LG AS-W096UBH0 Service Manual Download Page 63

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Service Manual 63

Troubleshooting Guide

Balance Refrigerant of the 3-way Valve

(Gas leakage)

• Procedure

(1) Confirm that both the 2-way and 3-way valves

are set to the back seat.

(2) Connect the charge set to the 3-way valve’s

port.
– Leave the valve on the charge set closed.
– Connect the charge hose to the service port.

(3) Open the valve (Lo side) on the charge set and

discharge the refrigerant until the gauge indi-
cates 0 kg/cm

– If there is no air in the refrigerant cycle (the

pressure when the air conditioner is not running
is higher than 1 kg/cm

G), discharge the refrig-

erant until the gauge indicates 0.5 to 1
kg/cm

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, the refrigeration oil will
also be discharged.

Open

3-Way
valve

Gas side

OPEN

Outdoor unit

Liquid side

Indoor unit

Summary of Contents for AS-W096UBH0

Page 1: ...096URH0 UBH0 UWH0 UMH0 AS W126URH0 UBH0 UWH0 UMH0 UCH0 AS W096URH1 UBH1 UWH1 UMH1 AS W126URH1 UBH1 UWH1 UMH1 CAUTION website http www lgservice com BEFORE SERVICING THE UNIT READ THE SAFETY PRECAUTIONS IN THIS MANUAL ONLY FOR AUTHORIZED SERVICE PERSONNEL ...

Page 2: ...ng Work 15 Connection of Piping 16 Connecting the Cables 22 Checking the Drainage 24 Forming the Piping 25 Air Purging 26 Test Running 28 Functions 30 Operation 33 Disassembly 47 Indoor Unit 47 Schematic Diagram 50 Electric Control device 50 Wiring Diagram 52 Components Location 54 Troubleshooting Guide 57 Refrigeration Cycle Diagram 57 Pipe Length and the Elevation 58 2 way 3 way Valve 59 Cycle P...

Page 3: ...r B 1 Auto Swing Plasma Filter C 2 Telephone LED Display D 3 Telephone LCD Display E 4 Auto Swing Plasma Filter Telephone LCD F 5 Low Ambient Ambient change G 6 Plasma Filter Low Ambient Ambient change H 7 Internet J 8 Auto Swing Plasma Filter Oxygen Generator K 9 Auto Swing Soft Start Z L Auto Swing Star Rating M Y Auto Swing Star Rating Plasma Filter N X Auto Swing Soft Start Star Rating P W Aut...

Page 4: ...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 ch...

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 Installation 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 t...

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: ...ad connection 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 ele...

Page 9: ...e electric 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 ...

Page 10: ...erts 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 Installation plate D H W MODEL DIM Unit W mm 1030 H mm 290 D mm 153 9k 12k Btu Series ...

Page 11: ... Manual 11 Outdoor Unit Dimensions W L2 L3 L1 D H L4 L5 Gas side 3 way valve Liquid side 2 way valve MODEL 9k 12k Btu Series DIM unit W mm 770 H mm 540 D mm 245 L1 mm 287 L2 mm 64 L3 mm 518 L4 mm 10 L5 mm 100 ...

Page 12: ...26 11 080 13 200 11 080 13 200 527 1 289 527 1 289 454 1 109 454 1 109 1 800 4 400 1 800 4 400 3 164 3 956 3 164 3 956 2 722 3 402 2 722 3 402 10 800 13 500 10 800 13 500 4 087 4 351 4 087 4 351 3 515 3 742 3 515 3 742 13 950 14 850 13 950 14 850 750 1 098 750 1 090 875 1 410 875 1 410 3 9 5 0 3 5 5 0 4 5 6 2 4 0 6 2 3 9 5 0 3 5 5 0 4 5 6 2 4 0 6 2 3 0 2 8 3 0 2 8 12 00 10 93 12 00 10 93 3 11 2 41...

Page 13: ...ilt 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 where noi...

Page 14: ...lect should be strong and solid enough to prevent vibration 1 Mount the installation plate on the wall with type A screws If mounting the unit on a concrete wall use anchor bolts Mount the installation plate horizontally by aligning the centerline using a level 2 Measure the wall and mark the centerline It is also important to use caution concerning the location of the installation plate routing o...

Page 15: ...nger than the pipe length Burrs removal 1 Completely remove all burrs from the cut cross section of pipe tube 2 Put the end of the copper tube pipe in a downward direction as you remove burrs in order to avoid drop ping 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 afte...

Page 16: ... 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 CAUTION If the drain hose is routed inside the room insulate the hose with an i...

Page 17: ...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 cover wh...

Page 18: ...tc between 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 Dra...

Page 19: ...pings 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 the bottom of 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 agains...

Page 20: ...UTION 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 21: ...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 22: ...olor codes referring to the wiring diagram CAUTION If a power plug is not used provide a circuit breaker between power source and the unit as shown by CAUTION 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 following...

Page 23: ...w which fasten the wiring in the casing of electrical fittings are liable to come loose from 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 voltag...

Page 24: ...y leakage and goes out the drain exit Drain piping 1 The drain hose should point downward for easy drain flow 2 Do not make drain piping like the following Drain pan Drain hose Leakage checking Connecting area drain hose Leakage checking Downward slope Do not raise Accumulated drain water Tip of drain hose dipped in water Air Waving Water leakage Water leakage Ditch Less than 50mm gap Water leakag...

Page 25: ...e and connecting cable from down to up 2 Secure the tapped piping along the exterior wall using saddle or equivalent In cases where the Outdoor unit is installed above the Indoor unit perform the following 1 Tape the piping and connecting cable from down to up 2 Secure the taped piping along the exterior wall Form a trap to prevent water entering the room 3 Fix the piping onto the wall by saddle o...

Page 26: ...es and dry nitrogen gas cylinder to this service port with charge hoses CAUTION Be sure to use a manifold valve for air purging If it is not available use a stop valve for this purpose The Hi knob of the manifold valve must always be kept close Pressurize the system to no more than 150 P S I G with dry nitrogen gas and close the cylinder valve when the gauge reading reached 150 P S I G Next test f...

Page 27: ... knob of the manifold valve and stop the vacuum pump Finishing the job 1 With a service valve wrench turn the valve stem of liquid side valve counter clockwise to fully open the valve 2 Turn the valve stem of gas side valve counter clockwise to fully open the valve 3 Loosen the charge hose connected to the gas side ser vice port slightly to release the pressure then remove the hose 4 Replace the f...

Page 28: ...of or rooftop anchor the mounting base securely with a nail or wire assuming the influence of wind and earthquake 3 If the vibration of the unit is transmitted to the hose secure the unit with an anti vibration rubber Evaluation of the performance Operate the unit for 15 20 minutes then check the sys tem refrigerant charge 1 Measure the pressure of the gas side service valve 2 Measure the temperat...

Page 29: ...ant CAUTION Be sure to perform Pump Down procedure in the cooling mode Pump Down Procedure 1 Connect a low pressure gauge manifold hose to the charge port on the gas side service valve 2 Open the gas side service valve halfway and purge the air in the manifold hose using the refrigerant 3 Close the liquid side service valve all the way 4 Turn on the unit s operating switch and start the cooling op...

Page 30: ...ver 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 ...

Page 31: ... the drive voltage of comp according 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...

Page 32: ... TEMPERATURE 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 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 Timer OF...

Page 33: ...ator On while in appliance operation off while in appliance pause Blinking 3sec off 0 5sec on according to Error Code as long as the system malfunctions On while in sleep timer mode off when sleep timer cancel or 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 h...

Page 34: ...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 35: ... 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 freq step o...

Page 36: ... temperature When 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 26 C intake air temp 24 C intake air temp 26 C 18 C intake air temp 24 C intake air temp 18 C Setting Temp...

Page 37: ... 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 The targeti...

Page 38: ... rule 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 t...

Page 39: ...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 40: ...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 41: ...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 42: ...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 43: ...ak 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 CODE ...

Page 44: ... 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 1 Fc 2 Fc 2 T T off T2...

Page 45: ...um Time 15s 5s 30s 10s 1 min 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 Setting Freq Setting Speed Setting Speed Hi Speed of Heating 15s 5s Main Deice time 30s 10s 1min Fh min Step 5 Step 6 ON OFF ON Hot Start OFF ON OFF OFF 0 1 2 3 4 5 6 350 Option 20s 20s off off Setting Freq Operating F...

Page 46: ...ondi tioner changes the operation mode automati cally to keep indoor temperature 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 ...

Page 47: ... OFF To remove the Grille from the Chassis Hold up Inlet Grille Horizentally To remove the Grille pull the lower left and right side of the grille toward you slightly tilted and lift it straight upward To seperate connecter assembly and than to remove Inlet Grille assembly 1 Before removing the control box be sure to take out the wire screwed at the other end ...

Page 48: ...ll the control box out from the chassis carefully 3 To remove the Discharge Grille Unhook the discharge grille and pull the dis charge 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 ...

Page 49: ...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 51: ...Service Manual 51 Schematic Diagram Outdoor AS W096 126U_0 1 Series ...

Page 52: ... OUT CN IN CN SW 2 CN SW 3 CN STEP2 CN STEP1 CN MAIN CN SW 1 RY PWR FORCED OPERATON S W SUC STEP MOTOR 1 ZNR01F THERMISTOR DISPLAY PWB ASM MOTOR MAIN PCB ASM POWER TO OUTDOOR UNIT TERMINAL BLOCK CONNECTOR PWB ASM BR BL RD GN YL BR BL RD GN YL 1 L 2 N 3 3 4 BL BR CN U D CN DISP1 STEP MOTOR CN L R CN HVB STEP MOTOR LIMIT S W 1 LIMIT S W 2 H V B A CL RD RD BK BK SUC STEP MOTOR 2 WIRING DIAGRAM ...

Page 53: ... 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 54: ... 0 7 K R 0 6 K Q01K D01D IC02K IC01K C07D R 0 2 D D 0 2 D IC01D C 0 6 D C03D L1 C01D WCN NOISE BD01D NTC POWER MODULE R 0 5 N JP2 IC02D C 0 8 D J01 C 0 4 D I C 0 1 A J 0 3 C05D J P 0 2 R 0 3 A R 0 9 H R 0 7 H C 0 3 H R 0 8 H J04 J05 Q03E R04D R 0 5 D C 0 2 D R 0 3 D R 0 2 A C 0 1 A R04E Q01E C01E J14 Q01D J 1 3 C01L EEPROM R01A IC01G J11 O S C C 0 1 X R 0 1 B C 0 2 H R04H R03K C N M O T O R R05K Z...

Page 55: ... ASSEMBLY AS W096 126U_0 1 Series TOP VIEW BOTTOM VIEW RECEIVER PWB ASM 6871A20463 PWB 6870A90178A LED MODULE C01G CN DISP LED MODULE R 0 4 G R 0 5 G R 0 1 G R 0 3 G R 0 6 G Scan3 Vo GND Vcc Scan5 Scan4 Scan2 Scan1 Data5 Data4 Data3 Data2 Data1 ...

Page 56: ...04C R04C R06S R06S R23P R23P R22P R22P R24P R24P R13Z R13Z CN D A CN D A EEPROM EEPROM C02Y C02Y R03N R03N C02B C02B C02N C02N C10S C10S C01C C01C C01L C01L R01L R01L C18Z C18Z C01F C01F R01F R01F R04Y R04Y R02B R02B C09B C09B 8 0 8 0 R02L R02L C05H C05H IC01D IC01D C03D C03D C02D C02D R07H R07H R03H R03H R01H R01H R05H R05H C04D C04D C01H C01H C05D C05D C04P C04P C03P C03P C02P C02P R21P R21P R19...

Page 57: ... GAS SIDE 3 WAY VALVE LIQUID SIDE EEV 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: ...rge 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 su...

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: ...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 the condition of connectors The condition of P C B pattern The electronic components Indoor Outdoor The cause of malfunction EEPROM Error EEPROM Check sum Error PSC Error PSC Fault Error Comp Phase Current Error Only 180 Driver Com...

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 IC02D 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: ...ew Exploded View 352150 354210 159901 249951 733010 346810 131410 146811 135311 135080 263020 237900 668713 135314 342800 267110 359011 159830 146811 668713 135312 146811 145200 152302 264110 W0CZZ 266090 268714 35211B 263230 Indoor Unit ...

Page 81: ...ice Manual 81 Exploded View 554032 437212 435511 552202 552116 552201 554160 561410 552111 550140 552203 1 552203 2 430410 649950 552102 437210 435301 559010 546810 661400 447910 263230 668711 Outdoor Unit ...

Page 82: ...A10006T 5983A10006T 5983A10006T R 159901 VANE HORIZONTAL 5990A20015B 5990A20015B 5990A20015B 5990A20015B R 237900 WINDOW DISPLAY 3790A20046E 3790A20046E 3790A20046E 3790A20046E R 249951 CONTROL BOX ASSEMBLY INDOOR 4995A20287N 4995A20287S 4995A20486X 4995A20486Y R 263230 THERMISTOR ASSEMBLY 6323A20004H 6323A20004H 6323A20004H 6323A20004H R 264110 POWER CORD ASSEMBLY 6411A20014V 6411A20026T 6411A200...

Page 83: ...0982E R 552111 TUBE ASSEMBLY CAPILLARY 5211A30331X 5211A30331U 5211A33058A 5211A33058A R 552116 TUBE ASSEMBLY REVERSING 5211A10260F 5211A30698A 5211A21491B 5211A21491D R 552202 VALVE REVERSING 5220AR3228F 5220AR3228F 5220AR3228D 5220AR3228D R 552203 1 VALVE SERVICE 5220A20001Q 5220A20006F 5220A20001Q 5220A20006F R 552203 2 VALVE SERVICE 2H02479P 2H02479P 5220A20005B 5220A20005B R 554031 CONDENSER ...

Page 84: ...P No 3828A20061Z April 2005 Printed in Korea ...

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