beginning of Fuzzy mode operation the setting temperature is automatically selected according to the intake air temperature at that time When the Fuzzy key setting temp key is input after the initial setting temperature is selected the Fuzzy key value and intake air temperature at that time are compared to sele...

Page 37: ...rflow speed of the indoor fan is automatically operated by Fuzzy logic at beginning during opertion Intake Air temp over 20 C below 20 C 16 30 C below 16 C over 30 C Setting temp intake air temp 0 5 C 20 C Fuzzy rule 16 C Fuzzy rule 30 C Fuzzy rule Fan speed Fuzzy airflow 3 Fuzzy operation for dehumidification At the beginning of Fuzzy mode operation the setting temperature is automatically select...

Page 38: ...the Jet Heat key cannot be input When it is input while in the Heating mode operation dehumidification the Jet Heat mode is operated In the Jet Heat mode the indoor fan is operated super high speed for 60 min at Heating mode operation In the Jet Heat mode the room temperature is controlled to the setting temperature 30 C When the sleep timer mode input while the Jet Heat mode operation the Jet Hea...

Page 39: ...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 40: ...emote control 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 th...

Page 41: ...ue and in case dectection of dc paeak current Control table 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 compre...

Page 42: ...he compressor operating frequency according to the compressor dome TH Refer to below Fig Temperature range by COMP SPEC varies by 10 C Operation 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...

Page 43: ...ince 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 15s 6s 30s 10s 1 min of Heating Main Deice time Fh min Fh min Step 5 Step 6 ON OFF Setting Speed ON Hot Start OFF Hot Starting ON OFF OFF 0 1 2 3 4 5 6 Setting 350 Option Starting step Setti...

Page 44: ... The air conditioner changes the operation 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 ev...

Page 45: ...n 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 Display P C B Conductor Step Motor Conductor Earth Conductor Motor Conductor Sensor Cond...

Page 46: ...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 CAUTION When repair do not damage the Caution label ...

Page 47: ...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 48: ...48 Room Air Conditioner Schematic Diagram Schematic Diagram Electric Control Device Indoor ...

Page 49: ...Service Manual 49 Schematic Diagram Outdoor AS W096_Series AS W126_Series ...

Page 50: ...50 Room Air Conditioner Schematic Diagram Outdoor AS W186_Series AS W246_Series ...

Page 51: ...TDOOR UNIT CN T BLOCK INDOOR THERMISTOR PIPE THERMISTOR STEP MOTOR STEP MOTOR AC250V T2A CN AC DC CN AC DC CN MOTOR CN TH CN U D CN L R CN HVB CN 12V CN CONT H V ASM S W1 S W2 AIR CLEAN PLASMA SH CAPA 4 3 MOTOR AC PWB ASSY DC PWB ASSY SSR GN GN YL OR BK BL WH Ribbed BL RD RD BK BK BK BK BK BK BK BK BK GR GN YL BR BK Plained BR BR YL 1 L 2 N 3 4 BK BK WH PTC HEATER PTC CONROL PWB ASSY CN PTC 4 3 CN...

Page 52: ...3 BK WCN NOISE 2 BK BL BK OR YL BK BK RD BL YL REVERSING VALVE REACTOR HEAT SINK TH OUTDOOR TH PIPE TH COMP TH RD GN YL CN FAN1 WCN CAP1 WCN CAP2 RY H CN COIL1 CN COIL2 CN U CN V CN W CN TH1 CN D PIPE Motor SPM2 COMP TERMINAL BLOCK TO INDOOR UNIT Outdoor PWB ASSY OUTDOOR WIRING DIAGRAM CN TH2 CN 4WAY RY 4WAY WCN NOISE 4 BK WCN NOISE 1 BK FUSE 1 L 2 N 3 ...

Page 53: ...Service Manual 53 Schematic Diagram Components Location INDOOR MAIN P W B ASSEMBLY DC PART TOP VIEW BOTTOM VIEW INDOOR MAIN P W B ASSEMBLY AC PART TOP VIEW BOTTOM VIEW ...

Page 54: ...54 Room Air Conditioner Schematic Diagram DISPLAY ASSEMBLY AS W096QGG1 AS W126RGH1 AS W186TGH1 AS W246TGH1 AS W246TLG1 TOP VIEW BOTTOM VIEW ...

Page 55: ...Service Manual 55 Schematic Diagram OUTDOOR MAIN P W B ASSEMBLY AS W096QGG1 AS W126RGH1 BOTTOM VIEW TOP VIEW ...

Page 56: ...56 Room Air Conditioner Schematic Diagram OUTDOOR MAIN P W B ASSEMBLY AS W186TGH1 AS W246TGH1 TOP VIEW BOTTOM VIEW ...

Page 57: ... GAS SIDE 3 WAY VALVE LIQUID SIDE EER 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 CHECK VALVE COOLING HEATING REVERSING VALVE 1 Model Capillary Tube Refrigeration Cycle Diagram 2 Model Adopted Electrion Expansion Valve ...

Page 58: ... unit B In case more than 5m 7k 14k 3 8 Ø9 52 1 4 Ø6 35 4 or 7 5 7 15 20 1 2 Ø12 7 1 4 Ø6 35 4 or 7 5 7 15 20 1 2 Ø12 7 1 4 Ø6 35 4 or 7 5 15 30 20 18k 28k 5 8 Ø15 88 1 4 Ø6 35 4 or 7 5 15 30 20 5 8 Ø15 88 3 8 Ø9 52 4 or 7 5 15 30 30 30k 38k 5 8 Ø15 88 3 8 Ø9 52 7 5 15 30 30 3 4 Ø19 05 3 8 Ø9 52 7 5 15 30 50 Pipe Size Capacity Btu h GAS LIQUID Additional Refrigerant g m Max Length A m Max Elevatio...

Page 59: ...ise 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 Flare...

Page 60: ...t Using 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 ...

Page 61: ...e 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 set ...

Page 62: ...ch 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 wren...

Page 63: ...t 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 suddenly...

Page 64: ...ward 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 L...

Page 65: ... 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 ope...

Page 66: ...ir 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 a...

Page 67: ... current is over loaded CT2 D PIPE TH is short or open The operating LED will be blink ing once The operating LED will be blink ing twice The operating LED will be blink ing 4 times The operating LED will be blink ing 5 times The operating LED will be blink ing 6 times The operating LED will be blink ing 7 times The operating LED will be blink ing 10 times Keep operating state Keep operating state...

Page 68: ...he outlet and make sure that the lamp on the control board outdoor unit is off The Diagnosis Procedure Check the supplied voltage to product AC 220V 230V 30V Check the connecting cable between Indoor and Outdoor Check the blinking number of operation indicator refer to the self diagnosis function Check the self diagnosis table Check the condition of connectors The condition of P C B pattern Check ...

Page 69: ...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 Specific...

Page 70: ...d by 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 MICO...

Page 71: ... fan is stopped Check the related circuit of R02H 12 1K R01H 6 2K R04H 1K R03H 1K C01H 102 C02H 102 Micom pin No Check the Indoor temperature sensor is disconnected or not Resistance is about 10K at 25 C Check the Relay RY PWR for driving Compressor Check the voltage between brown and blue cable of terminal to connect the Outdoor About AC220V 240V Check the related circuit of relay in Outdoor PCB ...

Page 72: ...Check the Fan Motor Check the Fuse AC250V T2A Turn on the main power Check the related circuit of indoor Fan Motor The pin No 45 of micom and the part for driving SSR Check the related pattern Check the SSR SSR Open Indoor Fan Motor never operate SSR short Indoor Fan Motor always operates in case of ON or OFF The voltage of Pin No 1 orange and 3 black of CN MOTOR About AC 180V over About AC 50V ov...

Page 73: ... PCB of CN U D Connector Check the operating circuit of the vertical louver Confirm that there is DC 12V between pin of CN U D and GND Confirm that there is a soldering short at following terminals Between 41 42 43 and 44 of MICOM Between 4 5 6 and 7 of IC01M Between 10 11 12 and 13 of IC01M When the horizontal louver does not operate Trouble 5 If there are no problems after above checks Confirm t...

Page 74: ...nnector on the indoor DC P C B Ass y Check the Heater driving Circuit Check the pattern between MICOM Pin No 48 IC02M Pin No 7 IC02M Pin No 10 CN PTC The heater does not operate at all Trouble 6 If there is no problem result of all above check Inner side disconnection of PTC Heater unit or restriced operating condition of PTC Heater pipe temp is over 45 C defrosting operation compressor off indoor...

Page 75: ...O NO Is the connection of cable between indoor and outdoor unit right Indoor Outdoor 1 Brown 1 Brown 2 Blue 2 Blue 3 Green YL 3 Green YL 4 Red 4 Red NO YES Is the voltage of Terminal Block in outdoor Control Box about AC220V 240V Check the Fuse of Outdoor PCB Ass y NO YES Is the voltage of NF01J in outdoor PCB Ass y about AC220V 240V when Operation s ON Check the PTC and RY PWR NO YES Is the Bridg...

Page 76: ...ectors in PCB Ass y If CN UWV is connected the comprressor can be operated a opposite direction NO YES Is the power module in PCB Ass y right Check the short P N P U V W and N U V W of IPM and then collector emiter of IGBT NO YES Is the voltage of T Block over than AC150V Check the supplied voltage NO YES Is the voltage of GND IPM 32 pin over than about DC280V Check the DC voltage between IPM 1pin...

Page 77: ...heck Fuse Noise Filter PTC etc NO YES Is the voltage of BR BK RD AC220 240V in Main PCB Ass y Electrical wiring diagram Colors Check the connecting state of connectors in outdoor PCB Ass y Check the Fuse of outdoor PCB Ass y NO YES Is the connection of CN T Block and in CN AC DC indoor P C B Ass y is right Replace the PCB Ass y Main PCB Ass y Indoor Outdoor Control Box Ass y Reconnect the connecto...

Page 78: ...ES Is the courrent transformer CT in Main PCB Ass y right Check the PCB pattern resoldering NO YES Is the indoor outdoor fan locked Check the indoor outdoor fan motor NO YES Is the discharge temperature of Indoor unit right 11 C 17 C in the cooling mode Check the compressor NO YES Is the refrigerant pressure right Supply the refrigerant or Discharge the refrigerant NO YES Replace the PCB Ass y Mai...

Page 79: ...oor fan motor The operation LED blinks 5 times Communication error Don t operate the power display module The operation LED blinks twice Enable to receive remote singnal Malfunctions UP DOWN step motor Don t operate louver Malfunctions indoor fan motor Problem error mode Connectors Condition OPEN OPEN OPEN Stop compressor Malfunctions 4 WAY valve Malfunctions fan Problem error mode CN TH CN UVW CN...

Page 80: ...loded View Exploded View 346810 135516 352150 266090 267110 146811 131410 359011 342800 147581 268711 1 159830 135311 135312 249951 733010 152313 135314 152302 268714 1 268714 2 263230 264110 354210 W6640 W0CZZ 35211B Indoor Unit ...

Page 81: ... 81 Exploded View 554032 437212 435511 552202 552116 552201 554160 561410 552113 550140 552203 1 552203 2 430410 649950 552102 1 437211 435301 559010 546810 437210 447910 263230 1 435512 268711 Outdoor Unit 552102 2 ...

Page 82: ...20004K 6323A20004K 6323A20004K R 264110 POWER CORD ASSEMBLY 6411A20046C 6411A20046D 6411A20046E 6411A20005P 6411A90032D R 266090 H V ASSEMBLY 6609A10003U 6609A10003U 6609A10003P 6609A10003P 6609A10003P R 267110 REMOTE CONTROLLER ASSEMBLY 6711A20073U 6711A20091H 6711A20091H 6711A20091H 6711A20077D R 268712 PWB PCB ASSEMBLY DISPLAY 6871A20254B 6871A20254B 6871A20254C 6871A20254C 6871A20254C R 268714...

Page 83: ...982E 4H00982E 4H00637A 4H00637A 4H00637A R 552102 TUBE CAPILLARY BEND 5210A31461A 5210A21447F 5210A31380D 5210A31380C 5210A31380C R 5210A21447F 5210A33068A 5210A31380E 5210A31380F 5210A31380F 552116 TUBE ASSEMBLY REVERSING 5211A10465A 5211A10466A 5211A21140A 5211A30668B 5211A30668B R 552201 VALVE CHECK 3H01552F 3H01552F 5220A30004A 5220A30004A 5220A30004A R 552202 VALVE REVERSING 5220AR3228F 5220A...

Page 84: ...P No 3828A20195S February 2007 Printed in Korea ...

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