Goldstar M2404hr Service Manual

Thru-the-Wall Series

Service and Parts

Manual

US08/US10/US12 (05/05)

Thru-the-Wall Series

115 Volts US08B US10B US12B 230 Volts US10B US12B

CONTENTS

1. PREFACE

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

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

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

1.4 FEATURES .....................................................5

1.5 CONTROL LOCATIONS.................................5

2.

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

ORIFICE, HEATER ASSY AND TURBO FAN

2.2.2 FAN ........................................................7

2.2.3 SHROUD................................................8

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

2.3.1 MOTOR..................................................8

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

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

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

2.3.5 THERMISTOR .......................................9

.........7

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

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

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

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

3.

TROUBLESHOOTING GUIDE

3.1 OUTSIDE DIMENSIONS...............................13

3.2 PIPING SYSTEM ..........................................13

3.3 TROUBLESHOOTING GUIDE......................14

4. SCHEMATIC DIAGRAM

4.1 CIRCUIT DIAGRAM......................................19

5. EXPLODED VIEW..................................20

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, turn off the air conditioner 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 or green & 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.

4. The value should be over 1MΩ.

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LGE Internal Use Only

1.3 SPECIFICATIONS

1.3.1 FOR US08B10A, US10B10A, US12B10A

MODELS

ITEMS

POWER SUPPLY

CAPACITY (Btu/h)

INPUT (W)

RUNNING CURRENT (A)

E.E.R (Btu/w.h)

REFRIGERANT (R-22) CHARGE(g)

OPERATING

TEMPERATURE

INDOOR (°C)

OUTDOOR (°C)

EVAPORATOR

CONDENSER

FAN, INDOOR

FAN, OUTDOOR

FAN SPEEDS, FAN/COOLING

FAN MOTOR

US08B10A US10B10A US12B10A

1Ø, 115V,60Hz

8,000 9,800 11,700

830 1,110 1,250

7.5 10.2 11.4

9.6 8.8 9.4

540g(19.1OZ) 475g(16.8OZ) 485g(17.1OZ)

26.7(DB) 19.4(WB)

35(DB) 23.9(WB)

2 ROW 12STACKS 3 ROW 12STACKS

2 ROW 17STACKS, L-BENDING TYPE

TURBO FAN

PROPELLER TYPE FAN WITH SLINGER-RING

3/3

6 POLES 4POLES

REMARK

LOUVERED-FIN TYPE

OPERATION CONTROL

ROOM TEMP. CONTROL

AIR DIRECTION CONTROL

CONSTRUCTION

PROTECTOR

COMPRESSOR

FAN MOTOR

POWER CORD

DRAIN SYSTEM

NET WEIGHT (lbs/kg)

DIMENSION (inch)

(W x H x D) (mm)

SLEEVE DIMESION (inch)

(W x H x D) (mm)

SLEEVE DEPTH (inch)

ELECTRIC

THERMISTOR

VERTICAL LOUVER(RIGHT & LEFT)

HORIZONTAL LOUVER(UP & DOWN)

TOP-DOWN

EXTERNAL OVERLOAD PROTECTOR

INTERNAL THERMAL PROTECTOR

2.3m (3WIRES WITH GROUNDING)

ATTACHMENT PLUG(CORD-CONNECTED TYPE, LCDI)

SPLASHED BY FAN SLINGER

73/33 78/35 80/36

24 x 1413/32 x 20 3/32

610 x 366 x 499

25 7/

8 x 15

17

/

32 x 16

23

/

32

656 x 394 x 425

20 1/

20

OPTIONAL

PART

WITH FRONT GRILLE (mm)

- 3 -

521

LGE Internal Use Only

1.3.2 FOR US10B30A, US12B30A

MODELS

ITEMS

POWER SUPPLY

COOLING CAPACITY (Btu/h)

INPUT (W)

RUNNING CURRENT

(A)

E.E.R. (Btu/W.h)

OPERATING TEMPERA-TURE

INDOOR (°C)

OUTDOOR (°C)

REFRIGERANT (R-22) CHARGE (g)

EVAPORATOR

CONDENSER

FAN, INDOOR

FAN, OUTDOOR

FAN SPEEDS (FAN/COOLING/HEATING)

FAN MOTOR

OPERATION CONTROL

US10B30A US12B30A

1Ø, 230/208V,60Hz

10,000/9,800 11,700/11,400

1,060/1,040 1,250/1,210

4.7/5.2 5.8/6.2

9.4 9.4

480g(16.9OZ) 475g(16.8OZ)

26.7(DB) 19.4(WB)

35(DB) 23.9(WB)

2 ROW 12STACKS 3 ROW 12STACKS

2 ROW 17STACKS, L-BENDING TYPE

TURBO FAN

PROPELLER TYPE FAN WITH SLINGER-RING

3/3

6 POLES 4POLES

ELECTRIC

REMARK

LOUVERED-FIN TYPE

ROOM TEMP. CONTROL

AIR DIRECTION CONTROL

CONSTRUCTION

COMPRESSOR

PROTECTOR

FAN MOTOR

POWER CORD

DRAIN SYSTEM

NET WEIGHT (lbs/kg)

DIMENSION (inch)

(W x H x D) (mm)

SLEEVE DIMESION (inch)

(W x H x D) (mm)

SLEEVE DEPTH (inch)

WITH FRONT GRILLE (mm)

THERMISTOR

VERTICAL LOUVER(RIGHT & LEFT)

HORIZONTAL LOUVER(UP & DOWN)

TOP-DOWN

EXTERNAL OVERLOAD PROTECTOR

INTERNAL THERMAL PROTECTOR

2.3m (3WIRES WITH GROUNDING)

ATTACHMENT PLUG(CORD-CONNECTED TYPE, LCDI)

SPLASHED BY FAN SLINGER

78/35 80/36

24 x 14

13

/

32 x 20

3

/

32

610 x 366 x 499

25 7/

8

x 15

17

/

32

x 16

23

/

32

656 x 394 x 425

20 1/

20

521

OPTIONAL

PART

- 4 -

LGE Internal Use Only

1.4 FEATURES

PULL OPEN / PUSH CLOSE

REMOTE CONTROL SIGNAL RECEIVER

POWER

MODE

-

Push this button to shift mode of operation from COOL

→ MONEY SAVER → FAN.

- COOL :

• Fan runs continually for normal cooling operation.

- MONEY SAVER:

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

- FAN :

• Fan-only operation.

TIMER

- SHUT-OFF TIME

• You will usually use shut-off time while you sleep.

• If unit is running, use Timer to set number of

hours until shut-off.

• For your sleeping comfort, once Time is set, the Temperature setting will raise 2°F after 30 min., and once again after another 30 min.

• Push Timer button to advance setting from 1 Hour

→

2 Hours

→

....

→

12 Hours maximum.

- START TIME

• If unit is off, use Timer to set number of hours before unit starts.

• Push Timer button to advance setting from 1 Hour

→

2 Hours

→

.....

→

12 Hours maximum.

TEMPERATURE SETTING

• Use this button to automatically control the temperature of the room. The temperature can be set within a range of 60°F to 86°F by increments of 1°F.

• The setting appears in the display.

• To turn the air conditioner ON, push this button.

To turn the air conditioner OFF, push the button again.

• This button takes priority over any other button.

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

speed, and set at a temperature setting of 72°F.

FAN SPEED

• Every time you push this button, it advances the setting as follows: {High → Low → Med → High}

• Designed for cooling only.

• Powerful and quiet cooling.

• Top-down chassis for the simple installation and service.

1.5 CONTROL LOCATIONS

1.5.1 COOLING ONLY MODEL

• OPERATION

• Built in adjustable THERMISTOR and THERMOSTAT.

• Washable one-touch filter.

• Compact size.

• VENTILATION

Push the lever to the "CLOSE" position to cool, heat or recirculate room air only. Pull the lever to the "OPEN" position to exhaust smoke or stale air from the room. This feature is best used in conjunction with the FAN ONLY position.

CAUTION

When the air conditioner has been operating in the cooling and is turned off or set to the fan only position, wait at least 3 minutes before resetting to the cooling operation again.

- 5 -

LGE Internal Use Only

2. DISASSEMBLY INSTRUCTIONS

— Prior to disassembling the unit, make sure that the POWER is off and the power cord is unplugged from the

wall receptacle.

2.1 MECHANICAL PARTS

2.1.1 FRONT GRILLE

1. Open the inlet grille downward.

2. Remove the screw which fastens the front grille.

3. Pull the front grille from the right side.

4. Remove the front grille. (See Fig. 1)

5. Re-install the component by referring to the removal procedure.

Figure 1

2.1.2 CABINET

1. After disassembling the FRONT GRILLE, remove the 6 screws which fasten the cabinet at the both sides and the top. (See Fig. 2) Keep these for later use.

2.1.3 CONTROL BOX

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

2. Remove the screw which fasten the control box. (See Fig. 3)

3. Pull the control box from the barrier.(See Fig.3)

4. Discharge the capacitor by placing a 20,000 ohm resistor across the capacitor terminals.

5. Disconnect two wire housings in the control box.

6. Pull the control box forward completely.

7. Re-install the components by referring to the removal procedure. (See Fig. 3) (Refer to the circuit diagram found on pages

29~30 in this manual and on the control box.)

Figure 2

Figure 3

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LGE Internal Use Only

2.2 AIR HANDLING PARTS

2.2.1 ORIFICE, AND TURBO FAN

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

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

3. Remove the 2 screws which fasten the evaporator at the left side and the right side. (See Fig. 4)

4. Move the evaporator sideward carefully.

5. Remove the orifice. (See Fig. 5)

8. Using handheld pliers, remove the clamp which secures the turbo fan. (See Fig. 6)

Figure 4

Figure 5

9. Remove the turbo fan with pliers or your hand, without touching blades. (See Fig. 7)

10. Re-install the components by referring to the removal procedures, above.

2.2.2 FAN

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

2. Remove the brace.

(Refer to section 2.2.1)

3. Remove the 7 screws which fasten the condenser.

4. Move the condenser sideways carefully.

5. Using handheld pliers, remove the clamp which

secures the fan.

6. Remove the fan. (See Fig. 8)

7. Re-install the components by referring to the

removal procedures, above.

Figure 6

Figure 7

Figure 8

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LGE Internal Use Only