LG LS-K1863PL Service Manual Download Page 1

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SERVICE MANUAL

Room Air Conditioner

CAUTION

BEFORE SERVICING THE UNIT, READ THE SAFETY
PRECAUTIONS IN THIS MANUAL.

ONLY FOR AUTHORIZED SERVICE PERSONNEL.

MODEL : LS-K1863PL/RR

LS-K2462PL
LS-K1864PL
LS-K2463PL
(Applied to new Refrigerant R-410A)

WEBSITE

http://biz.LGservice.com

E-MAIL

http://www.LGEservice.com/techsup.html

Summary of Contents for LS-K1863PL

Page 1: ...ICING THE UNIT READ THE SAFETY PRECAUTIONS IN THIS MANUAL ONLY FOR AUTHORIZED SERVICE PERSONNEL MODEL LS K1863PL RR LS K2462PL LS K1864PL LS K2463PL Applied to new Refrigerant R 410A WEBSITE http biz LGservice com E MAIL http www LGEservice com techsup html ...

Page 2: ... Details 10 Display Function 17 Self diagnosis Function 17 Installation 18 Operation 31 Disassembly of the parts Indoor Unit 32 2 way 3 way Valve 35 Cycle Troubleshooting Guide 43 Electronic Parts Troubleshooting Guide 44 Electronic Control Device 51 Schematic Diagram 54 Exploded View and Replacement Parts List 55 2 ...

Page 3: ...hed to intermittent or irregular operation The fan speed is automatically switched from high to low speed The louver can be set at the desired position or swing up and down automatically Indoor Unit Operation ON OFF by Remote controller Sensing the Room Temperature Room temperature control Starting Current Control Time Delay Safety Control Indoor Fan Speed Control Operation indication Lamps LED So...

Page 4: ...W HIGH Cooling Operation Mode Heating Operation Mode Auto Operation Mode Fan Operation Mode Horizontal Airflow Direction Control Button Optional Room Temperature Display Setting the Time or Timer PLASMA Optional ON OFF SET PLASMA CANCEL Fan Speed Selection Low Med High CHAOS High 39 C Low 11 C OFF ON OFF ON Cancel Sleep Mode Timer ON or Timer OFF 1 2 3 4 5 6 7 Off Timer Fan Operates without coolin...

Page 5: ...ose Connecting Cable Power Cord Air Circulation Noise Level Input m3 min dB A 3 Indoor Outdoor Indoor Outdoor Indoor Outdoor Indoor Outdoor Indoor Outdoor Liquid Gas Service Valve Motor Output Dimensions W x H x D Net Weight W mm kg LS K186_Series LS K246_Series SPEC AT 230V 18000 19000 2 5 1Ø 220 240V 50Hz 12 42 39 53 1900 1950 8 5 9 9 47 2 85 20 62 1 080 x 314 x 181 870 x 655 x 320 12 59 1 300 O...

Page 6: ... 6 Tubing hole cover D H W Installation plate Dimensions 1 Indoor Unit MODEL DIM Unit W mm 1 080 H mm 314 D mm 181 ALL MODELS ...

Page 7: ... W L7 L6 L8 L9 D L1 L2 L3 L10 L11 L4 L5 H Gas side Liquid side MODEL DIM W mm 870 H mm 655 D mm 320 L1 mm 370 L2 mm 340 L3 mm 25 L4 mm 630 L5 mm 25 L6 mm 546 L7 mm 162 L8 mm 162 L9 mm 54 L10 mm 74 5 L11 mm 79 ALL MODELS ...

Page 8: ...CHANGE EVAPORATOR HEAT EXCHANGE CONDENSER HEAT EXCHANGE CONDENSER COMPRESSOR COMPRESSOR ACCUMU LATOR GAS SIDE GAS SIDE VALVE LIQUID SIDE LIQUID SIDE VALVE CAPILLARY TUBE CAPILLARY TUBE CHECK VALVE Heating Model only COOLING HEATING REVERSING VALVE Heating Model Only 1 Cooling Only Models 2 Cooling Heating Models ...

Page 9: ...N BR RD RD BR BL BK RD GN YL BR BL BK RD GN YL BK RD RD BR BR OR BK RD YL BK YL GN YL H C F 4 1 L 3 COMP FAN MOTOR REVERSING REVERSING VAL ALVE VE TERMINAL TERMINAL BLOCK BLOCK CAPACITOR HEA HEATER T B 3 T B 1 T B 4 TO INDOOR UNIT OUTDOOR WIRING DIAGRAM 3854A20051P PTC PRESSURE PRESSURE SWITCH SWITCH C S R 2 N BR RD RD BR BL BK RD GN YL BR BL BK RD GN YL BK RD RD BR BR OR BK RD YL BK YL H C F 4 1 ...

Page 10: ...r ON while in timer mode on off OFF when timer mode is completed or canceled Defrost Indicator OFF except when hot start during heating mode operation or while in defrost control Cooling Mode Operation When the intake air temperature reaches 0 5 C below the setting temp the compressor and the outdoor fan stop When it reaches 0 5 C above the setting temp they start to operate again Compressor ON Te...

Page 11: ...rry out defrost control or not and the time of defrost control are determined according to the following conditions 1 While in heating mode operation the maximum of the indoor pipe temperature is measured and it is com pared with the present indoor pipe temperature to get the difference of the indoor pipe temperatures the maximum temperature of indoor pipe the present temperature of indoor pipe ac...

Page 12: ...oor fan is operated for 15 seconds Then an operation mode is selected according to the intake air temp at that moment as follows 24 C Inatake Air Temp Fuzzy Operation for Cooling 21 C Inatake Air Temp 24 C Fuzzy Operation for Dehumidification Inatake Air Temp 21 C Fuzzy Operation for Heating If any of the operation modes among cooling dehumidification heating mode operations is carried out for 10 ...

Page 13: ...d by Fuzzy rule when the intake air temp is 3 C or more above the setting temp the compressor is turned off When below the setting temp the compressor is turned on Compressor ON Temp Setting Temp Compressor OFF Temp Setting Temp 3 C At the beginning of Fuzzy mode operation the setting temperature is automatically selected according to the intake air temp at that time 20 C Intake Air Temp Intake Ai...

Page 14: ... cannot be input While in cooling mode operation 30 min later since the start of the sleep timer the setting temperature increases by 1 C After another 30 min elapse it increases by 1 C again When the sleep timer mode is input while in cooling cycle mode the airflow speed of the indoor fan is set to the low When the sleep timer mode is input while in heating cycle mode the airflow speed of the ind...

Page 15: ...s pressed If you want to stop operation re press the button While in forced operation the key input by the remote control has no effect and the buzzer sounds 10 times to indicate the forced operation Test operation During the TEST OPERATION the unit operates in cooling mode at high speed fan regardless of room tem perature and resets in 18 1 minutes During test operation if remote controller signa...

Page 16: ...pipe from frosting When the indoor pipe temp is 7 C or higher after 3 min pause of the compressor the compressor and the outdoor fan is turned on according to the condition of the room temperature Buzzer Sounding Operation When the appliance operation key is input by the remote control the short beep beep sounds When the appliance pause key is input by the remote control the long beep sounds When ...

Page 17: ... Thermistor assembly check Communication line circuit check SVC check point 1 Heating Model 2 Cooling Model Cooling Soft Dry Fan Heating Cooling Soft Dry Fan Sleep Mode Sleep Mode Timer Mode Timer Mode Hot start Defrost PLASMA Mode PLASMA Mode Telephone Control Mode Telephone Control Mode Operation Indicator Timer Indicator Sleep Timer Indicator Defrost Indicator PLASMA Indicator Telephone control...

Page 18: ...bration are minimum Select a place so that the warm air and noise from the air conditioner do not disturb neighbors 2 Piping length and elevation Installation 1 Installation of indoor Outdoor unit 18 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 Install the indoor unit on the wall where the height from the floors more ...

Page 19: ... the walls typi cally Drilling the hole through the wall for piping connections must be done safely 4 Drill a hole in the wall Drill the piping hole with a ø70mm hole core drill Drill the piping hole at either the right or the left with the hole slightly slanted to the outdoor side Installation Plate Type A screw 5 7mm 3 16 5 16 Indoor WALL Outdoor Installation plate Ø70mm Left rear piping Right r...

Page 20: ...bing 3 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 4 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 5 Check Compare the flared work with figure below If flare is noted to be...

Page 21: ...al so that dripping from sweating condensation will not damage furniture or floors Foamed polyethylene or equivalent is recommended 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 instal lation plate Ensure that the hooks are properly seat ed on the installation plate...

Page 22: ...r where they fit into the rear piping housing section 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 For left rear piping 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 Open end wrench fixed Connectio...

Page 23: ...nch 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 piping housing section with vinyl tape mm inch kg m Ø6 35 1 4 1 8 Ø...

Page 24: ...gainst the installation plate until the hooks engage into their slots clicking sound 3 Connection of the pipes Outdoor 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 the arrow on the wrench mm inch ...

Page 25: ...30k 32k 36k 38k 1 0 1 5 2 5 2 5 5 5 Unit A Indoor Indoor Indoor Outdoor Outdoor Cable Type B H05VV F H05VV F H05VV F H05RN F H05RN F NORMAL CROSS SECTIONAL AREA Grade 7k 14k 18k 24k 28k 1 0 1 5 2 5 Cable Type B H07RN F H07RN F H07RN F NORMAL CROSS SECTIONAL AREA Grade 30k 32k 36k 38k 0 75 0 75 Cable Type B H07RN F H07RN F NORMAL CROSS SECTIONAL AREA Grade mm2 mm2 mm2 The power connecting cable con...

Page 26: ... 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 voltage is maintained at more than 90 percent of the rated voltage marked on the name plate 6...

Page 27: ...n outlet should 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...

Page 28: ...as and the liquid side on the outdoor unit Note that both the liquid and the gas side service valves on the outdoor unit are kept closed at this stage 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 cylinder valve when the gauge read...

Page 29: ...curely with an adjustable wrench This process is very important to prevent leakage from the system Replace the valve caps at both gas and liquid side service valves and fasten them tight This completes air purging with a vacuum pump The air conditioner is now ready to test run 1 Remove the caps from the 2 way and 3 way valves 2 Remove the service port cap from the 3 way valve 3 To open the 2 way v...

Page 30: ...ce the gas side pressure of optimum con dition is as below Cooling NOTE If the actual pressure is higher than shown the system is most likely over charged and charge should be removed If the actual pressure are lower than shown the system is most likely undercharged and charge should be added The air conditioner is now ready for use Bolt Tubing connection Discharge temperature Discharge air Intake...

Page 31: ...t louver movement and set the desired up down airflow direction ON OFF TIMER BUTTONS Used to set the time of starting and stopping operation TIME SETTING BUTTONS Used to adjust the time TIMER SET CANCEL BUTTONS Used to set the timer when the desired time is obtained and to cancel the Timer operation SLEEP MODE AUTO BUTTON Used to set Sleep Mode Auto operation AIR CIRCULATION BUTTON Used to circula...

Page 32: ...own 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 Co...

Page 33: ...ox out from the chassis careful ly 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 34: ...emove 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 35: ... 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 nut To piping connect...

Page 36: ...hexagonal wrench to press the valve core pin discharge for three seconds and then wait for one minute Repeat this three times 5 Use torque wrench to tighten the service port nut to a torque of 1 8kg cm 6 Set the 3 way valve to the back seat 7 Mount the valve stem nuts to the 2 way and 3 way valves 8 Check for gas leakage At this time especially check for gas leakage from the 2 way and 3 way valve ...

Page 37: ...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 indicating 3 to 5kg cm2 g 8 Disconnect the charge set and mount the 2 way and 3 way valve s stem nuts and the service port nut Use torque wrench to tighten the service port nut to a torque of 1 ...

Page 38: ...nut on the 2 way 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 discharge the refrigerant until the gauge indicates 3 to 5 kg cm2 g 6 Disconnect the charge set and the gas cylinder and set the 2 way and 3 way valves to the open position Be sure to use a hexagonal wrench to operate the valve stems 7 Mount...

Page 39: ...t and discharge the refrigerant until the gauge indicates 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 refrigerant until the gauge indicates 0 5 to 1 kg cm2 G if this is the case it will not be necessary to apply a evacuatin Discharge the refrigerant gradually if it is discharged too suddenly the...

Page 40: ...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 2 Way valve Outdoor unit Liquid side Indoor unit Gas side 3 Way valve CLOSE OPEN 40 CAUTION Use vacuum p...

Page 41: ...r conditioner in the cooling cycle however one time is not sufficient 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 discharged If the system has been charged with liquid refrigerant while operating the air conditioner turn off the air conditioner befor...

Page 42: ...nd outdoor temperature Find indoor temperature onto the curve of outdoor temperature Read suction pressure at the axis of ordinates The method of using equation Calculate suction pressure after putting indoor and outdoor temperature into the equation 13 At operating the Unit for 10 minutes Suction Pressure Kg cm 2 g Outdoor Temp C Indoor Temp C 12 11 10 9 8 7 6 5 5 10 15 20 25 30 35 40 50 C 40 C 3...

Page 43: ...m air humidity When the room air humidity is relativery higher temperature difference is smaller When the room air humidity is relatively lower temperature difference is larger 2 Check temperature and pressure of refrigeration cycle Notice 1 The suction pressure is usually 4 5 6 0 kg cm2 G Cooling at normal condition 2 The temperature can be measured by attaching the thermometer to the low pressur...

Page 44: ...tor ZNR01J Check the connection housing for contacting Connector related to CN TAB1 RY COMP NO 3 Connector related to CN MOTOR Connector contacting of Outdoor Fan Compressor Display PWB Assembly Check Check each load Indoor Outdoor Fan Motor Compressor Stepping Motor and contacting condition of related connector Main PCB Board Operation Check Items SMPS Transformer Indoor unit Input Voltage Output...

Page 45: ...ttery Check the contact of CN DISP1 connector When the compressor stopped Indoor Fan is driven by a low speed At this point the wind speed is not controlled by the remote controller When operated in the Sleeping Mode the wind speed is set to the low speed by force Check Display PWB Assembly Voltage between CN DISP1 DC 5V Check the connecting circuit between the remote controller MICOM No R17 2Ω IR...

Page 46: ...ssor Outdoor Fan is stopped Check the related circuit of RY FAN Check the indoor temperature sensor is disconnected or not About 10kΩ at 25 C Turn off Main Power Check the electrical wiring diagram of outdoor side Check the abnormal condition for the component of Compressor Outdoor Fan Motor Check the open or short of conmecting wires between indoor and outdoor Check Relay RY COMP for driving comp...

Page 47: ...circuit of indoor Fan Motor The pin NO 63 of Micom and the part for driving TRIAC the input and output signal of IC01M PIN NO 2 15 Check the pattern Check the TRIAC TRIAC Open Indoor Fan Motor never operate TRIAC short Indoor Fan Motor always operates in case of ON or OFF 4 When indoor Fan does not operate The voltage of PIN NO 1 blue and 3 yellow of CN MOTOR About AC 180V over About AC 50V over T...

Page 48: ...N U D Connector If there are no problems after above checks Confirm the assembly conditions that are catching and interfering parts in the rotation radial of the Vertical Louver 5 When Vertical Louver does not operate Check the operating circuit of the Vertical Louver Confirm that there is DC 12V between pin RED of CN U D and GND Confirm that there is a soldering short at following terminals Betwe...

Page 49: ...d or not about 10KΩ at 25 C Check the indoor pipe temperature is disconnected or not about 5KΩ at 25 C Turn ON Main Power Check the DC voltage on the PWB ASSEMBLY The details of check are as followings Check point Between Micom NO 62 and GND Between IC01M NO 14 and GND Comp ON DC 5V Below DC 1V Comp OFF DC 0V About DC 12V Check point Between Micom NO 54 and GND Between IC02M NO 16 and GND 4 way ON...

Page 50: ...in Power Check the electrical wiring diagram of outdoor side Check the abnormal condition for the component of Compressor Outdoor Fan Motor 4 way Check the open or short of connecting wires between indoor and outdoor ...

Page 51: ... 51 Electronic Control Device 1 MAIN P W B ASSEMBLY AC PART TOP VIEW 1 MAIN P W B ASM AC BOTTOM VIEW ...

Page 52: ... 52 2 MAIN P W B ASSEMBLY DC PART TOP VIEW 2 MAIN P W B ASM DC BOTTOM VIEW ...

Page 53: ... 53 3 DISPLAY ASSEMBLY 6871A20194 TOP VIEW 6871A30009 TOP VIEW BOTTOM VIEW BOTTOM VIEW ...

Page 54: ...Schematic Diagram TELEPHONE CONTROL MODEL ONLY 54 ...

Page 55: ...t Parts List 1 Indoor Unit 346810 354212 263230 268714 1 264110 268714 2 131410 359011 342800 159830 135311 135312 267110 249951 152313 135314 152302 35211B 135516 W0CZZ 266090 733010 268712 159901 1 159901 2 146811 1 146811 2 352150 ...

Page 56: ... POWER CORD ASSEMBLY 6411A20013B 6411A20013C 6411A20013B 6411A20013B 6411A20013C R 267110 REMOTE CONTROLLER ASSEMBLY 6711A20010B 6711A20010B 6711A20026V 6711A20010F 6711A20010F R 268712 PWB PCB ASSEMBLY DISPLAY 6871A30009T 6871A30009T 6871A20139F 6871A30009T 6871A30009T R 268714 1 PWB PCB ASSEMBLY MAIN AC 6871A20163A 6871A20163A 6871A20163A 6871A20163A 6871A20163A R 268714 2 PWB PCB ASSEMBLY MAIN ...

Page 57: ...2 Outdoor unit 57 552203 2 552203 1 552560 261704 552111 552102 1 552201 552102 2 552116 561410 552202 553000 ...

Page 58: ...10039A R 552116 TUBE ASSEMBLY REVERSING 5221AR2938V 5221AR2014W 5221AR2938V 5221AR2938V 5221AR2014W R 552201 VALVE CHECK 5220A30004A 5220A30004A 5220A30004A 5220A30004A 5220A30004A R 552202 VALVE REVERSING 5220AR3228C 5220AR3228C 5220AR3228C 5220AR3228C 5220AR3228C R 552203 1 VALVE SERVICE 5220A20006A 5220A20001C 2H02479F 2H02479F 5220A20001C R 552203 2 VALVE SERVICE 2H02479B 5220A20006A 5220A2000...

Page 59: ...P No 3828A20135E February 2003 Printed in Korea ...

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