Goldstar LWJ0611PCG User Manual

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ROOM AIR CONDITIONER

SERVICE MANUAL

CAUTION

BEFORE SERVICING THE UNIT, READ THE SAFETY PRECAUTIONS IN THIS MANUAL.

D r

F a

C o o

MODEL : M5403R, M5203R, M5203L, M6003R, WM-6011,

LWJ0611PCG, LWC061JGMK1

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CONTENTS

1. PREFACE ................................................................ 2

1.1 FEATURES.................................................................. 2

1.2 SPECIFICATIONS ...................................................... 3

1.3 SAFETY PRECAUTIONS ........................................... 3

1.4 INSULATION RESISTANCE TEST ............................. 3

1.5 LOCATIONS OF CONTROLS .................................... 4

2. DISASSEMBLY INSTRUCTIONS ............. 6

2.1 MECHANICAL PARTS ............................................... 6

2.1.1 FRONT GRILLE ................................................. 6

2.1.2 CABINET............................................................ 6

2.1.3 CONTROL BOARD ............................................ 6

2.2 AIR HANDLING PARTS ............................................. 7

2.2.1 AIR GUIDE UPPER............................................ 7

2.2.2 ORIFICE, TURBO FAN AND FAN...................... 7

2.2.3 MOTOR .............................................................. 8

2.2.4 AIR GUIDE ......................................................... 8

2.3 ELECTRICAL PARTS ................................................. 8

2.3.1 OVERLOAD PROTECTOR ................................ 8

2.3.2 COMPRESSOR.................................................. 9

2.3.3 CAPACITOR ...................................................... 9

2.3.4 THERMISTOR.................................................... 9

2.3.5 CONTROL PANEL.............................................. 9

2.3.6 POWER CORD ................................................ 10

2.4 REFRIGERANT CYCLE ........................................... 10

2.4.1 CONDENSER .................................................. 10

2.4.2 EVAPORATOR ................................................. 10

2.4.3 CAPILLARY TUBE .......................................... 11

3. INSTALLATION .................................................. 13

3.1 SELECT THE BEST LOCATION .............................. 13

3.2 HOW TO INSTALL .................................................... 13

4. TROUBLESHOOTING GUIDE ..................

4.1 OUTSIDE DIMENSIONS........................................... 16

4.2 PIPING SYSTEM ..................................................... 17

4.3 TROUBLESHOOTING GUIDE ................................. 18

5. SCHEMATIC DIAGRAM ............................... 26

5.1 CIRCUIT DIAGRAM.................................................. 26

5.2 ELECTRONIC CONTROL DEVICE.......................... 27

5.3

COMPONENTS LOCATION(FOR MAIN P.W.B ASM)

........ 28

5.4

COMPONENTS LOCATION(FOR DISPLAY P.W.B ASM)

... 28

6. EXPLODED VIEW ............................................ 29

7. SERVICE PARTS LIST .................................. 30

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 FEATURES

• DESIGNED FOR COOLING ONLY

• POWERFUL AND INCREDIBLE COOLING

• TOP-DOWN CHASSIS FOR THE SIMPLE INSTALLATION AND SERVICE

• WASHABLE ONE-TOUCH FILTER

• COMPACT SIZE

1.2 SPECIFICATIONS

• NOTE: Specifications are subject to minor change without notice for further improvement.

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MODELS

ITEMS

COOLING CAPACITY (BTU/h) 5,300 5,200 5,200 6,000 6,000 POWER SUPPLY (Phase, V, Hz) 1ø, 115V, 60HZ INPUT (W) 530 470 610 620 OPERATING CURRENT (AMP.) 4.8 4.3 5.6 5.8 REFRIGERANT CONTROL CAPILLARY TUBE REFRIGERANT CHARGE (R-22) 230g (8.1 Oz ) 330g(11.6 Oz) 335g (11.8 Oz)

235g (8.3 Oz) INSIDE FAN TURBO OUTSIDE FAN PROPELLER FAN WITH SLINGER RING AIR DISCHARGE 2-WAY (RIGHT AND LEFT) CHASSIS TOP-DOWN

PROTECTOR

TEMPERATURE CONTROL THERMISTOR ROTARY SWITCH

5 POSITIONS (LOW FAN, HIGH FAN, OFF, HIGH COOL, LOW COOL)

FAN MOTOR

6 POLES, 16W

6 POLES, 21.3W 6 POLES, 24W 6 POLES,

21.4W

• OVERLOAD PROTECTOR FOR COMPRESSOR

• INTERNAL PROTECTOR FOR FAN MOTOR

M5403R M5203R M5203L

M6003R

WM-6011

LWJ0611PCG

LWC061JGMK1

1.3 SAFETY PRECAUTIONS

1. When servicing, set the POWER of CONTROL BOARD to Off and unplug the power cord.

2. Observe the original lead dress. If a short circuit is found, replace all parts which have been overheated or damaged by the short circuit.

3. After servicing, make an insulation resistance test to prevent the customer's exposure to shock hazards.

1.4

INSULATION RESISTANCE TEST

1. Unplug the power cord and connect a jumper between 2 pins (black and white).

2. The grounding conductor (green or green and yellow) is to be open.

3. Measure the resistance value with an ohm meter between the jumpered lead and each exposed metallic part on the equipment at all Mode [except POWER OFF].

4. The value should be over 1 MΩ.

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1.5 LOCATIONS OF CONTROLS

1.5.1

CONTROLS

Dry Fan

Cool

ON/OFF TIMER

- STOPPING OPERATION

• Everytime you push this button, when the unit is operating, timer is set as follows.

(1Hour 2Hours 3Hours 4Hours 5Hours 6Hours

7Hours 8Hours 9Hours 10Hours 11Hours 12Hours Cancel)

• The Setting Temperature will be raised by 2°F(1°C) 30min. later and by 2°F(1°C) after another 30 min.

- STARTING OPERATION

• Everytime you push this button, when the unit is not operating, timer is set as follow.

(1Hour 2Hours 3Hours 4Hours 5Hours 6Hours

7Hours 8Hours 9Hours 10Hours 11Hours 12Hours Cancel)

FAN/COOL/DRY

• Everytime you push this button, it will toggle between COOL, FAN and DRY.

POWER

• To turn the unit ON, push the button. To turn the unit OFF, push the button again.

• This button takes priority over any other buttons.

• When you first turn it on, the unit is on the High cool mode

and the temp. at 72°F(22°C).

TEMPERATURE SETTING

• This button can automatically control the temperature of the room. The temperature can be set within a range of 60°F(16°C) to 86°F(30°C) by 1°F(1°C). Select the lower number for lower temperature of the room.

FAN SPEED

• Everytime you push this button it is set as follows. {High(F2) Low(F1) High(F2)...}.

ENERGY SAVER

The fan stops when the compressor stops cooling.

• Approximately every 3 minutes the fan will turn on and check the room air to determine if cooling is needed.

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1.5.2 REMOTE CONTROLLER

How to Insert Batteries

1. Remove the cover from the back of the

remote controller

2. Insert two batteries.

• Be sure that the (+) and (-) directions are correct.

• Be sure that both batteries are new.

3. Re-attach the cover.

• Do not use rechargeable batteries. Such batteries differ from standard dry cells in shape, dimensions, and performance.

• Remove the batteries from the remote controller if the air conditioner is not going to be used for an extended length of time.

Auto

Swing

Power

Temp

Fan Speed

Timer Mode

Energy

Saver

TEMPERATURE SETTING

ENERGY SAVER

The fan stops when the compressor stops cooling.

• Approximately every 3 minutes the fan will turn on and check the room air to determine if cooling is needed.

FAN SPEED

• Everytime you push this button it is set as follows. (High(F2) Low(F1) High(F2)...)

POWER

• To turn the Set ON, push the button. To turn the Set OFF, push the button again.

• This button takes priority over any other buttons.

• When you first turn it on, the Set is on the High cool mode and the temp. at 72°F(22°C).

COOL/FAN/DRY

ON/OFF TIMER

- STOPPING OPERATION

• Everytime you push this button, when the set is operating, timer is set as follows.

(1Hour 2Hours 3Hours 4Hours 5Hours 6Hours

7Hours 8Hours 9Hours 10Hours 11Hours 12Hours Cancel)

• The Setting Temperature will be raised by 2°F(1°C) 30min. later and by 2°F(1°C) after another 30 min.

- STARTING OPERATION

• Everytime you push this button, when the set is not operating, timer is set as follow.

(1Hour 2Hours 3Hours 4Hours 5Hours 6Hours

7Hours 8Hours 9Hours 10Hours 11Hours 12Hours Cancel)

• This button can automatically control the temperature of the room. The temperature can be set within a range of

60°F(16°C) to 86°F(30°C) by 1°F(1°C). Select the lower number for lower temperature of the room.

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2. DISASSEMBLY INSTRUCTIONS

2.1 MECHANICAL PARTS

2.1.1 FRONT GRILLE

1. Disconnect the unit from source of power.

2. Using a screwdriver, remove the screw that secures the front grille to control board. (See Figure 1)

3. Push the front grille up from the bottom. Pull the top of the front grille away from the cabinet as the top tabs lift out of their slots. (See Figure 2)

4. Replace the grille by placing the tabs in the slots and push the grille until it snaps into place.

2.1.2 CABINET

1. Disconnect the unit from the power source.

2. Remove the front grille. (Refer to section 2.1.1)

3. Remove 7 screws that secure the cabinet to the base pan and condenser. (See Figure 3)

4. Lift the cabinet from the unit.

5. Re-install by referring to the procedures above.

2.1.3 CONTROL BOARD

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 2 screws that secure the control board to base pan and air guide. (See Figure 4)

5. Pull the control board toward yourself.

6. Disconnect one housing terminal and 3 wires for the fan motor and compressor. (See Figure 5)

7. Re-install components by referring to procedures above. (Refer to circuit diagram on page 26 in this manual or inside control board.)

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

NOTE : Controls, wires, and capacitor are now

accessible for servicing. Discharge the capacitor before servicing. See step

2.3.3 on page 8 for procedures.

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2.2 AIR HANDLING PARTS

2.2.1 AIR GUIDE UPPER

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 control board. (Refer to Section 2.1.3)

5. Remove 2 screws that secure the air guide upper to air guide lower. (See Figure 6)

6. Lift air guide upper upward.

7. Re-install by referring to the procedures above.

2.2.2 ORIFICE, TURBO FAN AND FAN

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 control board. (Refer to Section 2.1.3)

5. Remove the air guide upper. (Refer to Section 2.2.1)

6. Remove 2 screws that secure the base pan to condenser. (See Figure 7)

7. Remove screw that secures the shroud to channel of condenser.

8. Press the snap area of shroud with your thumbs. This allows you to remove it from the condenser.

9. Lift the compressor upward with the evaporator and condenser. (See Figure 7)

10. Remove the orfice by pushing the snap area of the air guide blower. (See Figure 8)

11. Remove the clamp springs which are clamped to the boss of fan and turbo fan by hand plier. (See Figure 9)

12. Pull the fan and turbo fan outward.

13. Remove the shroud.

14. Re-install by referring to the procedures above.

Figure 6

Figure 7

Figure 8

Figure 9

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2.2.3 MOTOR

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 control board. (Refer to Section 2.1.3)

5. Remove the air guide upper. (Refer to Section 2.2.1)

Remove the compressor, turbo fan, fan and shroud. (Refer to

Section

2.2.2)

Remove 2 screws that secure the motor to the motor. (See Figure 10)

8. Remove the motor.

Re-install by referring to the procedures above.

2.2.4 AIR GUIDE

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 control board. (Refer to Section 2.1.3)

5. Remove the air guide upper. (Refer to Section 2.2.1)

Remove the compressor, turbo fan, fan and shroud. (Refer to

Section

2.2.2)

Remove the motor. (Refer to

Section

2.2.3)

8. Remove 2 screws that secure the air guide to the base pan. (See Figure 11)

9. Push the air guide backward and lift it upward. (See Figure 11)

10. Re-install by referring to the procedures above.

2.3 ELECTRICAL PARTS

2.3.1 OVERLOAD PROTECTOR

1. Remove the front grille and cabinet. (Refer to Section 2.1)

2. Remove the nut which fastens the terminal cover.

3. Remove the terminal cover.

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. (See Figure 12 and 13)

Figure 10

Figure 12

Figure 13

Figure 11

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2.3.2 COMPRESSOR

1. Remove the front grille and cabinet. (Refer to Section 2.1.2)

2. Discharge the refrigerant by using a refrigerant recovery system.

3. Remove the overload protector. (Refer to Section 2.3.1)

4. After discharging the unit completely, unbrace the suction and discharge pipes at the compressor connections.

5. Remove 3 nuts which fasten the compressor.

6. Remove the compressor.

7. Re-install by referring to the removal procedure above. (See Figure 14)

2.3.3 CAPACITOR

1. Remove the cabinet. (Refer to Section 2.1.2)

2. Remove the control board. (Refer to Section 2.1.3)

3. Discharge the capacitor by placing a 20 KΩ resistor across the capacitor terminals.

4. Pull the capacitor upward.

5. Remove all the leads of capacitor terminals.

6. Re-install the components by referring to the removal procedure above. (See Figure 15)

2.3.4 THERMISTOR

1. Remove the cabinet. (Refer to Section 2.1.2)

2. Remove the control board. (Refer to Section 2.1.3)

3. Disconnect the thermistor terminals from main P.W.B assembly.

4. Remove the thermistor.

5. Re-install the components by referring to the removal procedure above. (See Figure 16)

2.3.5 CONTROL PANEL

1. Remove the cabinet. (Refer to Section 2.1.2)

2. Remove the control board. (Refer to Section 2.1.3)

3. Pull the control panel forward and pull out it.

4. Remove 2 lead wire terminals.

5. Re-install the components by referring to the removal procedure above. (See Figure 17)

Figure 14

Figure 15

Figure 16

Figure 17

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2.3.6 POWER CORD

1. Disconnect the unit from source of power.

2. Remove the front grille. (Refer to Section 2.1.1)

3. Remove the cabinet. (Refer to Section 2.1.2)

4. Remove 2 screws that secure control board to base pan and orifice.

5. Pulls the control board toward you.

6. Remove the grounding screw.

7. Remove a screw securing the clip with cord to the control board.

8. Pull the power cord.

9. Re-install by referring to procedures above.

2.4 REFRIGERANT CYCLE

2.4.1 CONDENSER

1. Remove the cabinet. (Refer to Section 2.1.2)

2. Discharge the refrigerant by using a refrigerant recovery system.

3. Remove the air guide. (Refer to Section 2.2.1)

4. Remove 2 screws which fasten the condenser.

5. After discharging the refrigerant completely, unbraze the interconnecting tube at the condenser connections.

6. Remove the condenser.

7. Re-install by referring to the procedures above.

2.4.2 EVAPORATOR

1. Remove the cabinet.

2. Discharge the refrigerant by using a refrigerant recovery system.

3. Remove the air guide upper. (Refer to Section

2.2.1)

4. After discharging the refrigerant completely, unbraze the interconnecting tube at the condenser connections.

5. Remove the evaporator.

6. Re-install by referring to the procedures above.

Figure 18

Figure19

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