LG LW8012ER Service Manual Download

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Service Manual 3

Safety Precautions

Safety Precautions

To prevent injury to the user or other people and property damage, the following instructions must
be followed.

■

Incorrect operation due to ignoring instruction will cause harm or damage. The seriousness is
classified by the following indications.

■

Meanings of symbols used in this manual are as shown below.

WARNING

CAUTION

This symbol indicates the possibility of death or serious injury.

This symbol indicates the possibility of injury or damage to property only.

Be sure not to do.

Be sure to follow the instruction.

WARNING

Always install the expansion panel(s).

• Improper assembly or installation may cause

incorrect operation, including injury, fire, and
electric shock hazards.

Do not place the power cord near a heater.

• It may cause fire and electric shock.

Do not use the power cord near flammable
gas or combustibles such as gasoline,
benzene, thinner, etc.

• It may cause explosion or fire.

Do not disassemble or modify products.

• It may cause electric shock and failure.

Gasolin

Summary of Contents for LW8012ER

Page 1: ...LG Room Air Conditioner SERVICE MANUAL LG CAUTION website http www lgservice com BEFORE SERVICING THE UNIT READ THE SAFETY PRECAUTIONS IN THIS MANUAL ONLY FOR AUTHORIZED SERVICE PERSONNEL MODEL LW8012ER ...

Page 2: ...e Drain Pipe 8 How to Install 9 Operation 12 Function of Controls 12 Disassembly 13 Mechanical Parts 13 Air handling Parts 14 Electrical Parts 15 Refrigerating Cycle 17 Schematic Diagram 20 Electronic Control Device 20 Wiring Diagram 21 Components Location 22 Troubleshooting Guide 23 Pipeing System 23 Troubleshooting Guide 24 Electrical Parts Troubleshooting Guide 26 Electrical Parts 30 Exploded V...

Page 3: ...ity of death or serious injury This symbol indicates the possibility of injury or damage to property only Be sure not to do Be sure to follow the instruction WARNING Always install the expansion panel s Improper assembly or installation may cause incorrect operation including injury fire and electric shock hazards Do not place the power cord near a heater It may cause fire and electric shock Do no...

Page 4: ... power cord length It will cause electric shock or fire Use the air conditioner on a single outlet circuit Do not share the outlet with other appliances It will cause electric shock or fire Always plug into a grounded outlet No grounding may cause electric shock Do not use the socket if it is loose or damaged It may cause fire and electric shock Do not operate with wet hands or in damp environment...

Page 5: ...hock Never touch the metal parts of the unit when removing the filter They are sharp and may cause injury Do not block the inlet or outlet It may cause failure of appliance or performance deteriorate Ensure that the outer case is not damaged by age or wear If the outer case is damaged it must be repaired or replaced immediately Leaving it damaged could result in the air condi tioner falling out of...

Page 6: ... 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 497 F TIMER POWER MODE TEMP FAN SPEED F1 LOW F2 MED F3 HIGH Dry Timer Fan Energy Saver Cool 516 367 ...

Page 7: ...ted Amps Heating Features Thermostat Control Air Diflection Remote controller Auto swing Energy saver Fuction Timer Sleep Fan Speed Cooling Heating Fan Only Compressor In Door Fan Type Type Air Discharge Outdoor Vent Exhaust Rear grille Chassis Type LW8012ER 8 000 10 8 2 2 250 54 60 340 115 740 6 9 Thermistor 4 Way Yes Yes 24Hr On Off 3 3 Rotary TURBO Top Discharge Yes Top Down Product Specificati...

Page 8: ...lower than the front about 1 4 This will force condensed water to the outside 5 Install the unit with the bottom about 30 60 above the floor level The setting conditions must be checked prior to initial starting The following items are especially important checking points when the installation is finished 1 Grounding wire Green or Green and Yellow is provided in the power cord The green wire must ...

Page 9: ...er than the storm window frame STORM WINDOW FRAME or wood strip OUT DOORS to help condensation to drain properly to the outside 3 Install a second wood strip approximately 6 long by 11 2 wide and same thickness as first strip in the center of the outer sill flush against the back off the inner sill This will raise the L bracket as shown Figure 4 4 If the distance between STORM WINDOW FRAME and WOO...

Page 10: ...ng step hold unit firmly until window sash is lowered to top channel behind side panel frames Personal injury or property damage may result if unit falls from window 3 INSTALL THE AIR CONDITIONER IN THE WINDOW a Carefully lift the air conditioner and slide it into the open window Make sure the bottom guide of the air condition er drops into the notches of the L bracket See Figure 8 IMPORTANT When ...

Page 11: ...gure 11 6 Window installation of room air conditioner is now completed See ELECTRICAL DATA for attaching power cord to electrical outlet REMOVAL FROM WINDOW Trun the air conditioner off disconnect the power cord remove the L bracket and the screws installed through the top and bottom of the guide panels and save for reinstalla tion later Close the guide panels keeping a firm grip on the air condit...

Page 12: ...be set within a range of 60 F to 86 F by 1 F 16 C to 30 C by 1 C Select the lower number for lower temperature of the room OPERATION MODE SELECTION BUTTON Every time you push this button it will shift among COOL ENERGY SAVER FAN and DRY Energy Saver If Energy Save mode is selected the fan stops when the compressor stops cooling a Approximately every 3 minutes the fan will turn on and check the roo...

Page 13: ...install the components by referring to the removal procedure above 3 Control Box 1 Remove the front grille Refer to section 1 2 Remove the cabinet Refer to section 2 3 Remove the 1 screw which fasten the power cord 4 Disconnect the grounding screw from the evaporator channel 5 Remove the 2 screws that fastens the control box cover 6 Remove the housing that connects PCB and motor wire in the contro...

Page 14: ...11 Remove the clamp with hand pliers which secures the turbo fan 12 Remove the turbo fan 13 Remove the 2 screws that fasten the air guide from the base pan 14 Move the air guide backward and pull out from the base pan Move the air giude lower carefully 15 Re install the components by referring to the removal procedure above 5 FAN 1 Remove the cabinet Refer to section 2 2 Remove the brace Refer to ...

Page 15: ...eave the valve in place after servicing the system 3 Remove the overload protector Refer to sec tion 7 4 After purging the unit completely unbraze the suction and discharge tubes at the compressor connections 5 Remove the 3 nuts and the 3 washers which fasten the compressor 6 Remove the compressor See Figure 20 7 Re install the components by referring to the removal procedure above Service Manual ...

Page 16: ...only one ground marked hole for ground connection 7 If the supply cord of this appliance is damaged it must be replaced by the special cord The special cord means the cord which has the same specification marked on the supply cord attached at the unit 11 Motor 1 Remove the cabinet Refer to section 2 2 Remove the turbo fan Refer to section 4 3 Remove the fan Refer to section 5 4 Remove the 4 screws...

Page 17: ...6 Re install the components by referring to notes See Figure 23 13 Evaporator 1 Remove the control box Refer to section 3 2 Remove the air guide upper Refer to section 4 3 Remove the 2 screws that fasten the evapora tor 4 Move the evaporator sideways carefully Refer to section 4 5 After discharging the refrigerant completely unbraze the interconnecting tube at the evapo rator connections 6 Remove ...

Page 18: ...a possible leak or moisture remaining in the system With valves A and B closed stop the vacuum pump 4 Remove the hose from the vacuum pump and place it on the charging cylinder See figure 25B Open valve C Discharge the line at the manifold connection 5 The system is now ready for final charging 6 Recharge as follows 1 Refrigeration cycle systems are charged from the High side If the total charge c...

Page 19: ...making a vapor proof seal Leak detector Tubing cutter Hand Tools to remove components Service valve A COMPOUND GAUGE EVAPORATOR LOW PRESSURE SIDE COMPRESSOR CAPILLARY TUBE CONDENSER HIGH PRESSURE SIDE SEE INSETS BELOW MANIFOLD GAUGE B Figure 25A Pulling Vacuum Figure 25B Charging A B EXTERNAL VACUUM PUMP A CHARGING CYLINDER LOW HI B C ...

Page 20: ... 6 680pF C01L R01P 20K 50V 3 Digit0 5 10 a f a b Digit1 a 3 9 b 8 c d f d e d c 7 e 4 f 1 g e 6 g g COOL DEFROST DRY HEAT TIMER FAN E SAVER R02G R03G R04G R01G 680 680 680 680 R05G R06G R07G 12V 680 680 680 IC01G 15 14 13 4 3 2 16 1 12 11 10 7 6 5 9 8 ULN2004A 10K 5V 5V R12F R01E 1K 5V C06D BZ01E PKM13EPY 4002 C05D 50V 10V 220 0 01 10 12V 11 12 CN AC DC 51581 12 YEONHO 52044 1245 MOLEX C05D 5V 12V...

Page 21: ...SCRIPTION REMARKS Q TY PER SET MOTOR COMP CAPACITOR DC PCB ASSEMBLY THERMISTOR AIR FILTER ASSEMBLY AC PCB ASSEMBLY WIRING DIAGRAM SWITCH H V ASSEMBLY BK CN MOTOR CN PWR DC12V ZNR01J CN 12V CN HVB RY COMP 3 4 FUSE 250V T3 15A RY LOW RY MED RY HI CN AC DC POWER TRANS CN AC DC CN TH1 BL RD RD BK BL R S C OLP YL OR YL F C H WH BL Ribbed BK BR Plain GN YL GN GN YL GN BK RD OR BR 1 5 7 6 8 4 2 3 S Servi...

Page 22: ...04D D05D IC01D HEAT SINK QIC02DT J5 Q01T CN TELE CN TH2 CN PWR CN MOTOR ZNR01J CN 4WAY C01J R01J E03J E04J POWER TRANS FUSE 250V T3 15A RY COMP E05J E02J J8 E01J J6 J2 J3 RY HI PCB 6870A90068D ASSEMBLY 6871A20417C RY MED RY LOW RY 4WAY J7 J4 J1 D01T C02T Q02T CN CON CN 12V CN AC DC 2 DISPLAY P C B ASSEMBLY PCB 6870A90067C ASSEMBLY 6871A20418A ...

Page 23: ...ling cycle MOTOR COMPRESSOR OIL LIQUID REFRIGERANT CAPILLARY TUBE OUTSIDE COOLING AIR FOR REFRIGERANT PASS THROUGH SUCTION LINE COOL LOW PRESSURE VAPOR COOLED AIR COMPLETE LIQUID BOIL OFF POINT LIQUID PRESSURE DROP ROOM AIR HEAT LOAD VAPOR INLET HOT DISCHARGED AIR LIQUID OUTLET HIGH PRESSURE VAPOR LIQUID REFRIGERANT LOW PRESSURE VAPOR ROOM AIR CONITIONER EVAPORATOR COILS CONDENSER COILS CYCLE OF R...

Page 24: ...fan operation Check gas leakage Repair gas leak Replacement of unit if the unit is beyond repair Satisfactory operation with temperature difference of inlet outlet air 44 50 F 7 10 C Check heat load increase Clean condenser Not on separate circuit Check inside gas pressure Adjusting of refrigerant charged Malfunction of compressor Replacement of compressor Check cold air circulation for smooth flo...

Page 25: ...gular motor insulation Replacement of fan motor Regular but fails to start Replacement of compressor locking of rotor metal Improper thermostat setting Loose terminal connection Improper wiring Irregular motor resistance Irregular motor insulation Replacement of compressor Motor damaged Drop of power voltage Capacitor check Replacement Compressor only fails to start Defect of compressor capacitor ...

Page 26: ...No 18 of Micom DC 5V Replace AC PCB Ass y Is the connection between AC and DC OK Is the reset circuit good The No 14 of Micom is 5V Check the Fuse Check the wiring diagram Check the Main PCB pattern Replace the Trans Replace D02D D05D Replace IC01D Replace IC02D Replace IC01A C02A Connect connector exactly Check the PCB pattern NO NO NO NO NO NO NO YES YES YES YES YES YES YES NO YES Possible Troub...

Page 27: ...m Temp 0 5 C Is the voltage No 10 of IC01M 0V Replace IC01M Select the setting Temp to lower Number Wait 3 Minutes Does the Unit delay for 3 minutes Replace MAIN PCB Ass y Is the voltage N0 9 of IC01M DC 12V Check the RY COMP Check the wiring Diagram NO NO NO YES YES YES YES Is the wire connection of RY COMP OK Check the RY COMP Connect LEAD Wire to RY COMP again NO YES NO ...

Page 28: ... NO 1 or 2 or 4 of IC01M DC 12V Is the voltage NO 16 or 15 or 13 of IC01M 0V Check the RY Hi or RY Med or RY Lo Check the wiring diagram NO NO YES YES NO NO YES YES Is the mode key pushed once more from cool mode Is the voltage No 3 of CN AC DC of AC PCB Ass y DC 5V Reference to OWNER S MANUAL Set the mode key to Energy Saver mode Check the Energy Saver mode key Check the pattern of AC DC PCB ...

Page 29: ...y Replace IC01G Replace IC03G Q01G Q02G Q03G for Delux Model Connect connector to CN AC DC exactly Does the IC03G Q01G Q02G Q03G for Delux Model operate normally on DC PCB Ass y Check the PCB pattern Is the voltage of Battery over 2 3V Replace Receiver Ass y Is the connection of CN AC DC OK Is the voltage No 10 of CN AC DC on DC PCB Ass y DC 5V Replace the battery Check the PCB pattern Connect con...

Page 30: ... the voltage No 40 of Micom DC 5V Replace AC PCB Ass y Is the connection between AC and DC OK Is the reset circuit OK The No 14 of Micom is 5V Check the Fuse Check the wiring diagram Check the AC PCB pattern Replace the Trans Replace D02D D05D Replace IC01D Replace IC02D Replace IC01A C01A Connect connector exactly Check the PCB pattern NO NO NO NO NO NO NO YES YES YES YES YES YES YES NO YES Possi...

Page 31: ...oom Temp 0 5 C Is the voltage No 10 of IC01M 0V Replace IC01M Select the desired Temp to lower Number Wait 3 Minutes Is the Unit for 3 minutes delay Replace AC PCB Ass y Is the voltage N0 9 of IC01M DC 12V Check the RY COMP Check the wiring Diagram NO NO NO YES YES YES YES Is the wire connection of RY COMP OK Check the RY COMP Connect LEAD Wire to RY COMP again NO YES NO ...

Page 32: ... IC01M DC 5V Is the voltage NO 16 or 15 or 13 of IC01M 0V Check the RY Hi or RY Med or RY Lo Check the wiring diagram NO NO YES YES Check the PCB pattern Is the voltage of Battery over 2 3V Replace Receiver Ass y Is the connection of CN AC DC OK Is the voltage No 10 of CN AC DC on AC PCB Ass y DC 5V Replace the battery Check the PCB pattern Connect connector to CN AC DC exactly NO NO NO YES YES YE...

Page 33: ...t displays abnormally on DC PCB Ass y NO NO NO NO YES YES YES Are IC01G and IC02G OK Is the connection of CN AC DC OK Replace the DC PCB Ass y Replace IC01G IC02G Replace IC03G Connect connector to CN AC DC exactly Does the IC03G operate normally on AC PCB Ass y ...

Page 34: ...ngs Does the fan blade rotate freely If not replace fan motor Pay attention to any change from high speed to low speed If the speed does not change replace the motor If cracked out of balance or partially missing replace it If cracked out of balance or partially missing replace it Tighten it If knocking sounds continue when running or loose replace the motor If the motor hums or noise appears to b...

Page 35: ...cleaner do not damage fins or brush Clean the interior base before reassembling If condenser fins are closed over a large area on the coil surface head pressures will increase causing the compressor to overload Straighten the fins or replace the coil Test capacitor Check the terminals If loose repair or replace Check the system for a restriction If restricted clean of replace Close if open Determi...

Page 36: ... 349001 2 147581 147582 1 359011 349480 W48602 354210 267110 731373 132111 2 132111 1 159830 130411 554160 567502 135312 135303 352380 2 352380 1 352380 3 749740 147582 2 349001 1 145200 552113 352113 352115 35211A 268711 2 268711 1 238310 W0CZZ 135500 249950 567480 237200 264110 554030 ...

Page 37: ...P NO 3828A29003C January 2005 Printed in China ...

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