Goldstar R6003 Service Manual

Room Air Conditioner

SERVICE MANUAL

MODEL: R5003, R5204, R5205, WR-5210, R6003

WR-6010, R7003, LW5200E, R0500M

website http://www.lgservice.com

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

How to Install..............................................................................................................................................7

Kit Contents Installation ...........................................................................................................................8

Operation ......................................................................................................................................................10

Features ...................................................................................................................................................10

About the Controls on the Air Conditioner ...............................................................................................11

Disassembly ..................................................................................................................................................12

Mechanical Parts......................................................................................................................................12

Air Handling Parts ....................................................................................................................................14

Electrical Parts .........................................................................................................................................14

Refrigerating Cycle...................................................................................................................................16

Schematic Diagram.......................................................................................................................................19

Wiring Diagram.........................................................................................................................................19

Troubleshooting Guide.................................................................................................................................20

Piping System ..........................................................................................................................................20

Troubleshooting Guide .............................................................................................................................21

Room Air Conditioner Voltage Limits........................................................................................................23

Exploded View ..............................................................................................................................................26

Replacement Parts List..............................................................................................................................27A

2 Room Air Conditioner

Safety Precautions

WARNING

CAUTION

WARNING

Safety Precautions

To prevent injury to the user or other people and property damage, the following instructions must be followed.

■ Incorrect operation due to ignoring instruction will cause harm or damage. The seriousness is classified by the following indications.

This symbol indicates the possibility of death or serious injury.

This symbol indicates the possibility of injury or damage to property only.

■ Meanings of symbols used in this manual are as shown below.

Be sure not to do.

Be sure to follow the instruction.

■ 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

Sharp edges

Gasolin

Do not modify or extend the power cord.

• 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 install, remove, or re-install the unit by yourself.

• There is risk of fire, electric shock, explosion, or injury.

Do not store or use flammable gas or combustibles near the air conditioner.

• There is risk of fire or failure of product.

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

370 (14 9/16")

312 (12 1/4")

370 (14 9/16")

312 (12 1/4")

29 (1

/32")

120 (4 3/4")

27.5 (1

/32")

346 (13

/8")

472 (18 9/16")

42 (1 21/32")

155(6 3/32")

(0.4

1/16

472 (18 9/16")

22.5(0.8 3/32")

Operation

High Fan

Low Fan

High Cool

Off

Low Cool

Thermostat

Operation

High Fan

Low Fan

High Cool

Off

Low Cool

Thermostat

NOTICE

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.

This symbol indicates special notes.

Outside Dimensions

Dimensions

Service Manual 5

Product Specifications

NOTICE

Product Specifications

MODELS

ITEMS

COOLING CAPACITY (BTU/h) 5,000 5,200 6,000 7,000 5,200 5,050

POWER SUPPLY (Phase, V, Hz) 1ø, 115V, 60HZ

INPUT (W) 515 520(530) 620 720 480 520

OPERATING CURRENT (AMP.) 4.8 4.8 5.6 6.7 4.4 4.8

REFRIGERANT CONTROL CAPILLARY TUBE

REFRIGERANT CHARGE (R-22)

INSIDE FAN TURBO

OUTSIDE FAN PROPELLER FAN WITH SLINGER RING

AIR DISCHARGE 2-WAY (RIGHT AND LEFT)

CHASSIS TOP-DOWN

PROTECTOR

TEMPERATURE CONTROL THERMOSTAT

ROTARY SWITCH

R5003

220g (7.8 Oz) 230g (8.1 Oz) 335g(11.8Oz)

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

R5204, R5205

WR-5210

• OVERLOAD PROTECTOR FOR COMPRESSOR

• INTERNAL PROTECTOR FOR FAN MOTOR

R6003,

WR-6010

R7003 LW5200E R0500M

315g (11.1 Oz)

330g(11.6 Oz) 220g (7.8 Oz)

FAN MOTOR

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

6 POLES, 16W

6 POLES, 24W 6 POLES, 27W 6 POLES, 21W

6 Room Air Conditioner

Installation

NOTICE

ABOUT / "

Over 20"

HEAT

RADIATION

FENCE

AWNING

OUTSIDE

INSIDE

COOLED AIR

30"-60"

OUTDOORSINDOORS

INNERSILL

OUTER

SILL

INNER

SILL

WOOD STRIP

MOUNTED ON TOP

OF INNER SILL

WOOD STRIP

FOR

BRACKET

3/4"

CLEARANCE

1" MAX.

STORM

WINDOW

FRAME

OUTDOORSINDOORS

OUTER

SILL

This air conditioner is designed with a button-down chassis so it can be easily installed in a window.

Select the Best Location

1. To prevent vibration and noise, make sure the unit is installed securely and firmly.

2. Install the unit where the sun does not shine directly on the unit.

3. The outside of the cabinet must extend outward for at least 10" and there should be no obstacles, such as a fence or wall, within 20" from the back of the cabinet because it will prevent heat radiation of the condenser. Restriction of outside air will greatly reduce the cooling efficiency of the air conditioner.

CAUTION: All side louvers of the cabinet

must remain exposed on the outdside of

the structure.

Installation

4. Install the unit slanted slightly so the back is slightly lower

5. Install the unit with the bottom about 30"~60" above the

Window Requirements

1. This unit is designed for installation in standard double hung win-

2. If storm window presents interference, fasten a 2" wide wood strip

3. Install a second wood strip (approximately 6" long by 11/2" wide

4. If the distance between STORM WINDOW FRAME and WOOD

than the front (about 1/4"). This will force condensed water to the outside.

floor level.

How to Install

All supporting parts should be secured to firm wood, masonry, or metal.

dows with actual opening widths of 22" to 36". The upper and lower sash must open sufficiently to allow a clear vertical opening of 13" from the bottom of the sash to the window stool.

to the inner window sill across the full width of the sill. The wood strip should be thick enough to raise the height of the window sill so that the unit can be installed without interference by the storm window frame. See Figure. 3. Top of wood strip should be approximately 3/4" higher than the storm window frame (STORM WINDOW FRAME) or wood strip (OUTDOORS) to help condensation to drain properly to the outside.

and same thickness as first strip) in the center of the outer sill flush against the back off the inner sill. This will raise the L bracket as shown Figure. 3.

STRIP MOUNTED ON TOP OF INNER SILL is more than 1", two of wood strip are not necessary.

Figure 1

Figure 2

Figure 3

Service Manual 7

Installation

TYPE B: 4EA

(WOOD SCREW)

HARDWARE

TYPE A: 11EA

(SHORT SCREW)

TYPE C: 3EA

(L BACKET)

DRAIN PIPE

TYPE E: 1EA (SASH SEAL)

(Not adhesive backed)

TYPE D: 1EA

(SEAL STRIP)

(Adhesive backed)

TYPE F: 2EA

(GUIDE PANEL)

10mm

16mm

TYPE A

ROOM SIDE

CENTER LINE

INNER SILL

SEAL STRIP (TYPE D)

Installation Kits Contents

Before Installation

1. Insert the guide panels into the guides of the air conditioner. Fasten the curtains to the unit with screws (TYPE A) as shown Figure. 4.

2. Cut the adhesive-backed seal strip (TYPE D) to the window width. Remove the backing from the seal strip and attach the seal strip to the underside of the bottom window. (Figure. 5)

Now Start Installation

1. Locating Unit in Window

2. Attach L Bracket

Open the window and mark center line on the center of the inner sill, as shown in Figure. 6.

a. Install the L brackets behind the inner window sill, with

the short side of bracket as shown. Use the 2 screws (TYPE A) provided.

b. The bracket helps to hold unit securely in place. Be sure

to place bracket edge flush against back of inner sill. See Figure. 6.

CAUTION: During the following step, hold

unit firmly until window sash is lowered to

top channel behind side panel frames. Personal injury or property damage may result if unit falls from window.

Figure 4

Figure 5

Figure 6

8 Room Air Conditioner

How to Install(Models with Installaion Kit)

CENTER LINE

SEAL

WINDOW FRAME

BOTTOM GUIDE

ABOUT

1/4"

BRACKET

UPPER GUIDE

DRAIN PIPE

DRAIN CAP

hang push

SASH SEAL

(TYPE E)

L BRACKET

TYPE A

Operation

High Fan

Low Fan

High Cool

Off

Low Cool

Thermostat

OUTSIDE

INSIDE

BRACKET

OUTER SILL

SHORT SIDE

INNER SILL

TYPE A

CENTER LINE

3. WInstall the Air Conditioner in the Window

a. Carefully lift the air conditioner and slide it into the

open window. Make sure the bottom guide of the air conditioner drops into the notches of the L bracket. See Figure. 7.

Installation

IMPORTANT :

When the air conditioner drops into the L bracket, the air conditioner will be centered in window opening as shown in Figure. 8.

b. While steadying the air conditioner, carefully bring

the window sash down behind the upper guide of the air conditioner, as shown in Figure. 9.

4. Secure the Guide Panels

Extend the guide panels (TYPE F) to fill the window opening using 4 screws (TYPE B) to secure them, as shown in Figure. 10.

5. Install the Sash Seal and Sash Lock

a. Cut the sash seal (TYPE E) to the window width.

Stuff the sash seal between the glass and the window to prevent air and insects from getting into the room, as shown in Figure. 10.

b. Fasten the L bracket using a (TYPE A) screw, as

shown in Figure. 10.

6. Window installation of room air conditioner is now completed. See ELECTRICAL DATA for attaching power cord to electrical outlet.

Figure 7

Figure 8

Figure 9

TYPE B

Figure 10

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. (Figure. 11)

Figure 11

Service Manual 9

Operation

Feature

• DESIGNED FOR COOLING ONLY

• POWERFUL AND INCREDIBLE COOLING

• TOP-DOWN CHASSIS FOR THE SIMPLE INSTALLATION AND SERVICE

• BUILT-IN ADJUSTABLE THERMOSTAT

• WASHABLE ONE-TOUCH FILTER

• COMPACT SIZE

Insulation Resistance Test

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 positions [except Off] of the ROTARY SWITCH.

4. The value should be over 1 MΩ.

10 Room Air Conditioner

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