LG LWHD1200R Service Manual Download

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Room

Air Conditioner

SERVICE MANUAL

MODEL: LWHD1200R

CAUTION

website http://www.lgservice.com

• BEFORE SERVICING THE UNIT, READ THE SAFETY

PRECAUTIONS IN THIS MANUAL.

• ONLY FOR AUTHORIZED SERVICE PERSONNEL.

Summary of Contents for LWHD1200R

Page 1: ...G Room Air Conditioner SERVICE MANUAL LG MODEL LWHD1200R CAUTION website http www lgservice com BEFORE SERVICING THE UNIT READ THE SAFETY PRECAUTIONS IN THIS MANUAL ONLY FOR AUTHORIZED SERVICE PERSONNEL ...

Page 2: ...How to Install 8 Suggested Tool Requirements 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 23 Electrical Parts Troubleshooting Guide 26 Electrical Part...

Page 3: ...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 Installation Do not use damaged power cord plugs or a loose socket There is risk of fire or electric shock Always...

Page 4: ...ing and installing the product Sharp edges could cause injury Be especially careful of the case edges and the fins on the condenser and evaporator Do not store or use flammable gas or com bustibles near the air conditioner There is risk of fire or failure of product Be sure the installation area does not deterio rate with age If the base collapses the air conditioner could fall with it causing pro...

Page 5: ...r Cool W mm inch 600 23 5 8 H mm inch 380 14 31 32 D mm inch 567 22 5 16 Model Dimension HBLG1203R R1200E Outside Dimensions This symbol alerts you to the risk of electric shock This symbol alerts you to hazards that could cause harm to the air conditioner This symbol indicates special notes NOTICE Symbols Used in this Manual ...

Page 6: ...IN SYSTEM NET WEIGHT lbs kg OUTSIDE DIMENSION inch W x H x D mm 1ø 115 60Hz 12 000 1 220 11 0 9 8 19 4 WB 23 9 WB 490 17 3 oz 2 ROW 12 STACKS 2 ROW17 STACKS TURBO FAN PROPELLER TYPE FAN WITH SLINGER RING 3 3 6 POLES REMOTE CONTROLLER THERMISTOR VERTICAL LOUVER RIGHT LEFT HORIZONTAL LOUVER UP DOWN SLIDE IN OUT CHASSIS OVERLOAD PROTECTOR INTERNAL THERMAL PROTECTOR 3 WIRE WITH GROUDING ATTACHMENT PLU...

Page 7: ... the installation is finished 1 Grounding wire Green or Green and Yellow is provided in the power cord The green wire must be grounded 2 Connect to a single outlet 15A circuit or 20A circuit for Electric Heater Model 3 To avoid vibration or noise make sure the air conditioner is installed securely 4 Avoid placing furniture or draperies in front of the air inlet and outlet In humid weather excess w...

Page 8: ...MP FAN SPEED F1 LOW F2 MED F3 HIGH Dry Timer Fan Energy Saver Cool 1 WINDOW WIDTH A HEIGHT B 2 GASKET 3 WALL 4 DETAILS 5 1 x 30 ROUND HEAD WOOD SCREWS A B C D E F H I 625mm 392mm 280mm 30mm 0 25mm OVER 420mm 5 10mm 5 5mm 245 8 157 16 111 32 11 16 0 1 OVER 1617 32 3 16 3 8 3 16 3 16 27 to 39 16 min Stool Interior wall 235 8 min Without frame curtain Offset 1 2 to 11 4 Sill Exterior 1 2 3 4 8 11 12 ...

Page 9: ... to the unit with 4 Type A screws at the both sides Cabinet Installation 1 Open the window Mark a line on center of the win dow stool or desired air conditioner location Carefully place the cabinet on the window stool and align the center mark on the front angle with the center line marked in the window stool 2 Pull the bottom window sash down behind the upper guide until it meets Do not pull the ...

Page 10: ...ame Guides are broken easily 5 Attach the sill support to the cabinet track hole in relation to the selected position using 2 Type A screws in each support See Figure 5 6 The cabinet should be installed with a very slight tilt about 1 2 downward toward the outside See Figure 6 Adjust the bolt and the nut of Sill Support for balancing the cabinet 7 Attach the cabinet to the window stool by driving ...

Page 11: ...et See Fig 8 CAUTION For security purpose reinstall screws Type A at the cabinet s sides 11 Cut the Foam Strip to the proper length and insert between the upper and lower window sash See Fig 9 12 Attach the window Locking Bracket with a type C screw See Fig 10 13 Attach the front grille to the cabinet by inserting the tabs on the grille into the tabs on the front of the cab inet Push the grille in...

Page 12: ...hin 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 room air to d...

Page 13: ...the grounding screw from the evaporator channel 5 Remove the 1 screw that fasten the control box cover 6 Remove the housing which connects PCB and motor wire in the control box 7 Disconnect the housing that connects Plazma Air Purifier Optional 8 Remove the screw at left cover of filter case and open the cover to remove inner screw Optional 9 Remove the nut that fastens the terminal cover 10 Remov...

Page 14: ...Pull out the hook of orifice by pushing the tabs and remove it See Figure 19 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 abo...

Page 15: ...Remove the cabinet Refer to section 2 2 Discharge the refrigerant system using a FreonTM Recovery System If there is no valve to attach the recovery sys tem install one such as a WATCO A 1 before venting the FreonTM Leave 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 t...

Page 16: ...nel from the control box See Figure 25 4 Disconnect two leads from the capacitor and relay 5 Pull out the power cord 6 Re install the component by referring to the above removal procedure above Use 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 specificati...

Page 17: ...net Refer to section 2 2 Remove the 4 screws that fasten the brace Refer to section 4 3 Remove the 5 screws that fasten the condenser and shroud 4 After discharging the refrigerant completely unbraze the interconnecting tube at the con denser connections 5 Remove the condenser 6 Re install the components by referring to notes See Figure 27 13 Evaporator 1 Remove the control box Refer to section 3 ...

Page 18: ...acuum pump and place it on the charging cylinder See figure 29B 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 cannot be put in the High side the balance will be put in the suction line through the access valve which you installed as the sy...

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 29A Pulling Vacuum Figure 29B Charging A B EXTERNAL VACUUM PUMP A CHARGING CYLINDER LOW HI B C ...

Page 20: ...3 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 12...

Page 21: ... REMARKS Q TY PER SET MOTOR COMP CAPACITOR DC PCB ASSEMBLY THERMISTOR AIR FILTER ASSEMBLY AC PCB ASSEMBLY WIRING DIAGRAM 3854AR3563N SWITCH H V ASSEMBLY BK CN MOTOR CN PWR DC12V ZNR01J CN 12V CN HVB RY COMP 3 4 FUSE 250V T2A 115V T2A 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 ...

Page 22: ...01D C02D D02D D03D D04D 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 T2A RY COMP E05J E02J J8 E01J J6 J2 J3 RY HI PCB 6870A90068A ASSEMBLY 6871A20167 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 ...

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: ...the voltage 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 Po...

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: ...02D DC 5V Is 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 ...

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: ...4 268712 238310 W0CZZ 135500 249950 147581 147582 559010 552111 352113 352115 263230 237200 W48602 352390 2 148000 354212 267110 152312 152302 264110 130410 550140 35211A 554160 567502 135312 135313 352390 1 C TIMER PO WER MODE TE MP FA N SP EE D F1 LOW F2 MED F3 HIG H Dr y Tim er Fa n En erg y Sa ver Co ol ...

Page 37: ...64110 POWER CORD ASS Y 6411A20048U R 267110 REMOTE CONTROLLER ASSEMBLY 6711A20034G R 346811 MOTOR ASS Y 4681A20069J R 349001 VENTILATION DAMPER 4900A20002A R 349480 ORIFICE 4948A10015A R 352111 TUBE ASS Y CAPILLARY 5211A32004A R 352113 DISCHARGE TUBE 5211A10074S R 352115 TUBE FORMED EVAPORATOR 5210A21099J R 35211A SUCTION TUBE ASS Y 5211A20441J R 352390 1 AIR GUIDE ASSEMBLY 5239A20004A R 354212 EV...

Page 38: ...P No 3828A29003B January 2005 Printed in China ...

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