LG GCS165SVB Manual book [id]

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CHEST FREEZER

SERVICE MANUAL

CAUTION

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

COLOR: PCM-Super WhiteMODEL: GCS165SV

CONTENTS

(Page)

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

SERVICING PRECAUTIONS ....................................................................................................................................................... 3

SPECIFICATIONS .......................................................................................................................................................................... 4

DISASSEMBLY ................................................................................................................................................................................ 6

THERMOSTAT................................................................................................................................................................................ 6

HANDLE ........................................................................................................................................................................................ 6

DOOR .............................................................................................................................................................................................. 6

ADJUSTMENT ............................................................................................................................................................................ 7

CIRCUIT DIAGRAM ..................................................................................................................................................................... 8

TROUBLESHOOTING ................................................................................................................................................................... 9

COMPRESSOR AND ELECTRIC COMPONENTS ............................................................................................. ............................................................................................. . 10

PTC .............................................................................................. ................................................................................................... 11

OTHER ELECTRIC COMPONENTS ........................................................................................................................................... 12

EXPLODED VIEW .... . .................................................................................................................................................................. 13

SAFETY PRECAUTIONS

Please read the following before servicing your
refrigerator.

1. Check if electric leakage occurs in the set.

2. When servicing current applying parts, unplug prior to
servicing.

3. If testing with power on, wear rubber gloves to prevent
electric shock.

4. Be sure to check regular current, voltage, and capacity.

5. Don't touch metal products in a cold freezer compartment
with wet hands. It may cause frostbite or other injury.

6. Prevent water flowing to electric elements in mechanical
parts.

7. When tilting the set, remove any materials on the set,
especially thin plate type (ex,: glass plates or books.)

8. Do not open the sealed refrigeration system. It could
cause injury or pollute the air. Leave this job to an
autherized servicer with the appropriate refrigerant
recovery equipment.

9. Curatorial, combustible, explosive, corrosive and volatile
goods cannot be stored in the chest freezer.

10. Turn off the power and open the door, take the goods to
make defrosting when frost thickness is more than 5mm.
Acuate or hard tools are not allowed to make defrosting.

11. Chemic reagent is not allowed when washing the chest
freezer. Pls clean it both inside and outside with soft cloth
in litmusless soap water or abluent.

AIR RECHARGING IN COMPRESSOR

Test the refrigeration system by connecting it electrically before
beginning the refilling operation. This is necessary to ascertain
the function of the motor-compressor and identify defects
immediately. If defects have been found, empty the old system
of R134a residue by breaking off the end of the extension piece
at its narrow point.
(Figure 1) Use the appropriate refrigerant recovery equipment.
Replace the filter and any damaged components. Unsolder and
pull off the piece remaining inside the service tube and then
attach an extension with male Hansen, and last, solder it to the
same tube again. (Figure 2)

-2-

POINT TO BE

BROKEN

SERVICE TUBE

EXTENSION

Figure 1 Figure 2

CHARGE TUBE

EXTENSION

SOLDERING

POINT

FEMALE
HANSEN

MALE

HANSEN

SERVICING PRECAUTIONS

It is necessary to execute the soldering operation with valve
open so that the fumes caused by oil residue can come out
freely without blowholes between two tubes during heating the
point to be soldered.
The extension fitted with the male Hansen is connected to the
female fitting of the vacuum pump tube. (Figure 3) Air
evacuating from the system begins as soon as the pump starts.
The refrigeration system must be kept under vacuum until the
reading on the low-pressure gauge indicates vacuum (0
absolute, -1 atm., -760 mm hg.) In any case, it is advisable to
keep the pump running for about 60 minutes. (Figure 4)

If case that a considerable leakage occurs, it will be necessary
to stop the vacuum pump and add a small quantity of Freon to
the system, if vacuum should not be obtained (pressure gauge
doesn't fall to 1 atmosphere.) Start the refrigeration unit and
find the leakage with a special leak-finder. When the defective
soldering point is visible, repair it after opening the extension
tube valve and reestablishing the normal outside pressure
inside the system.
Because the melted solder is sucked into the tubes and blocks
them, the pressure must be rebalanced when vacuum is in the
system for soldering. As soon as the vacuum operation is over,
add the quantity (in grams) of R134a to the refrigeration
system. Remember that every system has an exact quantity of
R134a with a tolerance of ±5 grams than can be added.
(Figure 5)

Figure 3

Figure 4

TO THE

VACUUM

PUMP

PRESSURE

GAUGE

TO THE
R-134a CYLINDER

TO THE
REFRIGERATION
SYSTEM

Before performing this operation (if the vacuum pump and
refilling cylinder are connected), make sure that the valve
placed between the vacuum pump and refilling tube are closed
to keep the Freon from adding to the system.(Figure 6)
In addition, check the graduated scale on the cylinder for the
quantity of R134a to be added; for example, if we have 750
grams of Freon in the cylinder and must add 165 grams to the
group, this amount will be reached when R134a has dropped to
585 grams, remembering that the indicator shows a lower limit
of meniscus. Do this after choosing the scale corresponding to
the gas pressure different scales reported as the same gas
pressure indicated by the pressure gauge on the top of the
column.
To make R134a flow into the system, open the valve placed at
the base of the cylinder and connected to the filling tube. The
amount of Freon cannot be added to the system all at once
because it may cause a blocking of motor-compressor.
Therefore, proceed by adding original quantity of about 20-30
grams and close the valve
immediately thereafter.
The pressure rises and the motor-compressor must start,
sucking the gas and making the pressure go down again.
Regulate the valve again, maintaining the same manner until
reaching the quantity of R134a established for the system being
charged. When the system is running, the suction pressure
must be stabilized from 0.10 to 0.4 atmosphere.

Figure 5

FILLING OR
CHARGE TUBE

TO THE
REFRIGERATION
SYSTEM

VACUUM

TO THE

PUMP

VALVE TO BE
OPENED WHEN
REFILLING

TO THE
CHARGE
CYLINDER

VALVE TO BE
CLOSED
AFTER VACUUM

-3-

SPECIFIC A TIONS

Ref. No: GCS165SV

ITEMS SPECIFICATIONS

DIMENSIONS (mm)

NET WEIGHT (kg)

COOLING SYSTEM Direct Cooling

TEMPERATURE CONTROL

DEFROSTING SYSTEM

Heat preservation

COMPRESSOR PTC Starting Type

EVAPORATOR Fin Tube Type

CONDENSER

REFRIGERANT

Knob Dial

Heater Defrost

Cyclopentane

R134a(90 g)

ITEMS SPECIFICATIONS

Capillary

Drier

LOCK ASSEMBLY

Cover Glass

Manual,assembly owners (1EA)

Φ0.8

molecular siever

1 EA

1 EA

Manual owners (1EA)

Card, warranty (1EA)

Key (2EA)

Door

Leg Adjust

-4-

Lock

Decor, cover

Machine room

Thermistor

DISASSEMBLY

I. Instruction for removal of the temperature control component

1. Removal of the temperature control component:
hold the fixture on the upper part of the temperature
control panel to push the temperature control
component outwards the case from the compressor
cabinet; hold and lift upwards the top of the
temperature control panel to remove the temperature
control component from the case after pushing.

2. Removal of the temperature control knob:
pull the temperature control knob from the
temperature controller directly.

3. Removal of the temperature controller:
Remove the screw which is used to fix the case controller
and controller panel , separate these 2 parts. Loose and

remove the temperature controller fix nut with Φ15mm sleeve,

4. Removal of the indicator lamp:push aside the clamped hook a little ,
pull the indicator lamp outwards and remove it

II. Instruction for removal of the hinge components

6

5

3

2

4

1

1. Removal of the upper housing of the hinge: slightly
move the upper housing of the hinge outwards, and lift
upwards to remove.

2. Removal of the lower housing of the hinge: slightly
move the lower housing of the hinge outwards, and
push downwards to remove.

3. Removal of the hinge: screw off the screws for fixing
the hinge with the pneumatic screw driver to remove
the hinge from the case.

-5-

ADJUSTMENT

1. COMPRESSOR

1) Role

The compressor intakes low temperature and low
pressure gas evaporated from Evaporator of the
Refrigerator, and condenses this gas to high temperature
and high pressure gas, and then plays delivering role to
Condenser.

2) Composition

The Compressor is Composed of Compressor Apparatus
compressing gas, Compressor Motor moving Compressor
Apparatus and Case protecting Compressor Apparatus
and Motor. There are PTC-Starter, and Over Load
Protector (OLP) in the Compressor outside. On the other
hand, because the Compressor consists of 1/1000mm
processing precision components and is sealed after
production in absence of dust or humidity, deal and repair
with care.

3) Note for Usage

(1) Be careful not to allow over-voltage and over current.
(2) No Strike

If applying forcible power or strike (dropping or
careless dealing), poor operation and noise may occur

(3) Use proper electric components appropriate to the

Compressor.

(4) Note to Keep Compressor.

If Compressor gets wet in the rain and rust in the pin of
Hermetic Terminal, the result may be poor operation
and poor contact may cause.

(5) Be careful that dust, humidity, and flux welding don't

inflow in the Compressor inside in replacing the
Compressor. Dust, humidity, and flux due to welding
which inflows to Cylinder may cause lockage and
noise.

2. PTC-STARTER

1) Composition of PTC-Starter

(1) PTC (Positive Temperature Coefficient) is a no-contact

semiconductor starting device which uses ceramic
material and this material consists of BaTiO3.

(2) The higher the temperature is, the higher becomes the

resistance value. These features are used as starting
device for the Motor.

2) Role of PTC-Starter

(1) PTC is attached to Hermetic Compressor used for

Refrigerator, Show Case and starts Motor.

(2) Compressor for household refrigerator applies to

single-phase induction Motor.
For normal operation of the single-phase induction motor, in
the starting operation flows in both main coil and sub-coil.
After the starting is over, the current in subcoil is cut off. The
proper features of PTC play all the above roles. So, PTC is
used as a motor starting device.

3) PTC-Applied Circuit Diagram
According to Starting Method for the Motor

Optional

C

BL

BN

OVERLOAD

S

t

C

M

PROTECTOR

GN/YL

P.T.CSTARTER Compressor

Figure 19

4) Motor Restarting and PTC Cooling

(1) For restarting after power off during normal

Compressor Motor operation, plug the power cord
after 5 min. for pressure balance of Refrigerating Cycle
and PTC cooling.

(2) During normal operation of the Compressor Motor,

PTC elements generate heat continuously. Therefore,
if PTC isn't cooled for a while after the power has been
shut off, Motor can't operate again.

5) Relation of PTC-Starter and OLP

If the power is off during operation of Compressor and the

(1)

power is on before the PTC is cooled, (instant shut- off within
2 min. or reconnect a power plug due to misconnecting), the
PTC isn't cooled and a resistance value grows. As a result,
current can't flow to the sub- coil and the Motor can't operate
and the OLP operates by flowing over current in only in the
main-coil.

(2)

While the OLP repeats on and off operation about 3-5 times,
PTC is cooled and Compressor Motor performs normal
operation.
If OLP doesn't operate when PTC is not cooled,
Compressor Motor is worn away and causes circuitshort and
fire. Therefore, use a properly fixed OLP without fail.

6) Note to Use PTC-Starter

(1) Be careful not to allow over-voltage and over-current.
(2) No Strike

Don't apply a forcible power or strike.

(3) Keep apart from any liquid.

If liquid such as oil or water away enter the PTC,
PTC materials it may break due to insulation
breakdown of the material itself.

(4) Don't change PTC at your convenience.

Don't disassemble PTC and mold. If the exterior to the
PTC-starter is damaged, resistance value is altered
and it may cause poor starting of the compressor
motor may cause.

(5) Use a properly fixed PTC.

-6-

3. OLP (OVER LOAD PROTECTOR)

1) Definition of OLP

(1) OLP (OVER LOAD PROTECTOR) is attached to the

Hermetic Compressor and protects the Motor by
cutting off current in Compressor Motor in case of
over-rising temperature by Bimetal in the OLP.

(2) When over-voltage flows to Compressor motor, the

Bimetal works by heating the heater inside the OLP,
and the OLP protects Motor by cutting off current
which flows to the Compressor Motor.

2) Role of the OLP

(1) The OLP is attached to the Hermetic Compressor

used for the Refrigerator and Show Case and prevents
the Motor Coil from being started in the Compressor.

(2) Do not turn the Adjust Screw of the OLP in any way for

normal operation of the OLP.(Composition and
connection Diagram of OLP)

CIRCUIT DIAGRAM

CONTACTING
POINT

ADJUST
SCREW

COVER

HEATER

BIMETAL

CONTACTING
POINT

HEATER

TERMINALS

BIMETAL

Figure 20

CIRCUIT DIAGRAM

THERMOSTAT

L H

C

GN/YL

BN

POWER SUPER CORD

BN:BROWN BL:BLUE RD:RED BK:BLACK GN/YL:GREEN&YELLOW

THE PLUG TYPE ON CIRCUIT DIAGRAM IS SUBJECT TO
CHANGE IN DIFFRENT LOCALITIES.

GN/YL

BN

BL

Power pilot lamp

BL

BK

pilot lamp

Compressor

BL

Optional

BL

RD

BK

Fan

C

BL

P.T.CSTARTER Compressor

RD

GN/YL

BN

S

t

C

M

GN/YL

OVERLOAD

PROTECTOR

-7-

TROUBLESHOOTING (Mechanical Part)

1. COMPRESSOR AND ELECTRIC COMPONENTS

1

2

Power
Source.

Check the
resistance of
Motor
Compressor.

Remove the Relay Assy
from the Compressor
and measure the voltage
between Terminal C of
Compressor and
Terminals M or S of
Relay Assy

No Voltage.

Applied voltage isn't
in the range of Rating
Voltage

Check the resistance
among M-C, S-C and
M-S in Motor
Compressor.

±10%)

(Rating Voltage
±10%)

Advise the customer
to use a regular
Trans.

YES

NO

Replace Compressor.

YES

2

5

5

3

43

5

3

4

5

Check the
resistance of
PTC-Starter.

Check OLP.

Check
starting state.

Check the resistance of
two terminals in PTC­Starter.

Check if applying
a regular OLP.

Measure minimum
starting voltage after 5
min. for balancing cycle
pressure and cooling the
PTC.

YES

OLP works within
30 sec. in forcible
OLP operation by
turning instant power
on and off.

Components start in
the voltage of Rating
Voltage ±

10% below

YES

NO

NO

YES

NO

Replace
Relay Assy

YES

Replace
Relay Assy

O.K.

4

5

5

1

-8 -

2. RELAY ASSY (PTC AND OLP)

Normal operation of
Compressor is
impossible or poor.

Separate the Relay Assy
from Compressor and
measure the resistance
between M and S with a
Tester or Whistone Bridge.
(Figure 21)

Separate the Relay Assy
from the Compressor and
check the resistance value
between two terminals of
OLP with a Tester.

Observation value is
220V/50Hz : 22Ω±30%
115V/60Hz : 6.8Ω±30%
240V/50Hz : 33
127, 220V/60Hz :
22

Ω±

30%

The resistance value is 0
or serveral hundreds Ω.

The value is ∞.

YES

Check another
electric components.

NO

Replace Relay Assy.

Ω±

Check another
electric
components.

30%

Replace
Relay Assy.

T

L N

MCSMCS

22 erugiF12 erugiF

2

3 2

-9-

3. ANOTHER ELECTRIC COMPONENTS

Cooling is impossible

Compressor
doesn't run.

Running state of
Compressor is poor.

Check if current flows to
the following
components.

a. Thermistor

b. Starting devices

c. OLP

d. Compressor coil

e. Circuit Parts

Check a starting
voltage.

Check if current flows
to starting devices.

Check current flowing
in sub-coil of
Compressor.

Cause.

Poor contacting.

Shorted or broken.

Poor contacting
or shorted.

Coil shorted.

Poor contacting
or shorted.

Low voltage.

Poor contacting
and broken.

Shorted.

Replace
each component.

Raise the voltage.

Replace
each component.

Cooling ability is poor

Fan motor
doesn't run.

Much frost are sticked
to the EVAPORATOR.

Check capacity of OLP.

The items described
above are normal.

Check current flowing
in SWITCH, DOOR.

Check current flowing in the
MOTOR[MECH], FAN.

Check current flowing
of the following
components.

• THERMISTOR

• FUSE, MELTING

Check current flowing
of the following
components.

• HEATER, SHEATH

Lack of capacity.

Coil of motor
Compressor.

Poor contacting.

Coil is shorted.

Shorted.

Replace
the compressor.

Replace
each component.

Replace
each component.

Replace
the Heater, Sheath

-10 -

TROUBLE SHOOTING

Fault phenomenon Possible cause for faults Inspection scope Removal Notes:

White indicator

lamp not

operating

Pink indicator

lamp not

operating

machine set

operating

continuously

Excessive noise,

red and green

indicator lamps

operating, and

compressor not

operating

If the supply cords are damaged, in order to avoid danger, replacement of the supply cords must be carried out by the manufacturer or its maintenance

department

No input

voltage

existing

existing

opening

Compressor set

not opening

Over-temperat

ure in the case

the case

reached

Retaining screws of the compressor loosening Inspect whether the screws are

or similar full-time staff, and it is not allowed to replace without authorization.

Poor contact between the plug

and the socket

Poor contact with the white

indicator lamp

White indicator lamp damaged Remove the white indicator lamp Replace

Poor contact between the pink

indicator lamp and the plug

foot

pink indicator lamp damaged Remove the pink indicator lamp Replace

No put the temperature

controller to operating state

position

Poor contact with the

temperature controller

Temperature controller

damaged

Too mush frosting on

evaporator

Over-high frequency of

opening the door

Too mush articles in the case Inspect whether it is possible to

Refrigerating fluid leaking Repair in a maintenance point

Over-high ambient

temperature and too low

temperature of the temperature

Case no keep flat Inspect whether four castor

Pipelines contacting Separate the pipeline

Starting relay and thermal protection

connector assembly loosening

Compressor damaged Repair or replace the compressor

Voltage less th an 187V Inspect supply voltage Connect a voltage stabilizer over

controller

Temperature controller fault Replace the temperature controller

Inspect whether the plug and the

socket are loose

Inspect whether the connector

assembly is loose

Inspect whether the connector

assembly is loose

Inspect the temperature controller Put to the operating state position

Inspect whether the connector

assembly is damaged

Inspect whether open circuit

exists in two connector

assemblies

Inspect whether thickness is more

than 2mm

Reduce the frequency of opening

impact the circulation of cool air.

Inspect whether the knob is put

on Positions “2-4” or forced

cooling

wheels touch ground

screwed down.

Inspect whether the connector

assembly is damaged

Repair or replace the socket Call an electrician

Insert the connector assembly

tightly

Insert the connector assembly

tightly

as per consideration for use

Insert the connector assembly

tightly

Replace the temperature controller

Remove the frost timely

the door as much as possible

Take some food out

Adjust the knob to Positions

“2-4”

Cushion timely

Screw the screws down

Insert the connector assembly

tightly

1000V

for repair

Input voltage

Call professional

for repair

Temperature in

Call professional

for repair

Call professional

for repair

Note: the following phenomenon is not the fault phenomenon

1. Slight gurgle exists in the temperature-changeable freezing refrigerator occasionally;

2 The compressor and the condenser emit heat, even scald hands;

3 It is possible to generate water bubbles outside the refrigerating cabinet when the ambient temperature is higher.

4 The heat of 50 Celsius degree exists outside the temperature outside.

-11-

EXPLODED VIEW

201B

201A

200A

205A

208B

200B

310B

315A

205B

208B

314A

310B

315B

205A

207B

207A

301B

216B

207C

310B

207D

212A

303D

307A

213A

310B

213B

216A

303A

306D

300A

308A

300B

311C

214A

213C

309A

306B

310A