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LG Room Air Conditioner

SERVICE MANUAL
MODELS: LWHD1500ER,LWHD1800R,L1804R

CAUTION

BEFORE SERVICING THE UNIT, READ THE SAFETY PRECAUTIONS IN THIS MANUAL. ONLY FOR AUTHORIZED SERVICE PERSONNEL.
Air Conditioner Service Manual

TABLE OF CONTENTS

Safety Precautions.....3 Dimensions......5 Outside dimensions....5 Product Specifications.....6 Installation.....7 Select the Best Location.....7 Installation Check.....7 How to Secure the Drain Pipe....7 How to Install.....8 Cabinet Installation.....9 Operation.....11 Function of Controls....11 Disassembly.....12 Mechanical Parts....12 Air Handling Parts....13 Electrical Parts.....14 Refrigerating Cycle.....16 Schematic Diagram.....19 Electronic Control Device....19 Wiring Diagram.....20 Components Location....21 Troubleshooting Guide....22 Piping System.....22 Troubleshooting Guide.....23 Electrical Parts Troubleshooting Guide....25 Electric Parts.....29 Exploded View.....35 Replacement Parts List.....36

2 Room Air Conditioner

Safety Precautions
To prevent injury to the user or other people and property damage, the following instructions must be followed. s Incorrect operation due to ignoring instruction will cause harm or damage. The seriousness is classified by the following indications.

WARNING CAUTION

This symbol indicates the possibility of death or serious injury. This symbol indicates the possibility of injury or damage to properties only.
s Meanings of symbols used in this manual are as shown below.
Be sure not to do. Be sure to follow the instruction.

WARNING

s 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 terminal.
There is risk of electric shock.

Service Manual 3

Safety Precautions Do not modify or extend the power cord. Do not install, remove, or re-install the unit by yourself(customer).
There is risk of fire, electric shock, explosion, or injury.
There is risk or fire or electric shock.
Be cautious when unpacking 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 combustibles near the air conditioner.
There is risk of fire or failure of product.

Sharp edges

Gasolin
Be sure the installation area does not deteriorate with age.
If the base collapses, the air conditioner could fall with it, causing property damage, product failure, and personal injury.

4 Room Air Conditioner

Dimensions
Symbols Used in this Manual
This symbol alerts you to the risk of electric shock. This symbol alerts you to hazards that could cause harm to the air conditioner.

NOTICE

This symbol indicates special notes.

Outside Dimensions

Cool Energy Saver Fan Dry Timer

F1 LOW F2 MED F3 HIGH

FAN SPEED
Model HBLG1203R Dimension W H D mm(inch) mm(inch) mm(inch) 660(25 31/32) 428(16 27/32) 680(26 27/32)

Service Manual 5

Specfications

Product Specifications

MODELS ITEMS POWER SUPPLY CAPACITY COOLING INPUT RUNNING CURRENT E.E.R CAPACITY HEATING INPUT RUNNING CURRENT E.E.R OPERATING CONDITION EVAPORATOR CONDENSER FAN,INDOOR FAN,OUTDOOR FAN SPEEDS,FAN/COOLING/HEATING FAN MOTOR OPERATION CONTROL ROOM TEMP CONTROL AIR DIRECTION CONTROL CONSTRUCTION PROTECTOR COMPRESSOR FAN MOTOR INDOOR( OUTDOOR( ) ) (BTU/h) (W) (A) (BTU/h) (W) (A) (BTU/W.h) (BTU/W.h) 1 LWHD1500ER 115V 60Hz 1 LWHD1800R L1804R 208/230V 60Hz
15,12.0 10.8 26.7(DB)* 35(DB)* 680g(24.0oz)
17,500/18,000 1800/1850 9.0/8.3 9.7/9.7 19.4(WB)** 23.9(WB)** 710g(24.9oz)

REFRIGERANT(R-22) CHARGE

3 ROW 11 STACKS, LOUVER-FIN TYPE 2 ROW 19 STACKS,L-BENDED TYPE TURBO FAN PROPELLER TYPE FAN WITH SLINGER RING 3/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 PLUG (CORD-CONNECTED TYPE) DRAIN PIPE OR SPLASHED BY FAN SLINGER (lbs/kg) (inch) (mm) 126/57

Drain pipe Drain cap

Optional
1. Install the drain pan over the corner of the cabinet where you removed the plug with 4 (or 2) screws. 2. Connect the drain hose to the outlet located at the bottom of the drain pan. You can purchase the drain hose or tubing locally to satisfy your particular needs. (Drain hose is not supplied). 3. Select the most appropriate connection from among the following figures (by considering the hole of the unit) to fit drain pan to your own unit.

CABINET

DRAIN PAN

Fig. 1

DRAIN HOSE

Fig. 2

Fig. 3

Fig. 4

Service Manual 7

How to Install

When Using Installation Kits
1. Window Requirements This unit is designed for installation in standard double hung windows with actual opening widths from 29" to 41". The top and bottom window sash must open sufficiently to allow a clear vertical opening of 16" from the bottom of the upper sash to the window stool.
29" to 41" 18" min Stool Offset Less 11/4" Sill Interior wall 26" min (Without frame curtain) Exterior
2. Installation Kits Contents NO. 1 2
NAME OF PARTS FRAME CURTAIN SILL SUPPORT BOLT NUT SCREW(TYPE A) (10mm( /5")) SCREW(TYPE B) D5.1mm(0.2")/16mm(0.63") SCREW(TYPE C) D4.1mm(0.17")/16mm(0.63") FOAM-STRIP FOAM-PE (600mm x 25mm x 2mm) WINDOW LOCKING BRACKET FOAM-PE (920mm x 30mm x 2mm) DRAIN PIPE FRAME GUIDE

Q'TY 2

s Top retainer bar is in the product package.

8 Room Air Conditioner

Cabinet Installation
1. Open the window. Mark a line on the center of the window stool between the side window stop moldings. Loosely attach the sill bracket to the support bracket using the carriage bolt and the lock nut.
Sill Bracket Carriage Bolt (M-Screw) Support Bracket Lock nut
Figure 2 2. Attach the sill bracket to the window sill using the screws (Type B). Carefully place the cabinet on the window stool and align the center mark on the bottom front with the center line marked window stool.

Cabinet Track hole Support Bracket Carriage bolt and lock nut
Machine screw (Type D) and lock nut Outer edge of window sill Screw(Type B) Sill bracket
Figure 3 3. Using the M-screw and the lock nut, attach the support bracket to the cabinet track hole. Use the first track hole after the sill bracket on the outer edge of the window sill. Tighten the carriage bolt and the lock nut. Be sure the cabinet slants outward.

Top retainer bar

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.

Window stool Front angle

Figure 4

Window sash

Foam-PE Cabinet Frame curtain Foam-PE

Figure 5

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 window stool. 2. The cabinet should be installed with a very slight tilt downward toward the outside.

Screw(Type B)

Sash track

Front Angle

Figure 6

Service Manual 9

5. Pull each Frame curtain fully to each window sash track, and pull the bottom window sash down behind the Top retainer bar until it meets.

Screw(Type C)

6. Attach each Frame curtain the window sash by using screws (Type C). (See Fig. 7) Figure 7 7. Slide the unit into the cabinet. (See Fig. 8)
CAUTION: For security purpose, reinstall screws (Type A) at cabinet's sides.
Power Cord Screw (Type A)
Figure 8 8. Cut the Foam-strip to the proper length and insert between the upper window sash and the lower window sash. (See Fig. 9)

Foam-Strip

9. Attach the Window locking bracket with a screw (Type C). (See Fig. 10)

Figure 9

Window locking bracket
10. 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 Fig.11) 11. Lift the inlet grille and secure it with a screw (Type A) through the front grille. (See Fig. 11)

Figure 10

12. Window installation of room air conditioner is now completed.

Figure 11

Figure 12

10 Room Air Conditioner

Operation

Function of Controls

Designed for COOLING ONLY. Powerful and quiet cooling. Slide-in and slide-out chassis for the simple installation and service. Low air-intake, top cooled-air discharge. Built-in adjustable Thermistor Washable one-touch filter Compact size Equipped with reliable and efficient rotary compressor.

DISPLAY

REMOTE CONTROL

Fan Speed

Timer Mode
PRECAUTION: The Remote Control unit will not function properly if strong light strikes the sensor window of the air conditioner or if there are obstacles between the Remote Control unit and the air conditioner.
POWER BUTTON To turn the air conditioner ON, push the button. To turn the air conditioner OFF, push the button again. This button takes priority over any other buttons. ROOM TEMPERATURE SETTING BUTTON This button can automatically control the temperature of the room. The temperature can be set within a range of 60F to 86F by 1F. (16C to 30C by 1C) 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 determine if cooling is needed. FAN SPEED SELECTOR Every time you push this button, it is set as follows. (Hi [F3] Low [F1] Med [F2] Hi [F3] Low [F1].) ON/OFF TIMER BUTTON You can set the time when the unit will turn on or turn off automatically by pressing the timer button. If the unit is operating, this button controls the time it will be turned off. If the unit is off state, this button controls the time it will start. Every time you push this button, the remaining time will be set as follows. - Stopping operation (1Hour 2Hours 3Hours 4Hours 5Hours 6Hours 7Hours 8Hours 9Hours 10Hours 11Hours 12Hours 0Hour 1Hour 2Hours. ) - Starting operation (1Hour 2Hours 3Hours 4Hours 5Hours 6Hours 7Hours 8Hours 9Hours 10Hours 11Hours 12Hours off 1Hour 2Hours . ) 6 REMOCON SIGNAL RECEIVER

Service Manual 11

Disassembly
Before the following disassembly, CONTROL BOX set to OFF and disconnect the power cord.

Mechanical Parts

1. Front Grille
1. Open the lnlet grille downward and remove the air filter. 2. Remove the screw that fastens the front grille.(See Figure 13) 3. Pull the front grille from the right side. 4. Remove the front grille.(There are 4 hooks.) 5. Re-install the components by referring to the removal procedure, above.

2. Cabinet

1. After disassembling the FRONT GRILLE, remove the 2 screws that fasten the cabinet at both sides. 2. Remove the 2 screws that fasten the cabinet at back. 3. Pull the base pan forward. (See Figure 14) 4. Remove the cabinet. 5. Re-install the components by referring to the removal procedure, above. Figure 13

3. Control Box

1. Remove the front grille. (Refer to section 1) 2. Remove the cabinet. (Refer to section 2) 3. Remove the 2 screws which fasten the power cord. 4. Disconnect the grounding screw from the evaporator channel. 5. Remove the 1 screw that fastens the control box cover. 6. Remove the housing that 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. Remove the terminal cover. 11. Remove all the leads from the overload protector. 12. Discharge the capacitor by placing a 20,000 ohm resistor across the capacitor terminals. 13. Raise the control box upward completely. (See Figure 15) 14. Re-install the components by referring to the removal procedure, above. (Refer to the wiring diagram found on page 22 in this manual and on the control box.)
Coo l Ene rgy Save r Fan Dry

COO L FAN DRY HEA T

INDO OR

DEFR OST

DESI RED
F1 ENER LOW F2SAVE F3 MEDGY HIGH R

Tim er

AIR PURY FIER AUTO REST ART

DE TIM ER

FAN SP EE D PO WE R

Figure 14

Coo l Ene rgy Sav er Fan Dry Tim er

F1 F2 LOW F3 MED HIGH

FA SP N EE D PO WE R

Figure 15

12 Room Air Conditioner

Air Handling Parts

4. Air Guide and Turbo Fan
1. Remove the front grille. (Refer to section 1) 2. Remove the cabinet. (Refer to section 2) 3. Remove the control box. (Refer to section 3) 4. Remove the 4 screws that fasten the brace. 5. Remove the brace. 6. Remove the 2 screws that fasten the air guide upper. 7. Remove the air guide upper.(See Figure 16) 8. Remove the 2 screws that fasten the evaporator. 9. Move the evaporator forward and pulling it upward slightly. (See Figure 17) 10. Pull out the hook of orifice by pushing the tabs and remove it. (See Figure 18) 11. Remove the clamp with a hand plier that 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.

Figure 16

Figure 17

5. FAN

1. Remove the cabinet. (Refer to section 2) 2. Remove the brace (Refer to section 4) 3. Remove the 5 screws that fasten the condenser. 4. Move the condenser to the left carefully. 5. Remove the clamp that secures the fan. 6. Remove the fan. (See Figure 19) 7. Re-install by referring to the removal procedure.

DES IRED

MO DE TIM ER

FA SP N EE D

PO WE R

Figure 24

Service Manual 15

Disassembly 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 that fasten the motor from the air guide. (See Figure 25) 5. Remove the motor. 6. Re-install the components by referring to the removal procedure, above.(See Figure 25)

Figure 25

Refrigerating Cycle
12. Condenser CAUTION: Discharge the refrigerant system using a FreonTM Recovery System. If there is no valve to attach the recovery system, install one (such as a WATCO A-1) before venting the FreonTM. Leave the valve in place after servicing the system.
1. Remove the cabinet. (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 condenser connections. 5. Remove the condenser. 6. Re-install the components by referring to notes. (See Figure 26)

Figure 26

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 evaporator. 4. Move the evaporator sideways carefully. (Refer to section 4) 5. After discharging the refrigerant completely, unbraze the interconnecting tube at the evaporator connections. 6. Remove the evaporator. 7. Re-install the components by referring to notes. (See Figure 27)

Figure 27

16 Room Air Conditioner
Disassembly 14. Capillary Tube
1. Remove the cabinet. (Refer to section s2) 2. After discharging the refrigerant completely, unbraze the interconnecting tube at the capillary tube.(See caution above) 3. Remove the capillary tube. 4. Re-install the components by referring to notes.
Replacement of the refrigeration cycle. 1. When replacing the refrigeration cycle, be sure to Discharge the refrigerant system using a FreonTM recovery System. If there is no valve to attach the recovery system, install one (such as a WATCO A-1) before venting the FreonTM. Leave the valve in place after servicing the system. 2. After discharging the unit completely, remove the desired component, and unbraze the pinch-off tubes. 3. Braze service valves into the pinch-off tube ports, leaving the valves open. 4. Braze the pinch-off tubes with Service valves. 5. Evacuate as follows. 1) Connect the vacuum pump, as illustrated figure 28A. 2) Start the vacuum pump, slowly open manifold valves A and B with two full turns counterclockwise and leave the valves open. The vacuum pump is now pulling through valves A and B up to valve C by means of the manifold and entire system.

CAUTION: If high vacuum equipment is used, just crack valves A and B for a few minutes, then open slowly with the two full turns counterclockwise. This will keep oil from foaming and being drawn into the vacuum pump.
3) Operate the vacuum pump vaccum for 20 to 30 minutes, until 600 microns of vaccum is obtained. Close valves A and B, and observe vacuum gauge for a few minutes. A rise in pressure would indicate 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 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 system was opened. 2) Connect the charging cylinder as shown in figure 28B. With valve C open, discharge the hose at the manifold connection. 3) Open valve A and allow the proper charge to enter the system. Valve B is still closed. 4) If more charge is required, the high-side will not take it. Close valve A. 5) With the unit running, open valve B and add the balance of the charge. a. Do not add the liquid refrigerant to the Lowside. b. Watch the Low-side gauge; allow pressure to rise to 30 lbs. c. Turn off valve B and allow pressure to drop. d. Repeat steps b. and c. until the balance of the charge is in the system. 6) When satisfied the unit is operating correctly, use the pinch-off tool with the unit still running and clamp on to the pinch-off tube. Using a tube cutter, cut the pinch-off tube about 2 inches from the pinch-off tool. Use sil-fos brazing and braze pinch-off tube closed. Turn off the unit, allow it to set for a while, and then test the leakage of the pinch-off connection.

Service Manual 17

Equipment needed: Vacuum pump, Charging cylinder, Manifold gauge, Brazing equipment. Pin-off tool capable of making a vapor-proof seal, Leak detector, Tubing cutter, Hand Tools to remove components, Service valve.
CONDENSER (HIGH PRESSURE SIDE)
COMPOUND GAUGE MANIFOLD GAUGE

CAPILLARY TUBE

SEE INSETS BELOW EVAPORATOR (LOW PRESSURE SIDE)

COMPRESSOR

EXTERNAL VACUUM PUMP CHARGING CYLINDER
Figure 28A-Pulling Vacuum

Figure 28B-Charging

18 Room Air Conditioner

Schematic Diagram

Electronic Control Device

Service Manual 19

Wiring Diagram
GN/YL (GN) CN-MOTOR CN-AC/DC CN-AC/DC

RY-LOW

RY-MED

CAPACITOR

CN-TH1

BK BL RD YL OR

DC PCB ASSEMBLY

GN/YL (GN)

CN-MOTOR

CN-AC/DC

F C OR(BR) BK H WH(BL) (Ribbed) BK(BR) (Plain) GN/YL (GN) RD CN-PWR ZNR01J DC12V CN-12V POWER TRANS

POWER TRANS CN-PWR

THERMISTOR

OR(BR) BK RD

ZNR01J

SWITCH

H WH(BL) (Ribbed) BK(BR) (Plain) GN/YL (GN)

DC12V CN-12V

FUSE 250V/T2A (115V/T2A)

FUSE 250V/T3.15A

CN-HVB

R S BL OLP

H.V. ASSEMBLY

RY-COMP

AC PCB ASSEMBLY

AIR FILTER ASSEMBLY

WIRING DIAGRAM

3854AR3563N

3854AR3563P
S: Service Parts N: Non Service Parts REMARKS S S S S S S S S

LOCATION NO. 7 8

DESCRIPTION MOTOR ASSY CAPACITOR COMPRESSOR OVERLOAD PROTECTOR DC PCB ASSEMBLY AC PCB ASSEMBLY THERMISTOR PLASMA FILTER ASSY

Q'TY PER SET 1 1

20 Room Air Conditioner

Components Location

1. MAIN P.C.B ASSEMBLY
R01T Q01T J4 Q02T D01T C02T J5 CN-12V CN-HVB Q03T J2 J7

CN-CON

CN-TELE

CN-TH2 CN-PWR

HEAT SINK

QIC02DT

ZNR01J R01J

CN-4WAY C01J

C04D C05D RY-LOW

E03J J8

C01D RY-4WAY

POWER TRANS FUSE

ASSEMBLY:6871A20167
2. DISPLAY P.C.B. ASSEMBLY
CN-AC/DC J05 J01 J02 J04 SW04G TIMER C05D SW01G FAN SPEED SW05G MODE R10G J17 J12 SW02G TEMP DOWN SW06G TEMP UP BZ01E J24 ZD01F C02A SW03G POWER J2ZD02F J20 J19 J18 OSC01B RECEIVER IC03G IC01A CN-TH1
R01G R02G R03G R04G R05G R06G R07G R08G R09G

J14 J15 J16

J08 J07 J08

J09 J10 J11 J13

J21 J22 J23

Service Manual 21

Troubleshooting Guide

Piping System

CONDENSER COIL FAN MOTOR COMPRESSOR CAPILLARY TUBE

TURBO FAN

EVAPORATOR COIL

Figure 29 is a brief description of the important components and their function in what is called the refrigeration system. This will help you to understand the refrigeration cycle and the flow of the refrigerant in the cooling cycle.

ROOM AIR CONITIONER

CYCLE OF REFRIGERATION

EVAPORATOR COILS

COMPLETE LIQUID BOIL OFF POINT COOLED AIR SUCTION LINE COOL LOW PRESSURE VAPOR

CONDENSER COILS

VAPOR INLET HOT DISCHARGED AIR

ROOM AIR HEAT LOAD

OUTSIDE COOLING AIR FOR REFRIGERANT PASS THROUGH

LIQUID PRESSURE DROP

LIQUID OUTLET
(LIQUID REFRIGERANT) CAPILLARY TUBE
HIGH PRESSURE VAPOR LIQUID REFRIGERANT LOW PRESSURE VAPOR

Figure 29

22 Room Air Conditioner
In general, possible trouble is classified in two kinds. The one is called Starting Failure which is caused from an electrical defect, and the other is ineffective Air Conditioning caused by a defect in the refrigeration circuit and improper application.
Unit runs but poor cooling.

Ineffective Cooling

Check cold air circulation for smooth flow.
Check outdoor coil (heat exchanger) & the fan operation.
Check heat load increase.
Dirty indoor coil (Heat exchanger)
Clean condenser. Check gas leakage.
Not on separate circuit. Malfunction of fan Repair gas leak.

Clogged of air filter.

Replacement of unit if the unit is beyond repair.
Check inside gas pressure.
Obstruction at air outlet
Adjusting of refrigerant charged.
Correct above trouble Malfunction of compressor.
Check clogging in refrigeration circuit.
Replacement of compressor.
Repair clogging in refrigeration circuit.
Satisfactory operation with temperature difference of inlet & outlet air ; 44~50F(7~10C)

Service Manual 23

Fails to Start

Check of power source.

Check circuit breaker and fuse.
Check of control switch setting.
Gas leakage of feeler bulb of thermostat

Check of control switch.

Compressor only fails to start.

Fan only fails to start.

Improper wiring. Drop of power voltage. Improper thermostat setting. Defect of compressor capacitor. Loose terminal connection. Capacitor check. Improper wiring. Replacement Replacement of fan motor. Defect of fan motor capacitor.

Irregular motor resistance ( ). Irregular motor insulation ( ).
Irregular motor resistance (
Regular but fails to start.
Irregular motor insulation (
) Replacement of compressor (locking of rotor, metal).
Replacement of compressor (Motor damaged)

24 Room Air Conditioner

Electrical Parts Troubleshooting Guide
Possible Trouble 1 The unit does not operate.
Is the Trans input power AC 115V? (208/230V for LWL1230WAL) YES
Check the Fuse. Check the Fuse. Check the wiring diagram. Check the wiring diagram.
Is the Trans output power about AC 14V? YES
Is shorted the Trans. output?
Check the Main PCB pattern.
Replace the Trans. Replace D02D~D05D. Replace IC01D.
Is output Voltage of IC01D DC 12V? YES
Is output Voltage of IC02D DC 5V? YES

Replace IC02D.

Is the reset circuit OK? (The No.14 of Micom is 5V.) YES Is the connection between AC and DC OK? YES

Replace IC01A, C02A.

Connect connector exactly.
Is the voltage No.18 of Micom DC 5V? YES Replace AC PCB Ass'y.

Check the PCB pattern.

Service Manual 25
Possible Trouble 2 The compressor does not operate.
Is setting Temp. set lower than Room Temp.-0.5C? YES NO
Select the setting Temp. to lower Number.
Is the voltage No.10 of IC01M 0V? YES Check the RY-COMP. Check the wiring Diagram.
Is the voltage N0.9 of IC01M DC 12V? YES Replace IC01M.
Does the Unit delay for 3 minutes? YES Wait 3 Minutes.

Replace MAIN PCB Ass'y.

Possible Trouble 3
The compressor always operate.
Is the wire connection of RY-COMP OK? YES Check the RY-COMP.
Connect LEAD Wire to RY-COMP again.

26 Room Air Conditioner

Possible Trouble 4

FAN does not operate.

Is the voltage NO.1 or 2 or 4 of IC01M DC 12V? YES

Replace IC01M.

Is the voltage NO.16 or 15 or 13 of IC01M 0V? YES Check the RY-Hi or RY-Med or RY-Lo. Check the wiring diagram.

Possible Trouble 5

The function of Energy Saver does not operate.
Is the mode key pushed once more from cool mode? YES

Capacitor (Discharge capacitor before servicing.) Compressor Overload
Compressor cycles on overload.

Voltage Overload

Fan motor Condenser air flow restriction

Condenser fins (damaged)

Capacitor Wiring Refrigerating system
Insufficient cooling or heating
Air filter Exhaust damper door Unit undersized

Excessive noise

Turbo or fan

Copper tubing

34 Room Air Conditioner

Exploded View

749740

731273 130910

148000 149980

559011 554031

W48602 349480

W48602 749750

354210

349600

267110

147582-1 147581

349001

147582-2

135312 554160

249950

550140

135314

352115-1 268711-1

268711-2

W0CZZ 352115-2

552102

IND OO

238310

FR OS T
EN ER SA GY VE R PU AIR RY FIE AU RE TO R STA RT

264110 567480

352111
Co ol En erg Sa y ver Fa n Dr y Tim er

TIM ER

MO DE TE MP PO WE

F1 F2 LOW F3 MED HIG H

PO WER

137215

35211A 352113

Service Manual 35

R eplacement Parts List
R eplacement Parts L is t

LO CATIO N NO.

D E S C R IP T IO N BASE ASSEMBLY, W ELD[SINGLE] CABINET ASSEMBLY, SINGLE GRILLE ASSEMBLY, FRONT(SINGLE) GRILLE, INLET COVER LOUVER, HORIZONTAL LOUVER, VERTICAL LOUVER, VERTICAL BRACE SHROUD FILTER ASSEMBLY, AIR CLEANER PANEL, CONTROL CONTROL BOX ASSEMBLY, SINGLE PW B(PCB) ASSEMBLY, MAIN(AC) ESCUTCHEON PW B(PCB) ASSEMBLY, MAIN(DC) THERMISTOR ASSEMBLY POW ER CORD ASSEMBLY MOTOR ASSEMBLY, SINGLE VENTILATION DAMPER ORIFICE MOUNT, MOTOR TUBE, CAPILLARY BEND TUBE ASSEMBLY, DISCHARGE SINGLE TUBE , FORMED TUBE , FORMED TUBE ASSEMBLY, SUCTION(OUTDOOR) AIR GUIDE ASSEMBLY EVAPORATOR ASSEMBLY, FIRST ANTI-VIBRATION BUSH CONDENSER ASSEMBLY, FIRST COMPRESSOR SET FAN ASSEMBLY, AXIAL FAN ASSEMBLY, TURBO REMOTE CONTROLLER ASSEMBLY CLAMP, SPRING CAPACITOR, DRAW ING INSTALL PARTS ASSEMBLY
PART NO. LW HD1450ER 3041A20023T 3091AR6057V 3531A10201A 3530A10146A 3550A20089A 4758A30022A 4758A20042A 4758A20042B 4800A20001A 4998A10013A 5231A20008A 3720A10112A 4995A26003B 6871A20617E 3831A10021F 6871A20604A 6323A20012C 6411A20048U 4681A23010A 4900A20004A 4948A30008A 4960AR1596A 5211AR3332Z 5211A34005A 5210A23358C 5210A23358D 5211A20441K 5239A20002A 5421A20091F 4H00982C 5403A20062B 2520UCBK025 5900AR1508A 5901A20009A 6711A20034G 3H02932C 0CZZA20001L 3127AR3403U LW HD1800R 3041A20067B 3091AR6057V 3531A10201A 3530A10146A 3550A30122A 4758A30022A 4758A20042A 4758A20042B 4800A20001A 4998A10026A 5231A20008A 3720A10112A 4995A26003A 6871A20617D 3831A10021F 6871A20604A 6323A20012C 6411A20048J 4681A20081A 4900A20004A 4948A30008A 4960AR1596A 5211A30275Z 5211A30066N 5210A21099E 5210A21099F 5211A20441L 5239A20002A 5421A20091G 4H00982C 5403A20112B 2520UCBJ002 5900AR1508A 5901A20009A 6711A20034G 3H02932C 6120AR2194F 3127AR3403U

REM ARK R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R
147582-1 147582-352113 W 52106-1 W 52106-2 35211A W 48602 W 0CZZ 731373
36 R oom Air C onditioner
D E S C R IP T IO N BASE ASSEMBLY, W ELD[SINGLE] CABINET ASSEMBLY, SINGLE GRILLE ASSEMBLY, FRONT(SINGLE) GRILLE, INLET

GUIDE LOUVER, HORIZONTAL

PART NO. L1804R 3041A20023T 3091AR6057V 3531A20095A 3530A10080A

2H00858D 4758A30022A

135312 135314

749740 147581

147582-1 147582-149980
LOUVER, VERTICAL LOUVER, VERTICAL BRACE SHROUD FILTER ASSEMBLY, AIR CLEANER PANEL, CONTROL CONTROL BOX ASSEMBLY, SINGLE PW B(PCB) ASSEMBLY, MAIN(AC) ESCUTCHEON PW B(PCB) ASSEMBLY, MAIN(DC) THERMISTOR ASSEMBLY POW ER CORD ASSEMBLY MOTOR ASSEMBLY, SINGLE VENTILATION DAMPER ORIFICE MOUNT, MOTOR TUBE, CAPILLARY BEND TUBE ASSEMBLY, DISCHARGE SINGLE TUBE , FORMED TUBE , FORMED TUBE ASSEMBLY, SUCTION(OUTDOOR) AIR GUIDE ASSEMBLY EVAPORATOR ASSEMBLY, FIRST ANTI-VIBRATION BUSH CONDENSER ASSEMBLY, FIRST COMPRESSOR SET FAN ASSEMBLY, AXIAL FAN ASSEMBLY, TURBO REMOTE CONTROLLER ASSEMBLY CLAMP, SPRING CAPACITOR, DRAW ING INSTALL PARTS ASSEMBLY TUBE,CAPILLARY
4758A20042A 4758A20042B 4800A20001A 4998A10026A 5231A20008A 3720A10112A 4995A26003A 6871A20617D 3831A10021F 6871A20604A 6323A20012C 6411A20048J 4681A20081A 4900A20004A 4948A30008A 4960AR1596A 5211A30275Z 5211A30066N 5210A21099E 5210A21099F 5211A20441L 5239A20002A 5421A20091G 4H00982C 5403A20112B 2520UCBJ002 5900AR1508A 5901A20009A 6711A20034G 3H02932C 6120AR2194F 3127AR3403U 5210A23357A

268711-268711-1

567480 264110

352111 352113

352115-1 352115-2 35211A 749750 354210

554160 559011

359012 267110
W 48602 W 0CZZ 731273 552102

R oom Air C onditioner

38 Room Air Conditioner

P/No.: 3828A29003A

January, 2006 Printed in China

website http://www.lgservice.com

LG Room Air Conditioner

SERVICE MANUAL
MODELS: LWHD1450ER LWHD1800R

CAUTION

BEFORE SERVICING THE UNIT, READ THE SAFETY PRECAUTIONS IN THIS MANUAL. ONLY FOR AUTHORIZED SERVICE PERSONNEL.
Air Conditioner Service Manual

TABLE OF CONTENTS

Safety Precautions.....3 Dimensions......5 Outside dimensions....5 Product Specifications.....6 Installation.....7 Select the Best Location.....7 Installation Check.....7 How to Secure the Drain Pipe....7 How to Install.....8 Cabinet Installation.....9 Operation.....11 Function of Controls....11 Disassembly.....12 Mechanical Parts....12 Air Handling Parts....13 Electrical Parts.....14 Refrigerating Cycle.....16 Schematic Diagram.....19 Electronic Control Device....19 Wiring Diagram.....20 Components Location....21 Troubleshooting Guide....22 Piping System.....22 Troubleshooting Guide.....23 Electrical Parts Troubleshooting Guide....25 Electric Parts.....29 Exploded View.....35 Replacement Parts List.....36

2 Room Air Conditioner

Safety Precautions
To prevent injury to the user or other people and property damage, the following instructions must be followed. s Incorrect operation due to ignoring instruction will cause harm or damage. The seriousness is classified by the following indications.

WARNING CAUTION

This symbol indicates the possibility of death or serious injury. This symbol indicates the possibility of injury or damage to properties only.
s Meanings of symbols used in this manual are as shown below.
Be sure not to do. Be sure to follow the instruction.

WARNING

s 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 terminal.
There is risk of electric shock.

Service Manual 3

Safety Precautions Do not modify or extend the power cord. Do not install, remove, or re-install the unit by yourself(customer).
There is risk of fire, electric shock, explosion, or injury.
There is risk or fire or electric shock.
Be cautious when unpacking 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 combustibles near the air conditioner.
There is risk of fire or failure of product.

Sharp edges

Gasolin
Be sure the installation area does not deteriorate with age.
If the base collapses, the air conditioner could fall with it, causing property damage, product failure, and personal injury.

4 Room Air Conditioner

Dimensions
Symbols Used in this Manual
This symbol alerts you to the risk of electric shock. This symbol alerts you to hazards that could cause harm to the air conditioner.

NOTICE

This symbol indicates special notes.

Outside Dimensions

Cool Energy Saver Fan Dry Timer

F1 LOW F2 MED F3 HIGH

FAN SPEED
Model HBLG1203R Dimension W H D mm(inch) mm(inch) mm(inch) 660(25 31/32) 428(16 27/32) 680(26 27/32)

Service Manual 5

Specfications

Product Specifications

MODELS ITEMS POWER SUPPLY CAPACITY COOLING INPUT RUNNING CURRENT E.E.R CAPACITY HEATING INPUT RUNNING CURRENT E.E.R OPERATING CONDITION EVAPORATOR CONDENSER FAN,INDOOR FAN,OUTDOOR FAN SPEEDS,FAN/COOLING/HEATING FAN MOTOR OPERATION CONTROL ROOM TEMP CONTROL AIR DIRECTION CONTROL CONSTRUCTION PROTECTOR COMPRESSOR FAN MOTOR INDOOR( OUTDOOR( ) ) (BTU/h) (W) (A) (BTU/h) (W) (A) (BTU/W.h) (BTU/W.h) 1 LWHD1450ERR 115V 60Hz 1 LWHD1800R 208/230V 60Hz
14,12.0 10.7 26.7(DB)* 35(DB)* 680g(24.0oz)
17,500/18,000 1800/1850 9.0/8.3 9.7/9.7 19.4(WB)** 23.9(WB)** 725g(25.5oz)

REFRIGERANT(R-22) CHARGE

3 ROW 11 STACKS, LOUVER-FIN TYPE 2 ROW 19 STACKS,L-BENDED TYPE TURBO FAN PROPELLER TYPE FAN WITH SLINGER RING 3/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 PLUG (CORD-CONNECTED TYPE) DRAIN PIPE OR SPLASHED BY FAN SLINGER (lbs/kg) (inch) (mm) 126/57

POWER CORD DRAIN SYSTEM NET WEIGHT OUTSIDE DIMENSION (W X H X D)
25 31/32 X 16 27/32 X 26 27/32

660 x 428 x 680

* DB : dry bulb ** WB : wet bulb
Note: Please refer to Label Quality on the product Since this sepcification may be changed for improving performance.

6 Room Air Conditioner

Installation

Select the Best Location

1. To avoid vibration and noise, make sure the unit is installed securely and firmly. 2. Install the unit where the sunlight does not shine directly on the unit. If the unit receives direct sunlight, build an awning to shade the cabinet. 3. There should be no obstacle, like a fence, within 20" which might restrict heat radiation from the condenser. 4. To prevent reducing performance, install the unit so that louvers of the cabinet are not blocked. 5. Install the unit a little obliquely outward not to leak the condensed water into the room (about 1/2" or 1/4 bubble with level). 6. Install the unit with its bottom portion 30~60" above the floor level. 7. Stuff the foam between the top of the unit and the wall to prevent air and insects from getting into the room. 8. The power cord must be connected to an independent circuit. 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.

1/4 Bubble

AWNING FOAM COOLED AIR 30-60"

HEAT RADIATION

About 1/2" Over 20"

Figure 1

Installation Check
The setting conditions must be checked prior to initial starting. The following items are especially important check 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. (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.
How to Secure the Drain Pipe
In humid weather, excess water may cause the BASE PAN to overflow. To drain the water, remove the DRAIN CAP and secure the DRAIN PIPE to the rear hole of the BASE PAN. Press the drain pipe into the hole by pushing down and away from the fins to avoid injury.

Drain pipe Drain cap

Optional
1. Install the drain pan over the corner of the cabinet where you removed the plug with 4 (or 2) screws. 2. Connect the drain hose to the outlet located at the bottom of the drain pan. You can purchase the drain hose or tubing locally to satisfy your particular needs. (Drain hose is not supplied). 3. Select the most appropriate connection from among the following figures (by considering the hole of the unit) to fit drain pan to your own unit.

CABINET

DRAIN PAN

Fig. 1

DRAIN HOSE

Fig. 2

Fig. 3

Fig. 4

Service Manual 7

How to Install

When Using Installation Kits
1. Window Requirements This unit is designed for installation in standard double hung windows with actual opening widths from 29" to 41". The top and bottom window sash must open sufficiently to allow a clear vertical opening of 16" from the bottom of the upper sash to the window stool.
29" to 41" 18" min Stool Offset Less 11/4" Sill Interior wall 26" min (Without frame curtain) Exterior
2. Installation Kits Contents NO. 1 2
NAME OF PARTS FRAME CURTAIN SILL SUPPORT BOLT NUT SCREW(TYPE A) (10mm( /5")) SCREW(TYPE B) D5.1mm(0.2")/16mm(0.63") SCREW(TYPE C) D4.1mm(0.17")/16mm(0.63") FOAM-STRIP FOAM-PE (600mm x 25mm x 2mm) WINDOW LOCKING BRACKET FOAM-PE (920mm x 30mm x 2mm) DRAIN PIPE FRAME GUIDE

Q'TY 2

s Top retainer bar is in the product package.

8 Room Air Conditioner

Cabinet Installation
1. Open the window. Mark a line on the center of the window stool between the side window stop moldings. Loosely attach the sill bracket to the support bracket using the carriage bolt and the lock nut.
Sill Bracket Carriage Bolt (M-Screw) Support Bracket Lock nut
Figure 2 2. Attach the sill bracket to the window sill using the screws (Type B). Carefully place the cabinet on the window stool and align the center mark on the bottom front with the center line marked window stool.
Cabinet Track hole Support Bracket Carriage bolt and lock nut
Machine screw (Type D) and lock nut Outer edge of window sill Screw(Type B) Sill bracket
Figure 3 3. Using the M-screw and the lock nut, attach the support bracket to the cabinet track hole. Use the first track hole after the sill bracket on the outer edge of the window sill. Tighten the carriage bolt and the lock nut. Be sure the cabinet slants outward.

Top retainer bar

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.

Window stool Front angle

Figure 4

Window sash

Foam-PE Cabinet Frame curtain Foam-PE

Figure 5

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 window stool. 2. The cabinet should be installed with a very slight tilt downward toward the outside.

Screw(Type B)

Sash track

Front Angle

Figure 6

Service Manual 9

5. Pull each Frame curtain fully to each window sash track, and pull the bottom window sash down behind the Top retainer bar until it meets.

Screw(Type C)

6. Attach each Frame curtain the window sash by using screws (Type C). (See Fig. 7) Figure 7 7. Slide the unit into the cabinet. (See Fig. 8)
CAUTION: For security purpose, reinstall screws (Type A) at cabinet's sides.
Power Cord Screw (Type A)
Figure 8 8. Cut the Foam-strip to the proper length and insert between the upper window sash and the lower window sash. (See Fig. 9)

Foam-Strip

9. Attach the Window locking bracket with a screw (Type C). (See Fig. 10)

Figure 9

Window locking bracket
10. 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 Fig.11) 11. Lift the inlet grille and secure it with a screw (Type A) through the front grille. (See Fig. 11)

Figure 10

12. Window installation of room air conditioner is now completed.

Figure 11

Figure 12

10 Room Air Conditioner

Operation

Function of Controls

Designed for COOLING ONLY. Powerful and quiet cooling. Slide-in and slide-out chassis for the simple installation and service. Low air-intake, top cooled-air discharge. Built-in adjustable Thermistor Washable one-touch filter Compact size Equipped with reliable and efficient rotary compressor.

DISPLAY

REMOTE CONTROL

Fan Speed

Timer Mode
PRECAUTION: The Remote Control unit will not function properly if strong light strikes the sensor window of the air conditioner or if there are obstacles between the Remote Control unit and the air conditioner.
POWER BUTTON To turn the air conditioner ON, push the button. To turn the air conditioner OFF, push the button again. This button takes priority over any other buttons. ROOM TEMPERATURE SETTING BUTTON This button can automatically control the temperature of the room. The temperature can be set within a range of 60F to 86F by 1F. (16C to 30C by 1C) 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 determine if cooling is needed. FAN SPEED SELECTOR Every time you push this button, it is set as follows. (Hi [F3] Low [F1] Med [F2] Hi [F3] Low [F1].) ON/OFF TIMER BUTTON You can set the time when the unit will turn on or turn off automatically by pressing the timer button. If the unit is operating, this button controls the time it will be turned off. If the unit is off state, this button controls the time it will start. Every time you push this button, the remaining time will be set as follows. - Stopping operation (1Hour 2Hours 3Hours 4Hours 5Hours 6Hours 7Hours 8Hours 9Hours 10Hours 11Hours 12Hours 0Hour 1Hour 2Hours. ) - Starting operation (1Hour 2Hours 3Hours 4Hours 5Hours 6Hours 7Hours 8Hours 9Hours 10Hours 11Hours 12Hours off 1Hour 2Hours . ) 6 REMOCON SIGNAL RECEIVER

Service Manual 11

Disassembly
Before the following disassembly, CONTROL BOX set to OFF and disconnect the power cord.

Mechanical Parts

1. Front Grille
1. Open the lnlet grille downward and remove the air filter. 2. Remove the screw that fastens the front grille.(See Figure 13) 3. Pull the front grille from the right side. 4. Remove the front grille.(There are 4 hooks.) 5. Re-install the components by referring to the removal procedure, above.

2. Cabinet

1. After disassembling the FRONT GRILLE, remove the 2 screws that fasten the cabinet at both sides. 2. Remove the 2 screws that fasten the cabinet at back. 3. Pull the base pan forward. (See Figure 14) 4. Remove the cabinet. 5. Re-install the components by referring to the removal procedure, above. Figure 13

3. Control Box

1. Remove the front grille. (Refer to section 1) 2. Remove the cabinet. (Refer to section 2) 3. Remove the 2 screws which fasten the power cord. 4. Disconnect the grounding screw from the evaporator channel. 5. Remove the 1 screw that fastens the control box cover. 6. Remove the housing that 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. Remove the terminal cover. 11. Remove all the leads from the overload protector. 12. Discharge the capacitor by placing a 20,000 ohm resistor across the capacitor terminals. 13. Raise the control box upward completely. (See Figure 15) 14. Re-install the components by referring to the removal procedure, above. (Refer to the wiring diagram found on page 22 in this manual and on the control box.)
Coo l Ene rgy Save r Fan Dry

COO L FAN DRY HEA T

INDO OR

DEFR OST

DESI RED
F1 ENER LOW F2SAVE F3 MEDGY HIGH R

Tim er

AIR PURY FIER AUTO REST ART

DE TIM ER

FAN SP EE D PO WE R

Figure 14

Coo l Ene rgy Sav er Fan Dry Tim er

F1 F2 LOW F3 MED HIGH

FA SP N EE D PO WE R

Figure 15

12 Room Air Conditioner

Air Handling Parts

4. Air Guide and Turbo Fan
1. Remove the front grille. (Refer to section 1) 2. Remove the cabinet. (Refer to section 2) 3. Remove the control box. (Refer to section 3) 4. Remove the 4 screws that fasten the brace. 5. Remove the brace. 6. Remove the 2 screws that fasten the air guide upper. 7. Remove the air guide upper.(See Figure 16) 8. Remove the 2 screws that fasten the evaporator. 9. Move the evaporator forward and pulling it upward slightly. (See Figure 17) 10. Pull out the hook of orifice by pushing the tabs and remove it. (See Figure 18) 11. Remove the clamp with a hand plier that 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.

Figure 16

Figure 17

5. FAN

1. Remove the cabinet. (Refer to section 2) 2. Remove the brace (Refer to section 4) 3. Remove the 5 screws that fasten the condenser. 4. Move the condenser to the left carefully. 5. Remove the clamp that secures the fan. 6. Remove the fan. (See Figure 19) 7. Re-install by referring to the removal procedure.

Figure 18

Figure 19

Service Manual 13

Disassembly 6. Shroud
1. Remove the fan. (Refer to section 5) 2. Remove the shroud. (See Figure 20) 3. Re-install the components by referring to the removal procedure, above.

Figure 20

Electrical Parts

7. Overload Protector

1. Remove the cabinet. (Refer to section 2) 2. Remove the nut that fastens the terminal cover. 3. Remove the terminal cover. (See Figure 21) 4. Remove all the leads from the overload protector. 5. Remove the overload protector. 6. Re-install the components by referring to the removal procedure, above. Figure 21

8. Compressor

1. 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 system, 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 section 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 22) 7. Re-install the components by referring to the removal procedure, above. Figure 22

14 Room Air Conditioner

Disassembly 9. Capacitor
1. Remove the control box. (Refer to section 3) 2. Open the top cover from the control box. (See Figure 23) 3. Pull out the capacitor from the control box. 4. Disconnect all the leads of capacitor terminals. 5. Re-install the components by referring to the removal procedure, above.
Co ol Ener Savgy er Fan Dry

IN DO OR

HE AT DEF RO ST

DES IR ED

EN LOW F2 ER SA G F3 MED Y HIVER GH PU AIR RY FI AU ER RES TO TA RT

F SPAN EE D PO WE R

Figure 27

16 Room Air Conditioner
Disassembly 14. Capillary Tube
1. Remove the cabinet. (Refer to section s2) 2. After discharging the refrigerant completely, unbraze the interconnecting tube at the capillary tube.(See caution above) 3. Remove the capillary tube. 4. Re-install the components by referring to notes.
Replacement of the refrigeration cycle. 1. When replacing the refrigeration cycle, be sure to Discharge the refrigerant system using a FreonTM recovery System. If there is no valve to attach the recovery system, install one (such as a WATCO A-1) before venting the FreonTM. Leave the valve in place after servicing the system. 2. After discharging the unit completely, remove the desired component, and unbraze the pinch-off tubes. 3. Braze service valves into the pinch-off tube ports, leaving the valves open. 4. Braze the pinch-off tubes with Service valves. 5. Evacuate as follows. 1) Connect the vacuum pump, as illustrated figure 28A. 2) Start the vacuum pump, slowly open manifold valves A and B with two full turns counterclockwise and leave the valves open. The vacuum pump is now pulling through valves A and B up to valve C by means of the manifold and entire system.
CAUTION: If high vacuum equipment is used, just crack valves A and B for a few minutes, then open slowly with the two full turns counterclockwise. This will keep oil from foaming and being drawn into the vacuum pump.
3) Operate the vacuum pump vaccum for 20 to 30 minutes, until 600 microns of vaccum is obtained. Close valves A and B, and observe vacuum gauge for a few minutes. A rise in pressure would indicate 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 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 system was opened. 2) Connect the charging cylinder as shown in figure 28B. With valve C open, discharge the hose at the manifold connection. 3) Open valve A and allow the proper charge to enter the system. Valve B is still closed. 4) If more charge is required, the high-side will not take it. Close valve A. 5) With the unit running, open valve B and add the balance of the charge. a. Do not add the liquid refrigerant to the Lowside. b. Watch the Low-side gauge; allow pressure to rise to 30 lbs. c. Turn off valve B and allow pressure to drop. d. Repeat steps b. and c. until the balance of the charge is in the system. 6) When satisfied the unit is operating correctly, use the pinch-off tool with the unit still running and clamp on to the pinch-off tube. Using a tube cutter, cut the pinch-off tube about 2 inches from the pinch-off tool. Use sil-fos brazing and braze pinch-off tube closed. Turn off the unit, allow it to set for a while, and then test the leakage of the pinch-off connection.

Service Manual 23

Fails to Start

Check of power source.

Check circuit breaker and fuse.
Check of control switch setting.
Gas leakage of feeler bulb of thermostat

Check of control switch.

Compressor only fails to start.

Fan only fails to start.

Improper wiring. Drop of power voltage. Improper thermostat setting. Defect of compressor capacitor. Loose terminal connection. Capacitor check. Improper wiring. Replacement Replacement of fan motor. Defect of fan motor capacitor.
Irregular motor resistance ( ). Irregular motor insulation ( ).
Irregular motor resistance (
Regular but fails to start.
Irregular motor insulation (
) Replacement of compressor (locking of rotor, metal).
Replacement of compressor (Motor damaged)

24 Room Air Conditioner

Electrical Parts Troubleshooting Guide
Possible Trouble 1 The unit does not operate.
Is the Trans input power AC 115V? (208/230V for LWL1230WAL) YES
Check the Fuse. Check the Fuse. Check the wiring diagram. Check the wiring diagram.
Is the Trans output power about AC 14V? YES
Is shorted the Trans. output?
Check the Main PCB pattern.
Replace the Trans. Replace D02D~D05D. Replace IC01D.
Is output Voltage of IC01D DC 12V? YES
Is output Voltage of IC02D DC 5V? YES

Replace IC02D.

Is the reset circuit OK? (The No.14 of Micom is 5V.) YES Is the connection between AC and DC OK? YES

Replace IC01A, C02A.

Connect connector exactly.
Is the voltage No.18 of Micom DC 5V? YES Replace AC PCB Ass'y.

Check the PCB pattern.

Service Manual 25
Possible Trouble 2 The compressor does not operate.
Is setting Temp. set lower than Room Temp.-0.5C? YES NO
Select the setting Temp. to lower Number.
Is the voltage No.10 of IC01M 0V? YES Check the RY-COMP. Check the wiring Diagram.
Is the voltage N0.9 of IC01M DC 12V? YES Replace IC01M.
Does the Unit delay for 3 minutes? YES Wait 3 Minutes.

Replace MAIN PCB Ass'y.

Possible Trouble 3
The compressor always operate.
Is the wire connection of RY-COMP OK? YES Check the RY-COMP.
Connect LEAD Wire to RY-COMP again.

26 Room Air Conditioner

Possible Trouble 4

FAN does not operate.

Is the voltage NO.1 or 2 or 4 of IC01M DC 12V? YES

Replace IC01M.

Is the voltage NO.16 or 15 or 13 of IC01M 0V? YES Check the RY-Hi or RY-Med or RY-Lo. Check the wiring diagram.

Possible Trouble 5

Units using slinger ring for condenser fan must have /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.
Fan motor runs intermittently

Revolves on overload.

Check voltage. 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.

Fan motor noise.

Fan Turbo Loose clamper Worn bearings
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 be internal while running, replace motor. Check voltage. If not within limits, call an electrician. Check the wire connections, if loose, repair or replace the terminal. If wires are off, refer to wiring diagram for identification, and replace. Check wire locations. If not per wiring diagram, correct.
Compressor will not run, but fan motor runs.

Voltage Wiring

Service Manual 33
COMPLAINT Compressor will not run, but fan motor runs. CAUSE Thermistor REMEDY Check the TEMP control. If not at the lowest number, set TEMP control to this setting and restart the unit. Check the continuity of the thermistor. Replace the thermistor if the circuit is open. Check the capacitor. Replace if not within 10% of manufacturers rating. Replace if shorted, open, or damaged. Check the compressor for open circuit or ground. If open or grounded, replace the compressor. Check 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. 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 cause. Replace if required. Remove the cabinet. inspect the interior surface of the condenser; if restricted, clean carefully with a vacuum 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. 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 turbo or fan is hitting air guide, rearrange the air handling parts. Remove the cabinet carefully and rearrange tubing not to contact cabinet, compressor, shroud, and barrier.

Capacitor (Discharge capacitor before servicing.) Compressor Overload
Compressor cycles on overload.

Voltage Overload

Fan motor Condenser air flow restriction

Condenser fins (damaged)

Capacitor Wiring Refrigerating system
Insufficient cooling or heating
Air filter Exhaust damper door Unit undersized

Excessive noise

Turbo or fan

Copper tubing

34 Room Air Conditioner

Exploded View

749740

731273 130910

148000 149980

559011 554031

W48602 349480

W48602 749750

354210

349600

267110

147582-1 147581

349001

147582-2

135312 554160

249950

550140

135314

352115-1 268711-1

268711-2

W0CZZ 352115-2

552102

IND OO

238310

FR OS T
EN ER SA GY VE R PU AIR RY FIE AU RE TO R STA RT

264110 567480

352111
Co ol En erg Sa y ver Fa n Dr y Tim er

TIM ER

MO DE TE MP PO WE

F1 F2 LOW F3 MED HIG H

PO WER

137215

35211A 352113

Service Manual 35

R eplacement Parts List
R eplacement Parts L is t

LO CATIO N NO.

D E S C R IP T IO N BASE ASSEMBLY, W ELD[SINGLE] CABINET ASSEMBLY, SINGLE GRILLE ASSEMBLY, FRONT(SINGLE) GRILLE, INLET

GUIDE LOUVER, HORIZONTAL

PART NO. LW HD1450ER 3041A20023T 3091AR6057V 3531A10201A 3530A10146A

2H00858D 4758A30022A

LW HD1800R 3041A20067B 3091AR6057W 3531A10201A 3530A10146A
REM ARK R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R

135312 135314

749740 147581

147582-1 147582-149980

LOUVER, VERTICAL LOUVER, VERTICAL BRACE SHROUD FILTER ASSEMBLY, AIR CLEANER PANEL, CONTROL CONTROL BOX ASSEMBLY, SINGLE PW B(PCB) ASSEMBLY, MAIN(AC) ESCUTCHEON PW B(PCB) ASSEMBLY, MAIN(DC) THERMISTOR ASSEMBLY POW ER CORD ASSEMBLY MOTOR ASSEMBLY, SINGLE VENTILATION DAMPER ORIFICE MOUNT, MOTOR TUBE, CAPILLARY BEND TUBE ASSEMBLY, DISCHARGE SINGLE TUBE , FORMED TUBE , FORMED TUBE ASSEMBLY, SUCTION(OUTDOOR) AIR GUIDE ASSEMBLY EVAPORATOR ASSEMBLY, FIRST ANTI-VIBRATION BUSH CONDENSER ASSEMBLY, FIRST COMPRESSOR SET FAN ASSEMBLY, AXIAL FAN ASSEMBLY, TURBO REMOTE CONTROLLER ASSEMBLY CLAMP, SPRING CAPACITOR, DRAW ING INSTALL PARTS ASSEMBLY TUBE,CAPILLARY
4758A20042A 4758A20042B 4800A20001A 4998A10013A 5231A20008A 3720A10112A 4995A26003B 6871A20617E 3831A10021M 6871A20604A 6323A20012C 6411A20056L 4681A23010A 4900A20004A 4948A30008A 4960AR1596A 5211AR3332Z 5211A34005A 5210A23358C 5210A23358D 5211A20441K 5239A20002N 5421A20091H 4H00982C 5403A20062P 2520UCBK025 5900AR1508A 5901A20009A 6711A20034G 3H02932C 0CZZA20001L 3127AR3403U 5210A30646A

4758A20042A 4758A20042B 4800A20001A 4998A10026A 5231A20008A 3720A10112A 4995A26003A 6871A20617D 3831A10021F 6871A20604A 6323A20012C 6411A20056L 4681A20081A 4900A20004A 4948A30008A 4960AR1596A 5211A30275Z 5211A30066N 5210A21099E 5210A21099F 5211A20441L 5239A20002N 5421A20091G 4H00982C 5403A20112B 2520UCBJ002 5900AR1508A 5901A20009A 6711A20034G 3H02932C 6120AR2194F 3127AR3403U 5210A23357A

268711-268711-1

567480 264110

352111 352113

352115-1 352115-2 35211A 749750 354210

554160 559011

359012 267110
W 48602 W 0CZZ 731273 552102
36 R oom Air C onditioner

P/No.: 3828A29003A

January, 2006 Printed in China