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Service Manual 21

Troubleshooting guide

Troubleshooting guide

Piping system

CAPILLARY TUBE

COMPRESSOR

BLOWER

EVAPORATOR COIL

CONDENSER COIL

FAN

MOTOR

: REFRIGERANT FLOW

MOTOR

COMPRESSOR

OIL

(LIQUID REFRIGERANT)

CAPILLARY TUBE

OUTSIDE COOLING
AIR FOR REFRIGERANT
PASS THROUGH

SUCTION LIME
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 PEFRIGERANT

LOW PRESSURE VAPOR

ROOM AIR CONDITIONER

EVAPORATOR COILS

CONDENSER COILS

CYCLE OF REFRIGERATION

Following is a brief description of the important components and their functions in the refrigeration system.

Refer to Fig. 36 to follow the refrigeration cycle and the flow of the refrigerant in the cooling cycle.

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Summary of Contents for M2400HR

Page 1: ...S website http www lgservice com BEFORE SERVICING THE UNIT READ THE SAFETY PRECAUTIONS IN THIS MANUAL ONLY FOR AUTHORIZED SERVICE Therm ostat Operat ion Wait Three Minutes Before Restarting Cooler Warmer Off Auto Swing Off On Fan Fan Low Heat Low Cool High Cool High Heat CAUTION ...

Page 2: ...n 9 Operation 11 Features 11 Control Locations Function of Controls 11 Disassembly instructions 13 Mechanical parts 13 Air Handling Parts 14 Electrical Parts 15 Refrigeration cycle 18 Troubleshooting guide 21 Piping System 21 Troubleshooting guide 22 Schematic Diagram 27 Electronic Control Device 27 Components location Main P W B Assembly 28 Wiring Diagram 29 Product Specifications 31 Exploded Vie...

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 WARNING Installation Do not use damaged power cord plugs or a loose socket There is risk of fire or electric shock Always use the power plug and socket with the ground termi...

Page 4: ...nd 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 property...

Page 5: ... 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 Service Manual 5 ...

Page 6: ...ower cord must be connected to an independent cir cuit The green wire must be grounded 9 Connect the drain tube to the base pan hole in the rear side if you need to drain consult a dealer Plastic hose or equivalent may be connected to the drain tube The grille is designed to clean the filter both upward and downward A BEFORE ATTACHING THE FRONT GRILLE TO THE CAB INET IF YOU WANT TO PULL OUT THE FI...

Page 7: ...ficiently to allow a clear vertical opening of 18 from the bot tom of the upper sash to the window stool 2 The stool offset height between the stool and sill must be less than 1 1 4 Installation Kits Contents some models including installation kit Foam PE Adhesive Backed Foam PE Adhesive Backed Type C 5 Type D 2 Type A 14 Carriage Bolt 2 Lock Nut 4 Top retainer bar Type B 7 Foam strip Plain Back R...

Page 8: ...h 3 holes and attach it to the bottom of the Top retainer bar 5 Attach the Top retainer bar onto the top of the cabinet with 3 screws Type A 6 Insert the Frame guides into the bottom of the cabinet 7 Insert the Frame Curtain into the Top retainer bar and Frame guides 8 Fasten the curtains to the unit with 10 screws Type A at both sides Foam PE Top retainer bar Top retainer bar Foam PE Screw Type A...

Page 9: ...utward CAUTION Do not drill a hole in the bottom pan The unit is designed to operate with approximately 1 2 of water in bottom pan 4 Pull the bottom window sash down behind the Top retainer bar until they meet 1 Do not pull the window sash down so tightly that the movement of Frame curtain is restricted Attach the cabinet to the window stool by driving the screws Type B through the cabinet into wi...

Page 10: ...the grille into the tabs on the front of the cabi net Push the grille in until it snaps into place See Fig 34 11 Lift the inlet grille and secure it with a screw Type A through the front grille See Fig 14 12 Window installation of room air conditioner is now completed Power Cord Screw Type A Screw Window locking bracket Foam Strip Screw Type C Thermo stat Operat ion Wait Three Minutes Before Resta...

Page 11: ...Turns the air conditioner off FAN Permits the low fan speed operation without cooling heating LOW COOL Permits cooling with the low fan speed operation HIGH COOL Permits cooling with the high fan speed operation LOW HEAT Permits heating with the low fan speed operation HIGH HEAT Permits heating with the high fan speed operation AUTO SWING ON Starts the operation of air swing OFF Stops the operatio...

Page 12: ...urs 9Hours 10Hours 11Hours 12Hours Cancel 4 FAN SPEED SELECTOR Everytime you push this button it is set as follows Hi Low Hi 5 ROOM TEMPERATURE SETTING BUTTON This button can automatically control the temperature of the room The temperature can be set within a range of 60 F to 86 F by 1 F 6 AUTO SWING This button can automatically control the air flow direction 7 ENERGY SAVER The fan stops when th...

Page 13: ...rmo stat Operatio n Wait Three Minutes Before Restarting Cooler Warmer Off Auto Swing Off On Fan Fan Low Heat Low Cool High Cool High Heat Figure 18 2 Cabinet 1 After disassembling the front grille remove the screws which fasten the cabinet at both sides Keep these for later use 2 Remove the two screws which fasten the cabinet at back See Fig 17 3 Pull the base pan forward 3 Control box 1 Remove t...

Page 14: ...e See Fig 19 3 Move the evaporator sideward carefully 4 Remove the 2 terminals carefully See Fig 20 5 Remove the 3 screws which fasten the Heater Cover See Fig 20 6 Remove the Heater Cover See Fig 20 7 Remove the orifice from the air guide carefully See Fig 21 8 Remove the clamp which secures the blower with plier See Fig 21 9 Remove the blower with plier or your hand without touching blades See F...

Page 15: ...n control box Refer to section 3 3 Remove the blower Refer to section 5 4 Remove the fan Refer to section 6 5 Remove the 4 screws which fasten the motor See Fig 25 6 Remove the motor 7 Re install the components by referring to the removal pro cedure above 9 Compressor 1 Remove the cabinet Refer to section 2 2 Discharge the refrigerant system using FreonTM Recovery System If there is no valve to at...

Page 16: ...ng screw from the control box 4 Disconnect 2 receptacles 5 Remove a screw which fastens the clip cord 6 Pull the power cord See Fig 28 7 Re install the component by referring to the removal pro cedure above Use only one ground marked hole for ground connection 8 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 sam...

Page 17: ...fer to section 10 3 Remove 2 screws which fasten the rotary switch 4 Disconnect all the leads of the rotary switch terminals 5 Remove the rotary switch See Fig 31 6 Re install the components by referring to the above removal procedure above 15 SYNCHRONOUS MOTOR 1 Remove the control box Refer to section 3 2 Unfold the control box Refer to section 10 3 Remove the crankshaft 4 Disconnect all the lead...

Page 18: ... notes See Fig 33 17 EVAPORATOR 1 Remove the cabinet Refer to section 2 2 Remove the top cover and the brace Refer to section 4 3 Discharge the refrigerant completely 4 Remove the 3 screws which fasten the evaporator at the left side and the top side 5 Move the evaporator sideward carefully and then unbraze the interconnecting tube at the evaporator connectors 6 Remove the evaporator 7 Re install ...

Page 19: ... 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 system was opened 2 Connect the charging cylinder as shown in Fig 35B With valve C open discharge...

Page 20: ... of 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 35A Pulling Vacuum Figure 35B Charging A B EXTERNAL VACUUM PUMP A CHARGING CYLINDER LOW HI B C ...

Page 21: ...OW 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 PEFRIGERANT LOW PRESSURE VAPOR ROOM AIR CONDITIONER EVAPORATOR COILS CONDENSER COILS CYCLE OF REFRIGERATION Following is a brief description of the important components and their functions in the refrigeration system Refer to Fi...

Page 22: ...ation 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 6 50 F Check heat load increase Unexpected residue Overloaded Circuit Check of inside gas pressure Adjusting of refrigerant charge Malfunction of compressor Replacement of compressor Check of cold air circulation for smooth flow Dirty in...

Page 23: ...regular 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 Check capacitor Replacement Only compressor fails to start Defect of compressor capacito...

Page 24: ...ew s Check fan motor bearings if motor shaft will not rotate replace the motor Check voltage See limits on this page If not within limits call an electrician Test capacitor Check bearings 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 Check grommets if worn or missing replace them If ...

Page 25: ...eck the compressor overload if externally mounted Replace if open If the compressor temperature is high remove the overload cool it and retest Check the voltage See the limits on the preced ing page If not within limits call an electrician Check overload if externally mounted Replace if open If the compressor temperature is high remove the overload cool and retest If not running determine the caus...

Page 26: ... hitting air guide rearrange the air handling parts Remove the cabinet and carefully rearrange tubing not to contact cabinet compressor shroud and bar rier Set the knob to HIGH COOL or LOW COOL while rocker switch is ON Check terminals If loose repair or replace Check the synchronous motor for open circuit Capacitor Wiring Refrigerating system Air filter Exhaust damper door Unit undersized Blower ...

Page 27: ...ON 29 28 27 SLIDE SW 40 KEY0 37 38 39 VDD SEG g 41 42 43 SEG f SEG e 44 SEG d TMP87CH47U MICOM 4 SEG b SEG a SEG c 3 2 1 7 6 5 Room TH Option2 Option1 Pipe TH 23 26 25 24 SYNC LOW 4WAY COMP 20 21 22 Reset Osc out Osc in 16 VAref VSS 18 19 17 13 14 15 TEST 11 SCL SDA 10 9 8 Tx 12 Rx 5V A1 3 4 GND SDA SCL A2 A0 1 2 EEPROM 24LC01BT SMW250 04 1 1 2 2 CN TH1 5V R01B R02H R01H 1 6 2K 1 12 1K RT8 00MG 1M...

Page 28: ...28 Room Air Conditioner Schematic diagram MAIN P W B ASSEMBLY MODEL M2400HR DISPLAY P W B ASSEMBLY MODEL M2400HR Components location ...

Page 29: ... L M OR BR OR BR BK BR SYNC MOTOR WH BR ROCKER SWITCH THERMOSTAT WH BK YL BL RD RD YL C L H 1 3 2 R S C BR YL O L P BK RD RD RD FUSE LINK BI METAL THERMOSTAT HEATER BL BK RD BL BK BR Plain WH BL Ribbed GN GN YL 1 3 4 5 6 8 2 7 9 NO 1 2 3 4 5 6 7 8 9 DESCRIPTION POWER CORD ROTARY SWITCH FAN MOTOR CAPACITOR THERMOSTAT OVERLOAD PROTECTOR COMPRESSOR ELECTRIC HEATER SYNCHRONOUS MOTOR ...

Page 30: ... BK BR POWER INPUT Plain CN TH CN SIGNAL CN SIGNAL RY HI CN DISP DISPLAY P W B ASSY RY COMP ZNR T B1 T B2 MAIN P W B ASSY 4 3 RY LO GN YL GN WH BL Ribbed YL BR BR SYNC MOTOR CN SYNC RY SYNC GN YL GN FUSE 250V T2A 115V T2A OLP FUSE LINK HEATER BI METAL THERMOSTAT SUB P W B ASSY 4 3 NO 1 2 3 4 5 6 7 8 9 DESCRIPTION POWER CORD FAN MOTOR CAPACITOR COMPRESSOR MAIN PWB ASSEMBLY DISPLAY PWB ASSEMBLY THER...

Page 31: ...00 3 100 3 670 3 750 3 770 15 0 16 0 18 0 16 0 26 7 DB 19 4 WB 35 DB 23 9 WB 21 1 DB 15 6 WB 8 3 DB 6 1 WB 710 25 0 OZ 880 31 0 OZ 3 ROW 18 STACKS 3 ROW 19 STACKS 2 ROW 19 STACKS L BENDED TYPE BLOWER PROPELLER TYPE FAN WITH SLINGER RING 1 2 2 2 2 2 6 POLES ROTARY SWITCH TOUCH PANEL THERMOSTAT VERTICAL LOUVER RIGHT LEFT HORIZONTAL LOUVER UP DOWN SLIDE IN OUT CHASSIS 3 5 KW 230V INTERNAL OVERLOAD PR...

Page 32: ...48000 352390 349600 346811 130410 354210 147582 349001 249950 359012 731273 349480 W48602 W48602 559010 149980 550140 554160 352115 1 352115 2 35211A 35211A 352111 263230 268712 146812 264110 267110 268714 137215 238310 W0CZZ 249950 135510 269310 W0CZZ 135500 146812 266003 264110 137215 149410 130910 753000 552206 ...

Page 33: ...0AR7265A R 349600 MOUNT MOTOR 4960AR1596A 4960AR1596A 4960AR1596A R 35211A TUBE ASSEMBLY SUCTION 5211A20204C 5211A20204C 5211A20204C R 352111 TUBE ASSEMBLY CONNECTOR 5211AR7059A 5211AR7059A 5211AR7059A R 352113 TUBE ASSEMBLY DISCHARGE SINGLE 5211A30066A 5211A30066A 5211A30066A R 352115 1 TUBE EVAPORATOR 5211A20433B 5211A20433B 5211A20433B R 352115 2 TUBE EVAPORATOR 5211A20434B 5211A20434B 5211A204...

Page 34: ...OTOR ASSEMBLY SINGLE 4681A20011L R 349001 DAMPER VENTILATION 4900AR7265A R 349480 ORIFICE 4948A20016A R 349600 MOUNT MOTOR 4960AR2895B R 35211A TUBE ASSEMBLY SUCTION 5211A20159C R 352113 TUBE ASSEMBLY DISCHARGE SINGLE 5211A20805V R 352115 TUBE EVAPORATOR 5211A20162A B C R 352390 AIR GUIDE ASSEMBLY 5239A20001N R 354210 EVAPORATOR ASSEMBLY FIRST 5421A20052B R 359012 FAN ASSEMBLY BLOWER 5834AR1599B R...

Page 35: ...Service Manual 35 Memo ...

Page 36: ...P No 3828A20190A Printed in Korea ...

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