Lg Gelp Owner's Manual

Room Air Conditioner

SVC MANUAL(Exploded View)

MODEL : LP6000ER LP7000R

CAUTION

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

Internal Use Only

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A20190H

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 TOP COVER ..........................................5

2.1.3 CABINET ................................................5

2.1.4 CONTROL BOX .....................................5

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

2.2.1 AIR GUIDE AND CROSS FLOW FAN ...6

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

2.2.3 INDOOR FAN MOTOR...........................7

2.2.4 AIR GUIDE LOWER ...............................7

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

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

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

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

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

2.3.5 OUTDOOR MOTOR...............................9

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

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

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

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

INSTALLATION

3.1 HOW TO INSTALL THE UNIT.......................12

3.2 CHECKING INSTALLATION .........................12

3.3 WINDOW REQUIREMENTS .........................12

3.4 INSTALLATION KITS CONTENTS ...............13

3.5 SUGGESTED TOOL REQUIREMENTS .......13

3.6 HOW TO INSTALL ........................................13

3.7 REMOVAL FROM WINDOW.........................16

TROUBLESHOOTING GUIDE

4.1 OUTSIDE DIMENSIONS ...............................16

4.2 PIPING SYSTEM...........................................17

4.3 TROUBLESHOOTING GUIDE ......................18

5. SCHEMATIC DIAGRAM

5.1 CIRCUIT DIAGRAM ......................................27

5.2 ELECTRONIC CONTROL DEVICE...............28

5.3

COMPONENTS LOCATION(FOR AC P.C.B ASM)

5.4

COMPONENTS LOCATION(FOR DC P.C.B ASM)

...

..29

6. EXPLODED VIEW ..................................30

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

1.3.1 FOR LP6000ER/LP7000R

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

INDOOR (°C)

OUTDOOR (°C)

LP6000ER LP7000R

115V, 60Hz

6,000 7,000

560 700

5.2 6.5

10.7 10.0

26.7(DB)* 19.4(WB)**

35(DB)* 23.9(WB)**

435g(15.3 oz) 350g(12.3 oz)

2 ROW 9 STACKS, SLIT FIN TYPE

2 ROW 14 STACKS, LOUVER FIN TYPE

CROSS FLOW FAN

AXIAL FAN

3/3

4 POLES

REMOTE CONTROLLER

ROOM TEMP. CONTROL

AIR DIRECTION CONTROL

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

THERMISTOR

VERTICAL LOUVER (RIGHT & LEFT)

HORIZONTAL LOUVER (UP & DOWN)

TOP-DOWN CHASSIS

OVERLOAD PROTECTOR

INTERNAL THERMAL PROTECTOR

3 WIRE WITH GROUNDING

ATTACHMENT PLUG (CORD-CONNECTED TYPE)

DRAIN PIPE SPLASHED BY FAN SLINGER

55/25 57/26

235/8 x 12 x 181/32

600 x 305 x 458

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LGE Internal Use Only

1.4 FEATURES

Timer

Air

Purifier

AIR

PURIFIER

Power

Temp

Timer Mode

Auto

Swing

Fan Speed

52 4

31 6

• Designed for COOLING ONLY.

• Powerful and quiet cooling.

• Simple installation and service.

• Low air-intake, top cool-air discharge.

• Built-in adjustable THERMISTOR

• Washable one-touch filter

• Compact size

• Reliable and efficient rotary compressor.

1.5 CONTROL LOCATIONS

Precaution: The Remote Control unit will not function properly if bright light strikes the sensor window of the air

conditioner or if there are obstacles between the Remote Control unit and the air conditioner.

POWER

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

• This button takes priority over any other button.

FAN SPEED

• Every time you push this button, it advances the setting as follows: {High(F3) → Low(F1) → Med(F2) → High(F3)}

• When you first turn it on, the unit is in cool mode, high fan speed, temperature setting at 72˚F.

TIMER

- SHUT-OFF TIME

TEMPERATURE SETTING

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

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

• With unit running, use Timer to set number of hours

until shut-off.

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

MODE

- Every time you push this button, it will cycle through COOL, ENERGY SAVER, FAN and DRY.

- ENERGY SAVER

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

• Every time you push Timer button, it advances the Timer setting as follows: 1 Hour → 2 Hours → etc. → 12 Hours maximum.

- START TIME

• While unit not running, use timer to set number of hours before unit starts.

• Every time you push Timer button, it advances the Timer setting as follows: 1 Hour → 2 Hours → etc. → 12 Hours maximum.

REMOTE CONTROL SENSOR

AUTO RESTART

When power is restored after an electrical power failure, the unit will begin to run at its last setting.

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LGE Internal Use Only

2. DISASSEMBLY INSTRUCTIONS

2.1 MECHANICAL PARTS

2.1.1 FRONT GRILLE

1. Unplug the unit from source of power.

2. Remove the 2 screws securing the front Grille.(See Figure 1)

3. Push the grille up from the bottom and pull the top of the grille way from the cabinet to lift the top tabs out of their slots.(See Figure 2)

4. Disconnect display connector.

2.1.2 TOP COVER

1. Disconnect the unit from the power source.

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

3. Remove curtains on both side.

4. Remove 5 screws that secure the top cover to the cabinet.(See Figure 3)

2.1.3 CABINET

1. Disconnect the unit from the power source.

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

3. Remove the top cover. (Refer to section 2.1.2)

4. Remove 4 screws that secure the cabinet to the base pan. (See Figure 4)

5. Remove the cabinet.

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

Figure 1

Figure 2

Figure 3

Figure 4

2.1.4 CONTROL BOX

1. Disconnect the unit from the power source.

2. Remove the front grille. (Refer to Section 2.1.1)

3. Remove the screw that fastens the power cord.

4. Remove the grounding screw from the evaporator channel and remove the thermistor from the evaporator fin.

5. Remove the 2 screws that fasten the control box cover and open the control box cover.(See Figure 5)

6. Remove the housing that connects motor and wires come form compressor.

7. Remove the screw that secures the control box and base pan.

8. Remove the 2 screws that secure the control box and motor mount.(See Figure 6)

9. Move the control box upward.

Figure 5

Figure 6

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LGE Internal Use Only

2.2 AIR HANDLING PARTS

2.2.1 AIR GUIDE UPPER AND CROSS FLOW FAN

1. Disconnect the unit from the power source.

2. Remove the front grille. (Refer to Section 2.1.1)

3. Remove the top cover. (Refer to Section 2.1.2)

4. Remove the cabinet. (Refer to Section 2.1.3)

5. Remove the control box. (Refer to Section

2.1.4)

6. Move the evaporator forward, pulling it upward slightly.

7. Pull the air guide upper and remove it.(See Figure 7)

8. Loosen the bolt securing the cross flow fan to the motor (do not remove).

9. Pull the cross flow fan and remove it.

10. Re-install by referring to the procedures

above.

Figure 7

Figure 8

2.2.2 FAN AND SHROUD

1. Disconnect the unit from the power source.

2. Remove the front grille. (Refer to Section 2.1.1)

3. Remove the top cover. (Refer to Section 2.1.2)

4. Remove the cabinet. (Refer to Section 2.1.3)

5. Remove 3 screws which the fasten the brace and the bracket. (See Figure 8)

6. Remove the brace and the bracket.

7. Remove 4 screws which fasten the condenser channel, shroud and base pan.

8. Move the shroud upward and remove it.

9. Move the condenser forward, pulling it slightly upward .

10. Remove the clamp with a hand plier which

secures the fan.(See Figure 9)

11. Remove the fan.

14. Re-install by referring to the procedures

above.

Figure 9

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LGE Internal Use Only

2.2.3 INDOOR FAN MOTOR

1. Disconnect the unit from the power source.

2. Remove the front grille. (Refer to Section 2.1.1)

3. Remove the control box. (Refer to Section 2.1.4)

4. Remove the air guide upper and cross flow fan. (Refer to Section 2.2.1)

5. Remove the motor.(See Figure 10)

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

2.2.4 AIR GUIDE LOWER

1. Disconnect the unit from the power source.

2. Remove the front grille. (Refer to Section 2.1.1)

3. Remove the top cover. (Refer to Section 2.1.2)

4. Remove the control box. (Refer to Section 2.1.4)

5. Remove the air guide upper and cross flow fan. (Refer to Section 2.2.1)

Remove the motor. (Refer to

Remove 2 screws which fasten the mount motor and remove mount motor. (

8. Remove the fan and shroud.(Refer to Section

2.2.2)

9. Remove 3 screws that secure the air guide to the base pan. (See Figure 11)

10. Pull the airguide toward youself. (See Figure

12)

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

Section

See Figure 11

2.2.3)

Figure 10

Figure 11

)

Figure 12

2.3 ELECTRICAL PARTS

2.3.1 OVERLOAD PROTECTOR

1. Remove the front grille, top cover and cabinet. (Refer to Section 2.1)

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 13 and 14)

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Figure 13

Figure 14

LGE Internal Use Only

2.3.2 COMPRESSOR

1. Remove the front grille, top cover and cabinet. (Refer to Section 2.1)

2. Discharge the refrigerant system using a FreonTMRecovery 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 that fasten the compressor.(See Figure 15)

6. Remove the compressor.

7. Re-install the components by referring to the removal procedure, above.

2.3.3 CAPACITOR

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

2. Open the capacitor cover. (See Figure 16)

3. Remove all the leads of capacitor terminals.

4. Re-install the components by referring to the removal procedure above.

Figure 15

Figure 16

2.3.4 POWER CORD

1. Remove the control box.(Refer to section 2.1.4)

2. Open the control box cover.

3. Disconnect two leads from the capactitor and relay.

4. Remove a screw securing the clip with cord to the control box.

5. Pull out the power cord.

6. Re-install by referring to procedures above.(Use only one ground-marked hole for ground connection.)

7. If the supply cord of this appliance is damaged, it must be replaced by the special cord. (The special cord means the cord that has the same specification marked on the supply cord attached at the unit.)

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Figure 17

LGE Internal Use Only

2.3.5 OUTDOOR MOTOR

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

2. Remote the top cover. (Refer to section 2.1.2)

3. Remove the cabinet. (Refer to section 2.1.3)

4. Remove the fan and shroud. (Refer to section

2.2.2)

5. Remove the 3 screws which fasten the motor from the mount motor. (See Figure 18)

6. Open the capacitor cover(Refer to section 2.3.3)

7. Disconnect the outdoor motor housing.

8. Remove the motor.

9. Re-install the components by referring to the removal procedure, above.

2.4 REFRIGERANT CYCLE

2.4.1 CONDENSER

CAUTION

Discharge the refrigerant system using a FreonTMRecovery 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.

Figure 18

Figure 19

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

2. Remove the top cover. (Refer to Section 2.1.2)

3. Remove the cabinet. (Refer to Section 2.1.3)

4. Remove the shroud. (Refer to Section 2.2.2)

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

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

7. Remove the condenser.

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

2.4.2 EVAPORATOR

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

2. Remove the top cover.(Refer to Section 2.1.2)

3. Remove the cabinet.(Refer to Section 2.1.3)

4. Remove the control box.(Refer to Section 2.1.4)

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

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

7. Remove the evaporator.

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

2.4.3 CAPILLARY TUBE

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

2. Remove the top cover.(Refer to Section 2.1.2)

3. Remove the cabinet.(Refer to Section 2.1.3)

4. Remove the control box.(Refer to Section 2.1.4)

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

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

7. Remove the capillary tube.

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

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LGE Internal Use Only

NOTES

— Replacement of the refrigerant.

1. When replacing the refrigerant, be sure to 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.

2. After discharging the unit completely, remove the desired component, and unbraze the pinch-off tubes.

3. Braze service valves into the pinch-off tube ports, leaving the valves open.

4. Braze the pinch-off tubes with Service valves.

5. Evacuate as follows.

1) Connect the vacuum pump, as illustrated figure

20A.

2) Start the vacuum pump, slowly open manifold

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

and entire system.

CAUTION

If high vacuum equipment is used, just crack valves A and B for a few minutes, then open slowly with the two full turns counterclockwise. This will keep oil from foaming and being drawn into the vacuum pump.

3) Operate the vacuum pump for 20 to 30 minutes,

until 600 microns of 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.

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.

5) The system is now ready for final charging.

6. Recharge as follows :

1) Refrigeration cycle 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 you installed as the system was opened.

2) Connect the charging cylinder as shown in figure 20B. With valve C open, discharge the hose at the manifold connection.

3) Open valve A and allow the proper charge to enter the system. Valve B is still closed.

4) If more charge is required, the high-side will not take it. Close valve A.

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. c. Turn off valve B and allow pressure to drop. d. Repeat steps b. and c. until the balance of the

charge is in the system.

6) When satisfied the unit is operating correctly, use the pinch-off tool with the unit still running and clamp on to 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 pinch-off tube closed. Turn off the unit, allow it to set for a while, and then test the leakage of the pinch-off connection.

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LGE Internal Use Only

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