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Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes

LGE Internal Use Only

4.2 PIPING SYSTEM

Following is a brief description of the important components and their function in what is called the refrigeration
system. Reference should made to Figure 36 to follow the refrigeration cycle and the flow of the refrigerant in the
cooling 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 REFRIGERATION

CAPILLARY TUBE

COMPRESSOR

BLOWER

EVAPORATOR COIL

CONDENSER COIL

FAN

MOTOR

Figure 36

4. TROUBLESHOOTING GUIDE

4.1 OUTSIDE DIMENSIONS

unit: mm(inch)

353(13

7

/

8

")

470(18

1

/

2

")

525(20

11

/

16

")

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...
16
17
18
19
20
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Summary of Contents for R-8000AY3

Page 1: ...ioner SVC MANUAL Exploded View MODEL R1003A3 R 8000AY3 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: ... 19 5 SCHEMATIC DIAGRAM 5 1 CIRCUIT DIAGRAM 24 6 EXPLODED VIEW 25 1 PREFACE This SERVICE MANUAL provides various service information including the mechanical and electrical parts etc This room air conditioner was manufactured and assembled under a strict quality control system The refrigerant is charged at the factory Be sure to read the safety precautions prior to servicing the unit 1 1 SAFETY PR...

Page 3: ...IGHT lbs kg OUTSIDE DIMENSION inch W x H x D mm 1ø 115 60Hz 10 000 8 000 1 020 820 9 2 7 6 9 8 26 7 DB 19 4 WB 35 DB 23 9 WB 460g 16 2oz 260g 9 2oz 3 ROW 14 STACKS SLIT FIN TYPE 2 ROW 16 STACKS L BENDED TYPE TURBO FAN PROPELLER TYPE FAN WITH SLINGER RING 2 3 6 POLES ROTARY SWITCH THERMOSTAT VERTICAL LOUVER RIGHT LEFT HORIZONTAL LOUVER UP DOWN SLIDE IN OUT CHASSIS OVERLOAD PROTECTOR INTERNAL THERMA...

Page 4: ...emperature of the room Select a higher number the right side of arc for a cooler temperature in the room The temperature is selected by positioning the knob to the desired position The 5 or 6 position the middle position of arc is a normal setting for average conditions OPERATION OFF Turns the air conditioner to off MED FAN Permits the medium fan speed operation without cooling LOW FAN Permits the...

Page 5: ...to the removal procedure above 2 1 3 CONTROL BOX 1 Disconnect the unit from the power source 2 Remove the front grille Refer to section 2 1 1 3 Remove the cabinet Refer to section 2 1 2 4 Remove the screw which fastens the control box cover 5 Remove the housing which connects motor wire in the control box 6 Remove the 3 leads from the compressor Refer to section 2 3 1 7 Discharge the capacitor by ...

Page 6: ...the tabs and remove it See Figure 5 10 Remove the clamp with a hand plier which secures the turbo fan 11 Remove the turbo fan 12 Remove the 4 screws which fasten the air guide from the barrier 13 Move the air guide backward pulling out from the base pan 14 Re install the components by referring to the removal procedure above 2 2 2 FAN AND SHROUD 1 Remove the cabinet Refer to section 2 1 2 2 Remove...

Page 7: ...before venting the FreonTM Leave the valve in place after servicing the system 3 Remove the overload protector Refer to section 2 3 1 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 8 7 Re install the components by referring to the removal p...

Page 8: ... fasten the thermostat 4 Disconnect 2 leads of thermostat terminals 5 Remove the thermostat 6 Re install the components by refereing to the above removal procedure See Figure 11 2 3 6 ROTARY SWITCH 1 Remove the control box Refer to section 2 1 3 2 Open the control box Refer to section 2 3 3 3 Remove the 2 screws which fasten the rotary switch 4 Disconnect all the leads of the rotary switch termina...

Page 9: ...ove the 2 screws which fasten the evaporator 3 Move the evaporator sideways carefully Refer to section 2 2 1 4 After discharging the refrigerant completely unbraze the interconnecting tube at the evaporator connections 5 Remove the evaporator carefully 6 Re install the components by referring to the removal procedure See Figure 15 2 4 3 CAPILLARY TUBE 1 Remove the cabinet Refer to section 2 1 2 2 ...

Page 10: ... See figure 16B 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 system was opened 2 Connect the charging cylinder ...

Page 11: ...e Brazing equipment Pin off tool capable 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 16A Pulling Vacuum Figure 16B Charging A B EXTERNAL VACUUM PUMP A CHARGING CYLINDER LOW HI B C ...

Page 12: ...setting conditions must be checked prior to initial starting The undermentioned 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 be grounded 2 Connect to a single outlet 15A circuit 3 To avoid vibration or noise make sure the air conditioner is installed securely 4 Avoid pla...

Page 13: ...GHT SIDE HORIZONTAL LINE B 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 G H J K 495mm 366mm 250mm 30mm 0 25mm OVER 420mm 12mm 32mm 5 10mm 0 5mm 191 2 147 16 10 11 16 0 1 OVER 1617 32 1 2 11 4 3 16 3 8 0 3 16 1 2 3 4 8 13 10 7 6 5 9 12 14 15 11 B INSTALLATION KITS CONTENTS 22 to 36 Stool Interior wall 181 2 min Without frame curtain Offset 1 2 to 1...

Page 14: ...per guide onto the top of the cabinet with 3 type A screws 6 Insert the frame guides into the bottom of the cabinet 7 Insert the Frame Curtain into the upper guide and frame guides 8 Fasten the curtains to the unit with 4 Type A screws CABINET INSTALLATION 1 Open the window Mark a line on center of the window stool or desired air conditioner location Carefully place the cabinet on the window stool...

Page 15: ... 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 23 6 The cabinet should be installed with a very slight tilt about 1 2 downward toward the outside See Figure 24 Adjust the bolt and the nut of sill support for balancing the cabinet 7 Attach the cabinet to the window stool by driving the screws Type B Length s...

Page 16: ...and the lower window sash See Figure 27 12 Attach the window locking bracket with a type C screw See Figure 28 13 Attach the front grille to the cabinet by inserting the tabs on the grille into the tabs on the front of the cabinet Push the grille in until it snaps into place See Figure 29 14 Lift the inlet grille and secure it with a type A screw through the front grille See Figure 30 15 Window in...

Page 17: ...te the inlet grille 180 degrees and insert the hooks into the lower holes of front grille Then insert the filter See Figure 32 33 2 Attach the front grille to the cabinet by inserting the tabs on the grille into the tabs on the front of the cabinet Push the grille in until it snaps into place See Figue 34 3 Lift the inlet grille and secure it with a type A screw through the front grille See Figure...

Page 18: ... 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 REFRIGERATI...

Page 19: ... Check outdoor coil heat exchanger and 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 Ch...

Page 20: ...citor Irregular motor resistance Irregular motor insulation Replacement of fan motor Regular but fails to start Replacement of compressor locking of piston 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 Compressor fails only to...

Page 21: ...f shorted open or damaged Fan blade hitting shroud or blower wheel hitting scroll Re align assembly Units using slinger ring condenser fan must have 1 4 to 5 16 inch clearance to the base If it hits the base shim up the bottom of the fan motor with mounting screw 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 c...

Page 22: ...he switch if the circuit is open Check the position of knob If not at the coldest setting advance the knob to this setting and restart the unit Check continuity of the thermostat Replace the thermostat if the circuit is open Check the capacitor Replace if not within 10 of manufacturer s rating Replace if shorted open or damaged Check the compressor for open circuit or ground If open or grounded re...

Page 23: ...ghten the fins or replace the coil Test the capacitor Check the terminals If loose repair or replace Check the system for a restriction If restricted clean of replace Close if open Determine if the unit is properly sized for the area to be cooled Check the set screw or clamp If loose or missing correct If the blower or fan is hitting air guide rearrange the air handling parts Remove the cabinet ca...

Page 24: ... POWER CORD 1 2 ROTARY SWITCH 1 3 FAN MOTOR 1 4 CAPACITOR 1 5 THERMOSTAT 1 6 OVERLOAD PROTECTOR 1 7 COMPRESSOR 1 THERMOSTAT COMP MOTOR WH BL POWER INPUT Plain GN GN YL BK BR Ribbed WIRING DIAGRAM 3854A20022A BL RD BK R C S YL YL OR BR RD BK BL BL RD ROTARY SWITCH BK BL L 7 1 8 6 4 5 3 2 H M OR BR T BLOCK BL CAPACITOR RD BK F C C H BR BK BK WH WH OR 1 3 2 MODE SWITCH OLP THERMOSTAT 2 7 4 5 3 1 6 ...

Page 25: ...d service purposes LGE Internal Use Only 554030 269310 266003 W0CZZ 135500 264110 137215 249950 149410 554031 352390 149980 346811 349600 559010 552113 552111 550140 554160 567502 35211A 352113 W52106A W52106B 731273 559012 130910 354210 349480 135313 152302 147582 130410 349001 135312 147581 ...

Page 26: ...P NO 3828A20294G FEBRUARY 2008 ...

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