Goldstar M1003r Service Manual

Room Air Conditioner

SVC MANUAL(Exploded View)

MODEL : LWC101GGMK1 LWC101GGMK0 LWC081GSMK1 LWC081GSMK0 LWC081GGMK0

CAUTION

Before Servicing the unit, read the safety precautions in General SVC manual. Only for authorized service personnel.

Internal Use Only

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CONTENTS

1. PREFACE

1.1 SAFETY PRECAUTIONS................................2

1.2 INSULATION RESISTANCE TEST.................2

1.3 SPECIFICATIONS...........................................3

1.4 FEATURES......................................................4

1.5 CONTROL LOCATIONS .................................4

DISASSEMBLY INSTRUCTIONS

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

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

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

2.1.3 CONTROL BOX .....................................6

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

2.2.1 AIR GUIDE AND BLOWER....................7

2.2.2 FAN AND SHROUD ...............................7

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

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

2.3.2 COMPRESSOR......................................8

2.3.3 CAPACITOR...........................................8

2.3.4 POWER CORD ......................................9

2.3.5 ROTARY SWITCH .................................9

2.3.6 MOTOR ..................................................9

2.4 REFRIGERATION CYCLE............................10

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

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

2.4.3 CAPILLARY TUBE...............................10

INSTALLATION

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

3.2 CHECK OF INSTALLATION..........................13

3.3 HOW TO DRAIN............................................13

3.4 HOW TO INSTALL ........................................14

3.5

HOW TO USE THE REVERSIBLE INLET GRILLE

TROUBLESHOOTING GUIDE

4.1 OUTSIDE DIMENSIONS...............................19

4.2 PIPING SYSTEM...........................................19

4.3 TROUBLESHOOTING GUIDE......................20

...18

5. SCHEMATIC DIAGRAM

5.1 CIRCUIT DIAGRAM ......................................29

5.2 ELECTRONIC CONTROL DEVICE...............30

5.3 COMPONENTS LOCATION

(OF MAIN P.C.B ASSEMBLY).......................31

5.4 COMPONENTS LOCATION

(OF DISPLAY P.C.B ASSEMBLY) ................31

6. EXPLODED VIEW..................................32

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 PRECAUTIONS

1. When servicing the unit, set the ROTARY SWITCH or POWER SWITCH 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 the unit, make an insulation resistance test to protect the customer from being exposed to shock hazards.

1.2

INSULATION RESISTANCE TEST

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

2. The grounding conductor (green) 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 OFF).

4. The value should be over 1MΩ.

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LGE Internal Use Only

1.3 SPECIFICATIONS

MODELS

ITEMS

POWER SUPPLY COOLING CAPACITY (Btu/h) INPUT (W) RUNNING CURRENT (A) E.E.R (BTU/W.h)

OPERATING CONDITION

REFRIGERANT (R-22) CHARGE FAN, INDOOR FAN, OUTDOOR FAN SPEEDS, FAN/COOLING FAN MOTOR OPERATION CONTROL ROOM TEMP. CONTROL

AIR DIRECTION CONTROL

INDOOR (°C)

OUTDOOR (°C)

KG8000RY3

LWC081GGMK0

8,000 7,800 10,000

820 720 1,020

7.6 6.6 9.2

9.8 10.8 9.8

260g(9.2 oz) 445g(15.7 oz) 460g (16.2 oz) 440g(15.5oz) 440g(15.5 oz)

M8003ER

BG8000ER

1ø, 115, 60Hz / 1ø, 220, 60Hz

26.7(DB)* 19.4(WB)** 35(DB)* 23.9(WB)**

BLOWER or TURBO FAN

PROPELLER TYPE FAN WITH SLINGER-RING

TOUCH & REMOTE CONTROL

THERMISTOR

VERTICAL LOUVER (RIGHT & LEFT)

HORIZONTAL LOUVER (UP & DOWN)

M1003RA3 M1003RY3

3/3

6 POLES

WG1000R

LWC101GGMK1

CONSTRUCTION

PROTECTOR

OUTSIDE DIMENSION

(W x H x D) (mm)

* DB:Dry Bulb **

WB:Wet Bulb

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

COMPRESSOR

FAN MOTOR

(inch)

181/2x 137/8 x 2011/16 235/8x 1431/32 x 225/16

470 x 353 x 525 600 x 380 x 567

SLIDE IN-OUT CHASSIS

OVERLOAD PROTECTOR

INTERNAL THERMAL PROTECTOR

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LGE Internal Use Only

1.4 FEATURES

CLOSE VENT OPEN

23 7

6 4

264 5

• Designed for COOLING ONLY.

• Powerful and whispering cooling.

• Slide-in and slide-out chassis for the simple installation and service.

• Side air-intake, side cooled-air discharge.

• Washable one-touch filter

• Compact size

• Reliable and efficient rotary compressor is equipped.

1.5 CONTROL LOCATIONS

1.5.1 COOLING ONLY MODEL

• VENTILATION

The ventilation lever must be in the CLOSE position in order to maintain the best cooling conditions. When a fresh air is necessary in the room, set the ventilation lever OPEN position. The damper is opened and room air is exhausted.

1.5.2 COOLING ONLY MODEL WITH REMOTE CONTROL AND T OUCH TYPE

• DISPLAY

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LGE Internal Use Only

Power

Temp

Fan Speed

Timer Mode

Energy

Saver

Auto

Swing

POWER

• 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.

• When you first turn it on, the air conditioner 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 to 86°F by 1°F.

(16˚C to 30˚C by 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(F3)

→

Low(F1)

→

Med(F2)

→

High(F3)...}.

ENERGY SAVER (AVAILABLE IN SOME MODELS)

• If the switch is set to "On", 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.

MODE

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

ON/OFF TIMER

- STOPPING OPERATION

• Everytime you push this button, when the air conditioner 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 air conditioner is not operating, timer is set as follow. (1Hour → 2Hours → 3Hours → 4Hours → 5Hours → 6Hours → 7Hours → 8Hours → 9Hours → 10Hours → 11Hours → 12Hours → Cancel)

AUTO SWING

• This button can automatically control the air flow direction.

REMOCON SIGNAL RECEIVER

• REMOTE CONTROLLER

778

Precaution: The Remote Controller will not function properly if strong light strikes the sensor window of the air

conditioner or if there are obstacles between the Remote Controller and the air conditioner.

AUTO RESTART

In failure of electric power, the unit runs as previous setting operation. (Available in some models)

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LGE Internal Use Only

2. DISASSEMBLY INSTRUCTIONS

— Before the following disassembly, POWER SWITCH set to OFF and disconnect the power cord.

2.1 MECHANICAL PARTS

2.1.1 FRONT GRILLE

1. Open the lnlet grille upward or downward.

2. Remove the screw which fastens the front grille.

3. Pull the front grille from the right side.

4. Remove the front grille.

5. Re-install the component by referring to the removal procedure, above.(See Figure 1)

Figure 1

2.1.2 CABINET

1. After disassembling the FRONT GRILLE, remove the 2 screws which fasten the cabinet at both sides.

2. Remove the 2 screws which fasten the cabinet at back.

3. Pull the base pan forward. (See Figure 2)

4. Remove the cabinet.

5. Re-install the component by referring 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 placing a 20,000 ohmresistor across the capacitor terminals.

8. Remove the 2 screws which fasten the control

box.(See Figure 3)

9. Pull the control box forward completely.

10. Re-install the components by referring to the removal procedure, above. (See Figure 3) (Refer to the circuit diagram found on page 24 in this manual or on the control box.)

Figure 2

Figure 3

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LGE Internal Use Only

2.2 AIR HANDLING PARTS

2.2.1 AIR GUIDE AND BLOWER

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

2. Remove the cabinet. (Refer to section 2.1.2)

3. Remove the control box. (Refer to section 2.1.3)

4. Remove the 3 screws which fasten the brace.

5. Remove the brace.

6. Remove the 2 screws which fasten the evaporator.

7. Move the evaporator forward and pulling it upward slightly. (See Figure 4)

8. Move the evaporator to the left carefully.

9. Pull out the hook of orifice by pushing the tabs and remove it. (See Figure 5)

10. Remove the clamp with a hand plier which

secures the blower.

11. Remove the blower.

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.

Figure 4

2.2.2 FAN AND SHROUD

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

2. Remove the brace (Refer to section 2.2.1)

3. Remove the 3 screws which fasten the condenser.

4. Move the condenser to the left carefully.

5. Remove the clamp which secures the fan.

6. Remove the fan and then pull out the shroud. (See Figure 6)

7. Re-install by referring to the removal procedure.

Figure 5

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Figure 6

LGE Internal Use Only

2.3 ELECTRICAL PARTS

2.3.1 OVERLOAD PROTECTOR

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

2. Remove the nut which fastens the terminal cover.

3. Remove the terminal cover. (See Figure 7)

4. Remove all the leads from the overload protector.

5. Remove the overload protector.

6. Re-install the component by referring to the removal procedure, above.

2.3.2 COMPRESSOR

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

2. Discharge the refrigerant system using a Freon 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

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 procedure, above.

Figure 7

Figure 8

2.3.3 CAPACITOR

1. Remove the control box. (Refer to section 2.1.3)

2. Remove the screw which fasten control panel from control box.

3. Remove the screw which located in the front.

4. Open the bottom side of control box.

5. Remove the screw and the clamp which fastens the capacitor.

6. Disconnect all the leads of capacitor terminals.

7. Re-install the components by referring to the removal procedure, above. (See Figure 9)

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Figure 9

LGE Internal Use Only

2.3.4 POWER CORD

1. Remove the control box. (Refer to section 2.1.3)

2. Open the control box. (Refer to section 2.3.3)

3. Disconnect the grounding screw from the control box.

4. Disconnect the 2 receptacles.

5. Remove a screw which fastens the clip cord. (See Figure 10)

6. Remove the power cord.

7. Re-install the component by referring to the above removal procedure, 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 same specification marked on the supply cord attached at the unit.)

2.3.5 MOTOR

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

2. Remove the evaporator. (Refer to section 2.2.1)

3. Remove the orifice. (Refer to section 2.2.1)

4. Remove the blower. (Refer to section 2.2.1)

5. Remove the fan. (Refer to section 2.2.2)

6. Remove the control box cover and housing of the motor in the control box. (Refer to section 2.1.3)

7. Remove the 2 screws which fasten the motor from the mount motor. (See Figure 11)

8. Remove the motor.

9. Re-install the components by referring to the removal procedure, above.(See Figure 11)

Figure 10

Figure 11

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LGE Internal Use Only

2.4 REFRIGERATING CYCLE

CAUTION

Discharge the refrigerant system using a FreonTMRecovery 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.

2.4.1 CONDENSER

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

2. Remove the 3 screws which fasten the brace.(Refer to section 2.2.1)

3. Remove the 3 screws which fasten the condenser and shroud.

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

5. Remove the condenser carefully.

6. Re-install the component by referring to notes. (See Figure 12)

Figure 12

2.4.2 EVAPORATOR

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

2. Remove 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 component by referring to notes. (See Figure 13)

2.4.3 CAPILLARY TUBE

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

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 component by referring to notes.

Figure 13

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LGE Internal Use Only

NOTES

— Replacement of the refrigeration cycle.

1. When replacing the refrigeration cycle, be sure to Discharge the refrigerant system using a Freon 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. Solder service valves into the pinch-off tube ports, leaving the valves open.

4. Solder the pinch-off tubes with Service valves.

5. Evacuate as follows.

1) Connect the vacuum pump, as illustrated figure

14A.

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 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 14B. 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 14B. 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 Low-

side.

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 solder and solder 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.

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