LG AS-W1863 Series Svc Manual Download

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Universal Air Conditioner

SVC MANUAL(Exploded View)

MODEL : AS-W1863_ Series

AS-W2463_ Series

CAUTION

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

Internal Use Only

http://biz.lgservice.com

Summary of Contents for AS-W1863 Series

Page 1: ...SVC MANUAL Exploded View MODEL AS W1863_ Series AS W2463_ Series CAUTION Before Servicing the unit read the safety precautions in General SVC manual Only for authorized service personnel Internal Use Only http biz lgservice com ...

Page 2: ...gth and Elevation 14 Fixing Installation Plate 14 Drill a Hole in the Wall 15 Flaring 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 Wiring Diagram 50 Components Location 52 Troubleshooting Guide 56 Refrigeration Cycle Diagram 56 Pipe ...

Page 3: ...nd LG Brand N 2nd OEM Brand Basic A 0 Plasma Filter 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 Fi...

Page 4: ...V 50Hz D 440 460 60Hz 3Phase 6 220 240V 50Hz E 265V 60Hz 7 110V 50 60Hz F 200V 50 60Hz 8 380 415V 50Hz 9 380 415V 60Hz 7 Chassis A Z Name of Chassis of Unit Ex LSP SP Chassis 8 Look A Z Look Color Artcool Model 9 Function A Z 10 Serial No 1 9 LG Model De ARTCOOL COLOR velopment Serial No Basic A Basic 4Way B Plasma Filter C Plasma Filter 4 Way D Tele LCD E Tele LCD Nano plasma 4Way F Nano Plasma F...

Page 5: ...icates the possibility of injury or damage to properties only Be sure not to do Be sure to follow the instruction Do not use damaged power cords plugs or a loose socket 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 I...

Page 6: ...roduct failure and personal injury Do not let the air conditioner run for a long time when the humidity is very high and a door or a 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 Op...

Page 7: ... electrical shock or product damage Do not place a 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...

Page 8: ...tc There is risk of fire electric shock or damage to the plastic parts of the product Do not touch the metal parts of the product when removing the air filter They are very sharp There is risk of personal injury Do not step on or put 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 whil...

Page 9: ...s 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 1170 H mm 315 D mm 173 18k 24k Btu Series 9 Copyright 2009 LG Electronics Inc All right reserved Only for training and service purposes LGE Internal Use Only ...

Page 10: ...rvice purposes LGE Internal Use Only Outdoor Unit Dimensions W L7 L6 L8 L9 D L1 L2 L3 L10 L11 L4 L5 H Gas side Liquid side MODEL 18k 24k Btu Series DIM unit 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 ...

Page 11: ...2 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 AS W1863_ Series AS W2463_ Series 1 612 1 386 5 500 5 274 4 536 18 000 5 831 5 015 19 900 1 670 1 436 5 700 6 065 5 216 20 700 6 739 5 796 23 000 4 430 3 810 15 120 7 032 6 048 24 000 7 735 6 653 26 400 4 1...

Page 12: ... Low dB A 3 Pressure 1m Outdoor Max dB A 3 Refrigerant R410A Charge g oz Power Cord P mm2 Connecting Cable P mm2 Connecting Tube Liquid Side mm in Ø Socket Flare Gas Side mm in Length std m in Dimension Indoor mm W H D in Outdoor mm in Net Weight Indoor kg lbs Outdoor kg lbs Energy Labeling Capacity Cooling Heating Energy Consumption Cooling Heating Star Rating Cooling Heating Tool IN OUT 1 612 1 ...

Page 13: ...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 noise and vibration are min imum 5 Select a place where the warm air a...

Page 14: ... Oil trap should be installed every 5 7 meters The wall you select 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 cauti...

Page 15: ...ger than measured distance 4 Cut the cable 1 5m longer 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 compl...

Page 16: ...o the indoor unit from the outdoor 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 CAUTION If the drain hose is rou...

Page 17: ... at the indoor unit install the drain 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 ...

Page 18: ... installation plate Insert the spacer etc 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 ...

Page 19: ...ain hose across the back of the chassis Set the pipings and the drain hose to the back of the chassis with the tubing holder Hook the edge of tubing holder to tap on chassis and push the bottom of tubing holder to be engaged at 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...

Page 20: ... purposes LGE Internal Use Only Installation CAUTION 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: ... nut by hand 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 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 ...

Page 22: ...door unit Connect the wires firmly so that they may not be pulled out easily Connect the wires according to color 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 Th...

Page 23: ...ram posted on the inside of control cover 2 The screw 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 capa...

Page 24: ...gh the drain hose of the indoor unit without any 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 Wate...

Page 25: ... perform the following 1 Tape the piping drain hose 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 t...

Page 26: ...t Connect the manifold valve with pressure gauges 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 th...

Page 27: ... 2 When the desired vacuum is reached close the Lo 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...

Page 28: ...or rigid mount 2 When installing on the wall roof 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 th...

Page 29: ...into the outdoor unit without the loss of refrigerant 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 th...

Page 30: ...gular 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 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 B...

Page 31: ...g to temp of indoor and outdoor It will be changed 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 ...

Page 32: ...n Control Cooling model only Heating model only 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 O...

Page 33: ...er Indicator PLASMA Indicator Timer Indicator Preheat Indicator Setting Temp 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 whe...

Page 34: ...is turned on according to the condition of the 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 Co...

Page 35: ... air temperature stay at the temperature between setting temp 0 5 C and setting 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 9...

Page 36: ...s automatically set according to the intake air 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 ...

Page 37: ...ve the setting temperature Condition of indoor fan turned off While in compressor 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 S...

Page 38: ...ng to the setting temperature selected by Fuzzy 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 int...

Page 39: ... to the Fuzzy rule While in Fuzzy operation the airflow 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 operati...

Page 40: ...rther While in cooling mode or Fuzzy operation 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 inpu...

Page 41: ...60 min later since the start of the sleep timer the 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 2 C Heating OFF temp Setting temp 4 C 1 2 Sleep time hr 1 0 C down 1 0 C down When the slee...

Page 42: ...erate the appliance by force in case that the remote 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 ma...

Page 43: ...een intial value 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 wh...

Page 44: ...hes over 130 C or below 30 C the compressor stop instantly It will be limited the 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 of...

Page 45: ...Defrosting control is available 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 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 ...

Page 46: ... operation the air condi 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 fro...

Page 47: ...king any checks Be sure the power switch is set to 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 th...

Page 48: ...emove the Control Box Remove securing screws Pull 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: ...ntil the tab is clear of the slot 5 To remove the 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 fro...

Page 50: ...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 3854A20305H FUSE AC250V T2A CN TH WCN NOISE GN YL CN COM CN OUT CN IN N 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 THERMISTOR DISPLAY PWB ASM MAIN PCB ASM POWER TO OUTDOOR UNIT TERMINAL BLOCK CONNEC...

Page 51: ... 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 3854A20310C WCN NOISE 20A AC 250V BR 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 C...

Page 52: ... 12 3 5 8 R03H R 0 1 D R 0 4 K C 0 1 K R 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 ...

Page 53: ... 53 Copyright 2009 LG Electronics Inc All right reserved Only for training and service purposes LGE Internal Use Only Schematic Diagram INDOOR MAIN P W B ASSEMBLY AS W2463_Series BOTTOM VIEW TOP VIEW ...

Page 54: ...E Internal Use Only Schematic Diagram DISPLAY ASSEMBLY AS W1863_ Series AS W2463_ 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 55: ...yright 2009 LG Electronics Inc All right reserved Only for training and service purposes LGE Internal Use Only Schematic Diagram OUTDOOR MAIN P W B ASSEMBLY AS W1863_Series AS W2463_Series BOTTOM VIEW TOP VIEW ...

Page 56: ...HEAT EXCHANGE CONDENSER COMPRESSOR ACCUMU LATOR 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 Drier COOLING HEATING REVERSING VALVE 1 Model Capillary Tube Refrigeration Cycle Diagram 2 Model Adopted Electrion E...

Page 57: ... Indoor unit A B A Oil trap Outdoor unit Indoor 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 Additio...

Page 58: ...with cap Closed Open Open clockwise counter clockwise 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 S...

Page 59: ...move the cap from the 3 way valve s service port 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 espec...

Page 60: ...e push pin to the service port 4 Air purging of the charge hose Open the low pressure valve on the charge set slightly to air purge from the charge hose 5 Set the 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 ...

Page 61: ...3 times After purging the air use a torque wrench to tighten the flare nut on liquid side valve 4 Check for gas leakage Check the flare connections for gas leakage 5 Discharge the refrigerant Close the valve on the gas cylinder and dis charge the refrigerant until the gauge indicates 3 to 5 kg cm2 g 6 Disconnect the charge set and the gas cylin der and set the Liquid side and Gas side valves to th...

Page 62: ...e service port 3 Open the valve Lo side on the 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...

Page 63: ...hour Confirm that the gauge needle has moved toward 76 cmHg vacuum of 4 mmHg or less 3 Close the valve Lo side on the charge set turn off the vacuum pump and confirm that the gauge needle does not move approxima tely 5 minutes after turning off the vacuum pump 4 Disconnect the charge hose from the vacuum pump Vacuum pump oil If the vacuum pump oil becomes dirty or depleted replenish as needed Lo O...

Page 64: ... of refrigerant it can be charged with a little at a time approximately 150g each time while operating the air conditioner in the cooling cycle however one time is not 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 ...

Page 65: ...ween intake and discharge air depends on room air humidity When the room air humidity is relativery higher temperature difference is smaller When the room air humidity is relatively lower tem perature difference is larger 2 Check temperature and pressure of refrigeration cycle 1 The suction pressure is usually 8 5 9 5kg cm2 G Cooling at normal condition 2 The temperature can be measured by attachi...

Page 66: ...r open Outdoor TH is short or open Temp of Heat sink is over 95 C Heat sink TH is short or open Comunication error serial comunication DC peak error Running current is over loaded CT2 D PIPE TH is short or open The display show C1 The display show C2 The display show C4 The display show C5 The display show C6 The display show C7 The display show CA Keep operating state Keep operating state Restart...

Page 67: ...ing or repairing job pull out the plug out of the 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 c...

Page 68: ...P1 CN DISP2 of indoor DC PCB Check the voltage of 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 p...

Page 69: ...d At this point the wind speed is not controlled by the remote controller When operated in the Sleeping Mode the wind speed is set to the low speed 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 ...

Page 70: ...d connection or are not engaged Compressor Outdoor 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 ...

Page 71: ...ff main power Check the connection of CN MOTOR 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...

Page 72: ... CN U D Connector Check the soldering condition on 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 ...

Page 73: ...ss y Check the soldering condition of CN PTC connector 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 ...

Page 74: ...le 7 YES Check the connecting state of connector NO 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...

Page 75: ...agram Colors Check the connecting state of connectors 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 abo...

Page 76: ...ing cable 3 line bewteen indoor and outdoor unit Check 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 Indoo...

Page 77: ...tdoor Unit Check fuse Noise Filter PTC etc NO YES 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 t...

Page 78: ...Malfunctions outdoor unit Stop compressor and outdoor 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 M...

Page 79: ...ded View 352150 145200C 145200B 145200D 354210 354212 147581 435301 249951 264100 131410 135511 146811A 135311 342800 267110 149304 159830 135313 146811B 145200A 268711C 268711D 135316 146811B 152302 135516 268711B 266090 268711A 567480 346810 733010 149303 W0CZZ W0FZZ W6640 352116 352115 35211B 359011 147582B 147582A W50400 Indoor Unit ...

Page 80: ...al Use Only Exploded View Outdoor Unit 554031 437212 435511B 552202 554160 552203A W6631 552203B 447910 552111 552201 559010 546810 435512 435301 349480 237202 437211 268711B 649950 263230B W6640 W0CZZ 263230A Discharge Thermistor 430410 152503 550140 W49810 552116 561410 261704 135500 549610 435511A 552112 ...

Page 81: ...P No 3828A20195V October 2009 ...

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