Goldstar WG5005R Service Manual

Room Air Conditioner

SERVICE MANUAL

MODELS: WG5005R

CAUTION

website http://www.lgservice.com

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

• ONLY FOR AUTHORIZED SERVICE PERSONNEL.

Room Air Conditioner

SERVICE MANUAL

CAUTION

website http://www.lgservice.com

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

• ONLY FOR AUTHORIZED SERVICE PERSONNEL.

Room Air Conditioner

SERVICE MANUAL

CAUTION

website http://www.lgservice.com

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

• ONLY FOR AUTHORIZED SERVICE PERSONNEL.

Room Air Conditioner

SERVICE MANUAL

CAUTION

website http://www.lgservice.com

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

• ONLY FOR AUTHORIZED SERVICE PERSONNEL.

Room Air Conditioner

SERVICE MANUAL

CAUTION

website http://www.lgservice.com

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

• ONLY FOR AUTHORIZED SERVICE PERSONNEL.

Room Air Conditioner

SERVICE MANUAL

CAUTION

website http://www.lgservice.com

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

• ONLY FOR AUTHORIZED SERVICE PERSONNEL.

Room Air Conditioner

SERVICE MANUAL

CAUTION

website http://www.lgservice.com

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

• ONLY FOR AUTHORIZED SERVICE PERSONNEL.

Room Air Conditioner

SERVICE MANUAL

CAUTION

website http://www.lgservice.com

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

• ONLY FOR AUTHORIZED SERVICE PERSONNEL.

2 Room Air Conditioner

Air Conditioner Service Manual

TABLE OF CONTENTS

Safety Precautions..........................................................................................................................................3

Dimensions .....................................................................................................................................................7

Outside Dimensions..............................................................................................................

.....................7

Product Specifications ...............................................................................................................................

...8

Installation ...............................................................................................................................

........................9

Select the Best Location ..........................................................................................................

..................9

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

.........................9

Installation Kits Contents ...............................................................................................................

..........10

How to Secure the Drain Pipe....................................................................................................................11

Operation ......................................................................................................................................................12

Feature ....................................................................................................................................................12

About the Controls of the Air Conditioner ................................................................................................13

Disassembly..................................................................................................................................................14

Mechanical Parts......................................................................................................................................14

Air Handling Parts....................................................................................................................................15

Electrical Parts .........................................................................................................................................16

Refrigerating Cycle...................................................................................................................................17

Schematic Diagram.......................................................................................................................................20

Circuit Diagram.........................................................................................................................................20

Electronic Control Device.........................................................................................................................21

Components Location(For Main P.W.B ASM)...........................................................................................22

Troubleshooting Guide.................................................................................................................................23

Piping System ........................................................................................................................................23

Troubleshooting Guide .............................................................................................................................24

Exploded View ..............................................................................................................................................32

Replacement Parts List ................................................................................................................................33

Service Manual 3

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.

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

Service Manual 3

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.

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

Service Manual 3

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.

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

Service Manual 3

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.

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

WARNING

This symbol indicates the possibility of death or serious injury.

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

This symbol indicates the possibility of death or serious injury.

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

This symbol indicates the possibility of death or serious injury.

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

This symbol indicates the possibility of death or serious injury.

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

WARNING

 Installation

Always install the expansion panel(s).

• Improper assembly or installation may cause incorrect operation, including injury, fire, and electric shock hazards.

Do not place the power cord near a heater.

• It may cause fire and electric shock.

Be sure not to do.

Be sure to follow the instruction.

 Installation

Always install the expansion panel(s).

• Improper assembly or installation may cause incorrect operation, including injury, fire, and electric shock hazards.

Do not place the power cord near a heater.

• It may cause fire and electric shock.

Be sure not to do.

Be sure to follow the instruction.

 Installation

Always install the expansion panel(s).

• Improper assembly or installation may cause incorrect operation, including injury, fire, and electric shock hazards.

Do not place the power cord near a heater.

• It may cause fire and electric shock.

Be sure not to do.

Be sure to follow the instruction.

 Installation

Always install the expansion panel(s).

• Improper assembly or installation may cause incorrect operation, including injury, fire, and electric shock hazards.

Do not place the power cord near a heater.

• It may cause fire and electric shock.

Be sure not to do.

Be sure to follow the instruction.

Do not use the power cord near flammable gas or combustibles such as gasoline, benzene, thinner, etc.

• It may cause explosion or fire.

Do not disassemble or modify products.

• It may cause electric shock and failure.

GasolinGasolinGasolinGasolinGasolinGasolinGasolinGasolin

CAUTION

4 Room Air Conditioner

Safety Precautions

Plug in the power plug prop- erly.

• Otherwise, it will cause electric

shock or fire.

Do not operate or stop the unit by inserting or pulling out the power plug.

• It will cause electric shock or fire.

Do not damage or use an unspecified power cord.

• It will cause electric shock or fire.

4 Room Air Conditioner

Safety Precautions

Plug in the power plug prop- erly.

• Otherwise, it will cause electric

shock or fire.

Do not operate or stop the unit by inserting or pulling out the power plug.

• It will cause electric shock or fire.

Do not damage or use an unspecified power cord.

• It will cause electric shock or fire.

4 Room Air Conditioner

Safety Precautions

Plug in the power plug prop- erly.

• Otherwise, it will cause electric

shock or fire.

Do not operate or stop the unit by inserting or pulling out the power plug.

• It will cause electric shock or fire.

Do not damage or use an unspecified power cord.

• It will cause electric shock or fire.

4 Room Air Conditioner

Safety Precautions

Plug in the power plug properly.

• Otherwise, it will cause electric

shock or fire.

Do not operate or stop the unit by inserting or pulling out the power plug.

• It will cause electric shock or fire.

Do not damage or use an unspecified power cord.

• It will cause electric shock or fire.

Do not modify power cord length.

• It will cause electric shock or fire

Use the air conditioner on a single outlet circuit.(See page

7.) Do not share the outlet with other appliances.

Always plug into a grounded outlet.

• No grounding may cause electric

Unplug the unit if strange sounds, odors, or smoke come from it.

• Otherwise it will cause fire and

electric shock accident.

Do not use the socket if it is loose or damaged.

• It may cause fire and electric

Do not operate with wet hands or in damp environment.

• It ma cause electric shock.

 Operation Operation Operation Operation

ON

• It will cause electric shock or fire.

shock.

Service Manual 5Service Manual 5Service Manual 5Service Manual 5

Close all doors, windows and other outside openings to the room.

• The air conditioner must be operated in a enclosed area to be most effective.

Ventilate before operating air conditioner when gas goes out.

• It may cause explosion, fire, and burn.



switch of the main body of appliance. Contact service center after taking the power plug ut from the socket.

• There is risk of fire or electric shock.

Do not clean the air conditioner with water.If water enters the product, turn off the power

• Water may enter the unit and degrage the insulation. It may cause an electric shock.

Installation

Never touch the metal parts of the unit when removing the filter.

• They are sharp and may cause injury.

CAUTION

Do not block the inlet or outlet.

• It may cause failure of appliance or performance deteriorate.

Ensure that the outer case is not damaged by age or wear.

• If the outer case is damaged, it must be repaired or replaced immediately. Leaving it damaged could result in the air conditioner falling out of the window, creating a safety hazard.

Wa

x

Thinner

Wa

x

Thinner

 Operation Operation

Be cautious not to touch the sharp edges when installing

• It may cause injury.

Sharp edges

Unplug the air conditioner before cleaning it.

• Since the fan rotates at high speed during operation, it may cause injury.

Hold the plug by the head when taking it out.

Unplug the air conditioner if it will not be used for a long period.

• It may cause electric shock and damage.

Do not put a pet or nouse plant where it will be exposed to direct air flow

• It will waste power consumption in vain and it may cause accident.

Do not use this appliance for special purposes such as pets, foods, precision machinery, or objucts of art.

• This could injury the pet or plant. • It is an air conditioner, not a precision refrigeration system.

Always insert the filter securely. Clean it every two weeks.

• Operation without filters will cause failure.

6 Room Air Conditioner6 Room Air Conditioner6 Room Air Conditioner6 Room Air Conditioner

Use a soft cloth to clean. Do not use wax, thinner, or a strong detergent.

• The appearance of the air conditioner may deteriorate, change color, or develop surface flaws.

Do not drink water drained from air conditioner. Do not direct airflow at room occupants only.

• It is not sanitary and could cause illness or personal injury hazard.

Service Manual 7

Dimensions

H

D

W

W mm(inch) 439(17 5/16")

H mm(inch) 283(11 1/8") D mm(inch) 326(12

13

/16")

Model

Dimension

All Model

Outside Dimensions

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.

NOTICE

Symbols Used in this Manual

8 Room Air Conditioner

Product Specifications

SPECIFICATIONS ARE SUBJECT TO MINOR CHANGE WITHOUT NOTICE FOR FURTHER IMPROVEMENT.

8 Room Air Conditioner

Product Specifications

SPECIFICATIONS ARE SUBJECT TO MINOR CHANGE WITHOUT NOTICE FOR FURTHER IMPROVEMENT.

8 Room Air Conditioner

Product Specifications

SPECIFICATIONS ARE SUBJECT TO MINOR CHANGE WITHOUT NOTICE FOR FURTHER IMPROVEMENT.

8 Room Air Conditioner

Product Specifications

SPECIFICATIONS ARE SUBJECT TO MINOR CHANGE WITHOUT NOTICE FOR FURTHER IMPROVEMENT.

NOTICE

COOLING CAPACITY (BTU/h) 5,050

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

INPUT (W) 520

OPERATING CURRENT (AMP.) 4.8

REFRIGERANT CONTROL CAPILLARY TUBE

REFRIGERANT CHARGE (R-22)

205g(7.2 Oz)

INSIDE FAN TURBO

OUTSIDE FAN ROPELLER FAN WITH SLINGER RING

AIR DISCHARGE 2-WAY (RIGHT AND LEFT)

CHASSIS TOP-DOWN

PROTECTOR

TEMPERATURE CONTROL THERMISTOR

• OVERLOAD PROTECTOR FOR COMPRESSOR

• INTERNAL PROTECTOR FOR FAN MOTOR

WG5005R

MODELS

ITEMS

COOLING CAPACITY (BTU/h) 5,050

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

INPUT (W) 520

OPERATING CURRENT (AMP.) 4.8

REFRIGERANT CONTROL CAPILLARY TUBE

REFRIGERANT CHARGE (R-22)

205g(7.2 Oz)

INSIDE FAN TURBO

OUTSIDE FAN ROPELLER FAN WITH SLINGER RING

AIR DISCHARGE 2-WAY (RIGHT AND LEFT)

CHASSIS TOP-DOWN

PROTECTOR

TEMPERATURE CONTROL THERMISTOR

• OVERLOAD PROTECTOR FOR COMPRESSOR

• INTERNAL PROTECTOR FOR FAN MOTOR

MODELS

ITEMS

COOLING CAPACITY (BTU/h) 5,050

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

INPUT (W) 520

OPERATING CURRENT (AMP.) 4.8

REFRIGERANT CONTROL CAPILLARY TUBE

REFRIGERANT CHARGE (R-22)

205g(7.2 Oz)

INSIDE FAN TURBO

OUTSIDE FAN ROPELLER FAN WITH SLINGER RING

AIR DISCHARGE 2-WAY (RIGHT AND LEFT)

CHASSIS TOP-DOWN

PROTECTOR

TEMPERATURE CONTROL THERMISTOR

• OVERLOAD PROTECTOR FOR COMPRESSOR

• INTERNAL PROTECTOR FOR FAN MOTOR

MODELS

ITEMS

COOLING CAPACITY (BTU/h) 5,050

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

INPUT (W) 520

OPERATING CURRENT (AMP.) 4.8

REFRIGERANT CONTROL CAPILLARY TUBE

REFRIGERANT CHARGE (R-22)

205g(7.2 Oz)

INSIDE FAN TURBO

OUTSIDE FAN ROPELLER FAN WITH SLINGER RING

AIR DISCHARGE 2-WAY (RIGHT AND LEFT)

CHASSIS TOP-DOWN

PROTECTOR

TEMPERATURE CONTROL THERMISTOR

• OVERLOAD PROTECTOR FOR COMPRESSOR

• INTERNAL PROTECTOR FOR FAN MOTOR

MODELS

ITEMS

Service Manual 9

Window Requirements

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

1. This unit is designed for installation in standard double hung windows with actual opening widths of 21" to 35". The upper and lower sash must open sufficiently to allow a clear vertical opening of 12" from the bottom of the sash to the window stool.

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

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

4. If the distance between STORM WINDOW FRAME and WOOD STRIP MOUNTED ON TOP OF INNER SILL is more than 1", two of wood strip are not necessary.

NOTICE

Installation

Select the Best Location

How to Install

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

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.

4. Install the unit slanted slightly so the back is slightly lower than the front (about 1/4"). This will force condensed water to the outside.

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

ABOUT / "

Over 20"

HEAT

RADIATION

FENCE

AWNING

OUTSIDE

INSIDE

COOLED AIR

30"-60"

1

2

OUTDOORSINDOORS

INNER SILL

OUTER

SILL

INNER

SILL

WOOD STRIP MOUNTED

ON TOP OF INNER SILL

WOOD STRIP

FOR

L

BRACKET

3

/4"

CLEARANCE

1" MAX.

STORM

WINDOW

FRAME

OUTDOORSINDOORS

OUTER

SILL

Figure 1

Figure 2

Figure 3

10 Room Air Conditioner

Installation

Installation Kits Contents(some Models)

Before Installation (Some Models Including Installation Kit)

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 E) 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)

Start Installation (Some Models Including Installation Kit)

1. Locating Unit in Window

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

2. Attach L Bracket

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.7.

HARDWARE

TYPE F: 1EA

(SASH SEAL)

(Not adhesive backed)

TYPE E: 1EA

(SEAL STRIP)

(Adhesive backed)

TYPE G: 2EA

(GUIDE PANEL)

TYPE D: 3EA

(L BACKET)

TYPE A: 14EA

(SHORT SCREW)

10mm

TYPE B: 2EA

(WOOD SCREW)

16mm

TYPE H: 1EA

(UPPER GUIDE)

16mm

TYPE C: 2EA

(WOOD SCREW)

ROOM SIDE

CENTER LINE

INNER SILL

SEAL STRIP (TYPE E)

OUTSIDE

INSIDE

L

BRACKET

OUTER SILL

INNER SILL

TYPE A

7.5"

CENTER LINE

TYPE A

Figure 4

Figure 5

Figure 6

Figure 7

Service Manual 11

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.

3. Install the Air Conditioner in the Window

a. Carefully lift the air conditioner and slide it into the open win-

dow. Make sure the bottom guide of the air conditioner drops into the notches of the L bracket.

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 G) to fill the window opening using 2 screws (TYPE B), 2 screws(TYPE C) to secure them as shown in Figure. 10.

5. Install the Sash Seal and Sash Lock

a. Cut the sash seal (TYPE F) 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.

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)

Press the drain pipe into the hole by pushing down and away from the fins to avoid injury.

Installation

How to Secure the Drain pipe

hang push

1 2

DRAIN PIPE

DRAIN CAP

CENTER LINE

SEAL

WINDOW FRAME

BOTTOM GUIDE

ABOUT 1/4"

UPPER GUIDE

L

BRACKET

L BRACKET

FOAM SEAL

(

TYPE

F)

TYPE A

TYPE B

TYPE C

Figure 8

Figure 9

Figure 10

Figure 11

12 Room Air Conditioner

Operation

Feature

Insulation Resistance Test

About the Controls of the Air Conditioner

• 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

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 ROCKER SWITCH.

4. The value should be over 1 MΩ.

Operation

CAUTION: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.

Power

Temp

Fan Speed

Timer Mode

Auto

Swing



Disassemblyly

Mechanical Parts

Disassembly

NOTICE

14 Room Air Conditioner

1. FRONT GRILLE

1. Disconnect the unit from source of power.

2. Using a screwdriver, remove the screw from the front

grille. (See Figure 13)

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 14)

4. Replace the grille by placing the tabs in the slots and

push the grille until it snaps into place.

2. CABINET

1. Disconnect the unit from the power source.

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

3. Remove 10 screws that secure the cabinet to the base

pan and condenser. (See Figure 15)

4. Lift the cabinet from the unit.

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

3. CONTROL PANEL

1. Disconnect the unit from the power source.

2. Remove the front grille. (Refer to Section 1)

3. Remove the cabinet. (Refer to Section 2)

4. Remove 2 screws that secure the control panel to control

box and base pan. (See Figure 16)

5. Pull the control board toward yourself.

NOTICE

6. Disconnect one housing terminal and 3 wires for the fan

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

Controls, wires, and capacitor are now accessible for servicing. Discharge the capacitor before servicing.

motor and compressor. (See Figure 17)

(Refer to wiring diagram on page 19 in this manual or on control box.)

NOTICE

4. AIR GUIDE UPPER

1. Disconnect the unit from the power source.

2. Remove the front grille. (Refer to Section 1)

3. Remove the cabinet. (Refer to Section 2)

4. Remove the control board. (Refer to Section 3)

5. Remove tape that attached the air guide upper and

lower.

6. Lift air guide upper upward. (See Figure 18)

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

5. ORIFICE, TURBO FAN AND FAN

1. Disconnect the unit from the power source.

2. Remove the front grille. (Refer to Section 1)

3. Remove the cabinet. (Refer to Section 2)

4. Remove the control panel. (Refer to Section 3)

5. Remove the air guide upper. (Refer to Section 4)

6. Remove 2 screws that secure the condenser to the base pan.

7. Remove the 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. Remove 1 screw that secure the evaporator to the base pan. (See Figure 19)

10. Remove the orifice by pushing the snap area of the air guide blower. (See Figure 20)

11. Remove the clamp springs which are clamped to the boss of fan and turbo fan by hand plier.

(See Figure 21)

12. Pull the fan and turbo fan outward.

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

Disassembly

Air Handling Parts

Figure 19

Figure 18

Figure 20

Figure 21

Service Manual 15

Disassembly

6. MOTOR

1. Disconnect the unit from the power source.

2. Remove the front grille. (Refer to Section 1)

3. Remove the cabinet. (Refer to Section 2)

4. Remove the control panel. (Refer to Section 3)

5. Remove the air guide upper. (Refer to Section 4)

6. Remove the compressor, turbo fan, axial fan and

shroud. (Refer to Section 5)

7. Remove 4 screws that secure the motor to the mount

motor of shroud. (See Figure 22)

8. Remove the motor.

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

7. AIR GUIDE LOWER AND SHROUD

1. Disconnect the unit from the power source.

2. Remove the front grille. (Refer to Section 1)

3. Remove the cabinet. (Refer to Section 2)

4. Remove the control panel. (Refer to Section 3)

5. Remove the air guide upper. (Refer to Section 4)

6. Remove the compressor, turbo fan, axial fan.

(Refer to Section 5)

7. Remove the motor. (Refer to Section 6)

8. Remove 2 screws that secure the shroud to the base

pan. (See Figure 23)

9. Lift air guide lower and shroud upward.

(See Figure 23)

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

8. OVERLOAD PROTECTOR

1. Remove the front grille and cabinet. (Refer to Section 1, 2)

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 24)

9. COMPRESSOR

1. Remove the front grille and cabinet. (Refer to Section 1, 2)

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

3. Remove the overload protector. (Refer to Section 8)

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 25)

Electrical Parts

Figure 22

Figure 23

Figure 24

Figure 25

16 Room Air Conditioner

Disassembly Disassembly Disassembly Disassembly

Refrigerating Cycle

10. CAPACITOR

Service Manual 17

10. CAPACITOR

1. Remove the cabinet. (Refer to Section 2)

2. Remove the control panel. (Refer to Section 3)

3. Discharge the capacitor by placing a 20 K resistor

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

across the capacitor terminals.

4. Remove all the leads of capacitor terminals.

5. Re-install the components by referring to the removal

5. Re-install the components by referring to the removal procedure above. (See Figure 26)

procedure above. (See Figure 26)

11. THERMISTOR

1. Remove the cabinet. (Refer to Section 2)

2. Remove the control panel. (Refer to Section 3)

3. Remove the main PCB inside the control box.

4. Remove the thermostat.

5. Re-install the components by referrig to the 

5. Re-install the components by referrig to the  temoval procedure above.

temoval procedure above.

Figure 26

12. POWER CORD

1. Disconnect the unit from source of power.

2. Remove the front grille. (Refer to Section 1)

3. Remove the cabinet. (Refer to Section .2)

Remove a screw that secures control panel to control

4.

4. box. (Refer to Section 3)

box. (Refer to Section 3)

5. Pull the power cord. (See Figure 29)

6. Re-install by referring to procedures above.

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

R erating Cyc

13. CONDENSER

1. Remove the cabinet. (Refer to Section 2)

2. Discharge the refrigerant by using a refrigerant recovery

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

system.

3. Remove 2 screws which fasten the condenser.

3. Remove 2 screws which fasten the condenser. (See Figure 30)

(See Figure 30)

4. After discharging the refrigerant completely, unbraze the

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

interconnecting tube at the condenser connections.

5. Remove the condenser.

le

Figure 27

Figure 29

Figure 30

Disassembly

15. EVAPORATOR

1. Remove the cabinet. (Refer to Section 2)

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

3. Remove the air guide upper. (Refer to Section 4)

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

5. Remove the evaporator.

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

16. CAPILLARY TUBE

1. Remove the cabinet. (Refer to Section 2)

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

3. Remove the air guide upper. (Refer to Section 4)

4. After discharging the refrigerant completely, unbraze the interconnecting tube of the capillary tube.

5. Remove the capillary tube.

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

Replacement of the refrigeration cycle.

1. When replacing the refrigerating cycle, be sure to discharge the refrigerant by using a refrigerant recovery system.

2. After discharging the unit completely, remove the desired components, 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. After completing the above procedures, the valve must be closed and left in place on the system for any subsequent procedures.

6. Evacuate as follows: 6-1. Connect the vacuum pump, as illustrated in

figure 31A.

6-2. Start the vacuum pump. Slowly open manifold

valves A and B with two full turns counterclockwise and leave the valves closed. The vacuum pump is now pulling through valves A and B up to valve C by means of manifold and the entire system.

CAUTION: If high vacuum equip-

ment is used, just crack valves A

and B for a few minutes, then open

slowly with the two full turns counter-clockwise. This will keep oil from foaming and being drawn into the vacuum pump.

6-3. Operate the vacuum pump for 20 to 30 minutes,

until 600 micron vacuum 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.

6-4. Remove the hose from the vacuum pump and

place it on the charging cylinder. See figure 20B. Open valve C. Discharge the line at the manifold connection.

6-5. The system is now ready for final charging.

7. Recharge as follows: 7-1. Rotary compressor 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 is installed as the system is opened.

7-2. Connect the charging cylinder as shown in fig-

ure 31B. With valve C open, discharge the hose at the manifold connection.

7-3. Open valve A and allow the proper charge to

enter the system. Valve B is still closed.

7-4. If more charge is required, the high-side will

not take it. Close valve A.

7-5. 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(0.2MP).

c. Turn off valve B and allow the pressure to

drop.

d. Repeat steps B and C until the balance of

the charge is in the system.

7-6. When the unit is operating correctly, use the

pinch-off tool with the unit still running and the clamp on 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 the pinch-off tube closed. Turn off the unit, allow setting for a while and then test the leakage of the pinch-off connection.

NOTICE

18 Room Air Conditioner

Disassembly

Equipment needed: Vacuum pump, charging cylinder, manifold gauge, brazing equipment, pinch-off tool capable of making a vapor proof seal, leak detector, tubing cutter, hand tools to remove components and service valve.

B

A

B

A

B

A

COMPOUND GAUGE

SEE INSETS

BELOW

CAPILLARY TUBE

EVAPORATOR (LOW PRESSURE SIDE)

COMPRESSOR

CONDENSER (HIGH PRESSURE SIDE)

EXTERNAL VACUUM PUMP

LO HI

CHARGING CYLINDER

MANIFOLD

GAUGE

C

Figure 31A-Pulling Vacuum

Figure 31B-Charging

Service Manual 19

Schematic Diagram

Circuit Diagram

DESCRIPTION & NAME

FAN MOTOR MAIN PCB DISPLAY TERMITOR COMPRESSOR POWER CORD ASSY

CAPACITOR OVERLOAD PROTECTOR

Q'TY

1 1 1 1 1 1 1 1

REF. NO

1 2 3 4 5 6 7 8

20 Room Air Conditioner

WP

Vcc

Digit3 (Scan3)

Digit4 (Scan4)

Digit1 (Scan1)

Digit2 (Scan2)

Digit0 (Scan0)

MAIN POWER

COMP

HERM

FAN

C

CAPACITOR

MOTOR

FAN

120 1/2W

ZNR01J

SVC271D-14A

250V/T2A

FUSE

G4A-1A-E-LG

RY-COMP

1000

D02D~D05D

1N4004

35V

D03D

D02D

POWER TRANS

1

2

7

4

D05D

+

D04D

C01D

R01J

CN-WOR

C01J

0.1/275V

CN-BK

CN-BL

CN-RD

RY-HI

RY-LOW

RY-MED

C06D

5V

0.01

0.1

50V

16V

1000

10V

0.01

50V

C04D

12V

IC01D

C03D

C02D

7812

O

I

+

220

C05D

O

IC02D

7805

+

I

C01L

680pF

1K

ULN2004A

IC01G

R01L

5V

1K

R01E

20

R02E

20K

R12F

10K

R02F

0.001

C02F

R01F

10K

C01F

0.001

ROOM-TH

PIPE-TH

SYNC

S/V-

4WAY

MOTOR

3

14

RY-SYNC

RY-4WAY

CN-4WAY

11

33

11

CN-SYNC

33

12V

RY-HI

RY-MED

ULN2004A

IC01M

9

15

16

821

12V

4 4

3

2

OR1H

RY-SYNC

RY-LOW

RY-4WAY

RY-COMP

111213

654107

OR2H

5V

12.1K

R21H

R03H

0K

12.1K

1%

R22H

HVB

KEY1

LED out2

LED out1

LED out0

34 35 36

LED out3

Receiver

30

Buzzer

333231

HI

MED

ION

292827

SLIDE SW

40

KEY0

37 38 39

VDD

SEG-g

41 42 43

SEG-f

SEG-e

44

SEG-d

TMP87CH47U

MICOM

4

SEG-b

SEG-a

SEG-c

321

765

Room TH

Option2

Option1

Pipe TH

232625

24

SYNC

LOW

4WAY

COMP

202122

/Reset

Osc out

Osc in

16

VAref

VSS

1819 17 131415

TEST

11

SCL

SDA

10

9

8

Tx

12

Rx

5V

A1

3

4

GND SDA

SCL

A2

A0

1

2

EEPROM

CAT93C46

SMW250-02

1

2 2

CN-TH1

5V

R01B

R02H

R01H

1%

6.2K

1%

12.1K

RT8.00MG

1M

OSC01B

50V

C01A

0.01

+

C02A

1uF

10V

3

20K

R01A

6

10

AIR PURIFIER

220

R07G

710

8

9

12V

16

2

12

15

3

6

220

R03G

314

512

6 11

4 13

R05G

R06G

220

R04G

116

2 15

R01G

R02G

11

10

7

8

9

8

9

10

A/RESTART

12 6

7

11

14

13

4

5

A/SWING

g

E/SAVER

+

88 SEGMENT

GND

RECEIVER

BZ01E

-4002

PKM13EPY

Vout

Vcc

8

10V

5V

220

C22L

d d

DEFROST

f

c

FAN

DRY/HEAT

TIMER

7

1

e

f

e

2

3

d

COOL

4

5

b

Digit1

a

b f

b

cc

e

g g

a a

Digit0

5V

17

1

17

1

D03F

5V

ENERGY

SAVER

SW3

D07F

TEMP UP

SW7

1K

R04P

6

5

20K

R02P

8

7

R03P

5V

A101S

D02F

TIMER

SW2

D01F

FAN

SW1

TEMP DOWN

D05F

SW5

MODE

D04F

SW4

D08F

AUTO SWING

SW8

SW6

ON/OFF

D06F

14

4

2

16

3

15

A101S

Q03G

A101S

Q02G

5

13

Q01G

A101S

1

IC01A

S7136

2

3.6V

5V

Q04G

CN-DISPCN-DISP

Electronic Control Device

Schematic Diagram

Service Manual 21

Components Location (For Main P.W.B ASM)

Trouleshooting Glwide

22 Room Air Conditioner

Troubleshooting Guide

Piping System

Following is a brief description of the important components and their function in what is called the refrigeration system. Reference should be made to Figure 32 to follow the refrigerating cycle and the flow of the refrigerant in the cooling cycle.

COOLED AIR

HOT DISCHARGED AIR

MOTOR

COMPRESSOR

ROOM AIR HEAT LOAD

CAPILLARY TUBE

(LIQUID REFRIGERANT)

LIQUID OUTLET

VAPOR INLET COMPLETE LIQUID BOIL OFF POINT

SUCTION LINE COOL LOW PRESSURE VAPOR

LIQUID PRESSURE DROP

DISCHARGE

LINE

NOT HIGH PRESSURE

VAPOR

OUTSIDE COOLING AIR FOR REFRIGERANT PASS THROUGH

EVAPORATOR COILS CONDENSER COILS

ROOM AIR CONDITIONER

CYCLE OF REFRIGERATION

HIGH PRESSURE VAPOR LIQUID REFRIGERANT LOW PRESSURE VAPOR

OIL

Figure 32

Service Manual 23

CONDENSER COILS

FAN

CAPILLARY

MOTOR

TUBE

TURBO FAN EVAPORATOR

COILS

Troubleshooting Guide

In general, possible trouble is classified in two kinds. The one is called Starting Failure which is caused by an electrical defect. The other is Ineffective Air Conditioning

caused by a defect in the refrigeration circuit and improper application.

Unit is running but cooling is ineffective.

Ineffective Cooling

Satisfactory operation with temperature difference of inlet & outlet air; 44~50°F (7~10°C)

Replacement of unit if the unit is beyond repair.

Check outdoor coil (heat exchanger) and fan operation.

Check heat load increase.

Check cold air circulation for smooth flow.

Check gas leakage.

Clean condenser.

Not on separate circuit

Check inside gas pressure.

Adjust refrigerant charge.

Malfunction of compressor.

Replacement of compressor.

Check clogging in refrigeration circuit.

Repair clogging in refrigeration circuit.

Dirty indoor coil (heat exchanger)

Repair gas leak.

Malfunction of fan.

Clogging of air filter.

Obstruction at air outlet.

Remove obstruction.

24 Room Air Conditioner

Troubleshooting Guide

Fails to Start

Improper thermostat setting

Loose terminal connection

Improper wiring

Check of power source.

Drop of power voltage.

Capacitor check.

Replacement.

Check of control switch setting.

Compressor fails only to start.

Defect of compressor capacitor.

Replacement of compressor (Motor damaged).

Irregular motor insulation (Ω)

Irregular motor resistance (Ω)

Check of circuit breaker and fuse.

Gas leakage of feeler bulb of thermostat.

Check control switch.

Fan only fails to start.

Improper wiring.

Defect of fan motor capacitor.

Replacement of fan motor.

Regular but fails to start.

Replacement of compressor. (Locking of piston, metal.)

Irregular motor resistance (Ω) Irregular motor insulation (Ω)

Service Manual 25

Troubleshooting Guide

ELECTRIC PARTS TROUBLESHOOTING GUIDE:

Possible Trouble 1

• The unit does not operate.

Is the Trans input power

AC 115V?

Is the Trans output power

about AC 14V?

Is shorted the Trans. output?

Is output Voltage of IC01D

DC 12V?

Is output Voltage of IC02D

DC 5V?

Is the voltage No.18 of Micom

DC 5V?

Exchange Main P.W.B Ass'y.

Is the

connection between

Main and Display

all right?

Is the reset circuit all right?

(The No.14 of Micom

is 5V.)

•

Check the Fuse.

•

Check the wiring diagram.

•

Check the Main

P.W.B pattern.

• Exchange the Trans.

•

Exchange D02D~D05D.

• Exchange IC01D.

• Exchange IC02D.

• Exchange IC01A.

• Connect connector

exactly.

• Check the

P.W.B

pattern.

NO

YES

NO

YES

26 Room Air Conditioner

Troubleshooting Guide

Is Temp.

setting set lower than Room

Temp.-0.5°C?

Is the voltage No.10

of IC01M 0V?

• Exchange IC01M.

• Set the Temp. setting to lower Temp.

• Wait 3 Minutes

Is the Unit for 3 minutes

delay?

• Exchange MAIN P.W.B Ass'y.

Is the voltage N0.7 of

IC01M DC 5V?

• Check the RY-COMP.

• Check the wiring

Diagram.

NO

NO NO

YES

Possible Trouble 2

• The compressor does not operate.

Is the wire connection of

RY-COMP all right?

• Check the RY-COMP.

• Connect LEAD Wire to

RY-COMP again.

NO

YES

Possible Trouble 3

• The compressor always operate.

• Exchange IC01M.

Is the voltage NO.1 or 4

of IC01M DC 5V?

Is the voltage NO.13 or 16

of IC01M 0V?

• Check the RY-Hi or RY-Lo.

•

Check the wiring diagram.

NO

YES

Possible Trouble 4

• Fan does not operate.

Service Manual 27

Troubleshooting Guide

Is the voltage of Battery

about over 2.3V?

•

Exchange Receiver Ass'y.

Is the connection of CN-DISP1 all right?

Is the voltage No.16

of CN-DISP1 on Main P.W.B

Ass'y DC 5V?

• Exchange the battery.

•

Check the P.W.B pattern.

• Connect connector to CN-DISP1 exactly.

NO

YES

Possible Trouble 5

• Romote controller does not operate.

NO

YES

Is the IC01G all right?

Is the connection of CN-DISP1 all right?

• Exchange the display P.W.B Ass'y.

• Exchange IC01G.

• Exchange Q01G,

Q02G, Q03G, Q04G

• Connect connector to CN-DISP1 exactly.

Does the Q01G,

Q02G, Q03G Q04G operate normally

on main P.W.B Ass'y?

Possible Trouble 6

• It displays abnormally on Display P.W.B Ass'y.

28 Room Air Conditioner

Troubleshooting Guide

Room Air Conditioner Voltage Limits

NAME PLATE RATING MINIMUM MAXIMUM

115V ± 10% 103.5V 126.5V

COMPLAINT CAUSE REMEDY

Fan motor will not run. No power Check voltage at outlet. Correct if none.

Power supply cord Check voltage to rotary switch. If none, check

power supply cord. Replace cord if circuit is open.

Rocker switch Check switch continuity. Refer to wiring diagram

for terminal identification. Replace switch if defective.

Wire disconnected or Connect wire. Refer to wiring diagram for connection loose terminal identification. Repair or replace loose

terminal.

Capacitor (Discharge Test capacitor. capacitor before testing.) Replace if not within ±10% of manufacturer's

rating. Replace if shorted, open, or damaged.

Will not rotate Fan blade hitting shroud or blower wheel hitting

scroll. Re-align assembly. Units using slinger ring condenser fans must

have 0.22~0.25 inch clearance to the base. If necessary, shim up the bottom of the fan motor with mounting screw(s).

Check fan motor bearings; if motor shaft will not rotate, replace the motor.

Fan motor runs. Revolves on overload Check voltage. See limits on this page.

If not within limits, call an electrician. Test capacitor.

Check bearings. Does the fan blade rotate

freely?

If not, replace fan motor. Pay attention to any change from high speed to

low speed. If the speed does not change, replace the motor.

Service Manual 29

Troubleshooting Guide

COMPLAINT CAUSE REMEDY

Fan motor noise. Tubo Fan If cracked, out of balance, or partially missing,

replace it.

Axial Fan If cracked, out of balance, or partially missing,

replace it. Loose set screw Tighten it. Worn bearings If knocking sounds continue when running or

loose, replace the motor. If the motor hums or

noise appears to be internal while running,

replace motor.

Compressor will not run, Voltage Check voltage. See the limits on the preceding fan motor runs. page. If not within limits, call an electrician.

Wiring Check the wire connections; if loose, repair or

replace the terminal. If the wires are discon-

nected, refer to wiring diagram for identification,

and replace the wires. Check the wire connections;

If not according to the wiring diagram, correct

the connections. Rocker Switch Check for continuity, refer to the wiring diagram

for terminal identification. Replace the switch if

the circuit is open. Thermostat Check the position of knob. If not at the coldest

setting, advance the knob to this setting and

restart the unit.

Check the continuity of the thermostat. Replace

the thermostat if the circuit is open.

Capacitor (discharge Check the capacitor. capacitor before Replace if not within ±10% of manufacturer’s servicing.) rating, replace if shorted, open, or damaged.

Compressor Check the compressor for open circuit or

ground. If open or grounded, replace the

compressor. Overload

Check the compressor overload if externally mounted.

Replace if open. (If the compressor temperature is

high, remove the overload, cool, and retest.)

Compressor cycles on Voltage Check the voltage. See the limits on the overload. preceding page. If voltage is not within these limits,

call an electrician. Overload Check overload, if externally mounted.

Replace if open. (If the compressor temperature

is high, remove the overload, cool, and retest.)

30 Room Air Conditioner

Troubleshooting Guide

COMPLAINT CAUSE REMEDY

Compressor cycles on Fan motor If not running, determine the cause. Replace if overload. required.

Condenser air flow Remove the cabinet, inspect the interior surface restriction of the condenser. If restricted, clean carefully

with a vacuum cleaner (do not damage fins) or

brush. Clean the interior base before

re-assembling. Condenser fins If the condenser fins are closed over a large

(damaged) area on the coil surface, head pressures will

increase, causing the compressor to cycle.

Straighten the fins or replace the coil. Capacitor Test the capacitor. Wiring Check the terminals. If loose, repair or replace. Refrigeration system Check the system for a restriction.

Insufficient cooling Air filter If restricted, clean or replace.

Unit undersized Determine if the unit is properly sized for the

area to be cooled.

Excessive noise Turbo Fan or Axial Fan Check the set screw, or clamp. If loose or miss-

ing, correct. If the tubo fan or axial fan is hitting

scroll or barrier, rearrange the air handling parts.

Copper tubing Remove the cabinet and carefully rearrange the

tubing not to contact the cabinet,

compressor, shroud, and barrier.

Service Manual 31

Exploded View

32 Room Air Conditioner

Exploded Vie w

267110

B A E

Temp

Fan Speed

Timer Mode

Pow er

Auto

Swing

264110

15 9830

238310

W0CZZ

249950

35 4210

237200

268711-1

268711-2

349480

567480

352380-1

W48602

148000

359012

149980

135312

147582-2

147582-1

346811

352115

731 273

554030

359011

W48602

552113

35211A

352113

352380-2

749740

130410

130910

C

567502

554 030

D

550140

Replacement Parts List

Service Manual 33

Replacement Parts List

LOCATION

NO.

130410 Base Assembly,Single 3041A10040P R 352380-2 Guide,Air 5238A10026A R 352380-1 Guide,Air 5238A10025A R

349480 Orifice 4948A20031B R

148000 Supporter 4800A30012A R

149980 Shroud 4998A10028B R

359011 Fan,Axial 5900A20042A R

346811 Motor Assembly,AC 4681A20116E R

359012 Fan,Turbo 5900A20040A R

W48602 Clamp,Spring 3H02932B R

354210 Evaporator Assembly,First 5421A20176B R

554030 Condenser Assembly,First 5403A20174A R

352115 Tube Assembly,Evaporator(In) 5211A25019B R

552102 Tube,Bending 5210A31415B R

552113 Tube Assembly,Condenser(Out) 5211A21145A R

35211A Tube Assembly,Suction 5211A21228B R

352113 Tube Assembly,Discharge 5211A21305A R

554030 Compressor Set,China 2520UCAA011 R

567502 Overload Protect 6750U-L050A R

550140 Damper,Compressor 5040AR4195A R

249950 Case Assembly,Control 4995A20378F R

237200 Panel,Control 3720A30076A R

567480 Thermistor,NTC 6323A20004R R

W0CZZ Capacitor,Film,Box 0CZZA20005B R

238310 Escutcheon 3831A10038D R 268711-1 PCB Assembly,Display 6871A20449A R 268711-2 PCB Assembly,Main 6871A10129D R

264110 Power Cord Assembly 6411A20056A R

130910 Cabinet Assembly,Single 3091A10055A R

135312 Grille Assembly,Front 3531A10243A R

159830 Filter Assembly,Air Cleaner 5231A20029A R 147582-1 Louver,Vertical 4758A30041A R 147582-2 Louver,Vertical 4758A30041B R

267110 Remote Controller Assembly 6711A20034C R

749740 Guide 4974A30066B R

731273 Install Part Assembly,Single 3127A20098A R

PART NO.

WG5005R

REMARKDESCRIPTION

P/No.: 3828A20517A

February, 2005

Printed in China

Goldstar WG5005R Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual