Goldstar R1003 Service Manual

Internal Use Only

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Room Air Conditioner

SVC MANUAL(Exploded View)

MODEL : R1003A3

R-8000AY3

CAUTION

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

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 ....................................5

2.1.1 FRONT GRILLE .....................................5

2.1.2 CABINET ................................................5

2.1.3 CONTROL BOX .....................................5

2.2 AIR HANDLING PARTS ..................................6

2.2.1 AIR GUIDE AND BLOWER ....................6

2.2.2 FAN AND SHROUD ...............................6

2.3 ELECTRICAL PARTS......................................7

2.3.1 OVERLOAD PROTECTOR ....................7

2.3.2 COMPRESSOR......................................7

2.3.3 CAPACITOR...........................................7

2.3.4 POWER CORD ......................................8

2.3.5 THERMOSTAT.......................................8

2.3.6 ROTARY SWITCH .................................8

2.3.7 MOTOR ..................................................8

2.4 REFRIGERATION CYCLE ..............................9

2.4.1 CONDENSER.........................................9

2.4.2 EVAPORATOR.......................................9

2.4.3 CAPILLARY TUBE .................................9

INSTALLATION

3.1 SELECT THE BEST LOCATION...................12

3.2 CHECK OF INSTALLATION..........................12

3.3 HOW TO DRAIN............................................12

3.4 HOW TO INSTALL ........................................13

3.5

HOW TO USE THE REVERSIBLE INLET GRILLE

TROUBLESHOOTING GUIDE

4.1 OUTSIDE DIMENSIONS ...............................18

4.2 PIPING SYSTEM...........................................18

4.3 TROUBLESHOOTING GUIDE ......................19

...17

5. SCHEMATIC DIAGRAM

5.1 CIRCUIT DIAGRAM ......................................24

6. EXPLODED VIEW ..................................25

1. PREFACE

This SERVICE MANUAL provides various service information, including the mechanical and electrical parts etc. This room air conditioner was manufactured and assembled under a strict quality control system. The refrigerant is charged at the factory. Be sure to read the safety precautions prior to servicing the unit.

1.1 SAFETY 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 the positions (except OFF) of the ROTARY SWITCH.

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

EVAPORATOR

CONDENSER

FAN, INDOOR

FAN, OUTDOOR

FAN SPEEDS, FAN/COOLING

FAN MOTOR

OPERATION CONTROL

ROOM TEMP. CONTROL

AIR DIRECTION CONTROL

INDOOR (°C)

OUTDOOR (°C)

R10003A3 R-8000AY3

1ø, 115, 60Hz

10,000 8,000

1,020 820

9.2 7.6

9.8

26.7(DB)*

35(DB)*

460g(16.2oz) 260g(9.2oz)

3 ROW 14 STACKS, SLIT-FIN TYPE

2 ROW 16 STACKS, L-BENDED TYPE

TURBO FAN

PROPELLER TYPE FAN WITH SLINGER-RING

ROTARY SWITCH

THERMOSTAT

VERTICAL LOUVER (RIGHT & LEFT)

HORIZONTAL LOUVER (UP & DOWN)

19.4(WB)**

23.9(WB)**

2/3

6 POLES

CONSTRUCTION

PROTECTOR

POWER CORD

DRAIN SYSTEM

NET WEIGHT (lbs/kg)

OUTSIDE DIMENSION (inch)

(W x H x D) (mm)

* DB:Dry Bulb **

WB:Wet Bulb

COMPRESSOR

FAN MOTOR

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

70/32

181/2 x 137/8 x 2011/16

470 x 353 x 525

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LGE Internal Use Only

1.4 FEATURES

CLOSE VENT OPEN

Operation

Off

Med

Fan

Low Fan

Low Cool

Med Cool

High Cool

Thermostat

• 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.

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.

• THERMOSTAT

Thermostat will automatically control the temperature of the room. Select a higher number (the right side of arc) for a cooler temperature in the room. The temperature is selected by positioning the knob to the desired position. The 5 or 6 position (the middle position of arc) is a

• OPERATION

normal setting for average conditions.

• Built-in adjustable THERMOSTAT

• Washable one-touch filter

• Compact size

• Reliable and efficient rotary compressor is equipped.

OFF : Turns the air conditioner to off.

MED FAN : Permits the medium fan speed

operation without cooling.

LOW FAN : Permits the low fan speed operation

without cooling.

HIGH COOL : Permits cooling with the high fan speed

operation.

MED COOL : Permits cooling with the medium fan

speed operation.

LOW COOL : Permits cooling with the low fan speed

operation.

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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 turbo fan.

11. Remove the turbo fan.

12. Remove the 4 screws which fasten the air guide

from the barrier.

13. Move the air guide backward, pulling out from the

base pan.

14. Re-install the components by referring to the

removal procedure, above.

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 screw which fastens the cover cond.

4. Remove the 5 screws which fasten the condenser.

5. Move the condenser to the left carefully.

6. Remove the clamp with a hand plier which secures the fan.

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

8. Re-install the components 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 knobs and the screw which fasten control panel from control box.

3. Remove the screw which is located in the front.

4. Open the bottom side of control box.

5. Remove the screw and the clamp which fasten 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 THERMOSTAT

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

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

3. Remove the 2 screws which fasten the thermostat.

4. Disconnect 2 leads of thermostat terminals.

5. Remove the thermostat.

6. Re-install the components by refereing to the above removal procedure. (See Figure 11)

Figure 10

Figure 11

2.3.6 ROTARY SWITCH

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

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

3. Remove the 2 screws which fasten the rotary switch.

4. Disconnect all the leads of the rotary switch terminals.

5. Remove the rotary switch.

6. Re-install the components by referring to the above removal procedure. (See Figure 12)

2.3.7 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 13)

8. Remove the motor.

9. Re-install the components by referring to the removal procedure, above.(See Figure 13)

Figure 12

Figure 13

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