Lg Kp05a10 Service Manual

Internal Use Only

http://biz.lgservice.com

Room Air Conditioner

SVC MANUAL(Exploded View)

MODEL : LWJ0515PCW/CG LWJ0514PCF LWJ0512PGG/CW/CG LWC071JGMK0 LWC051JGMK1/JPMK2 LWC061JPMK0 LWJ0611PCG

CAUTION

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

CONTENTS

1. PREFACE ....................................................................................................................................................................... 2

1.1 FEATURES ........................................................................................................................................................................ 2

1.2 SPECIFICATIONS ............................................................................................................................................................. 3

1.3 SAFETY PRECAUTIONS ................................................................................................................................................. 3

1.4 INSULATION RESISTANCE TEST .................................................................................................................................... 3

1.5 LOCATIONS OF CONTROLS ........................................................................................................................................... 4

2. DISASSEMBLY INSTRUCTIONS .................................................................................................................... 6

2.1 MECHANICAL PARTS ...................................................................................................................................................... 6

2.1.1 FRONT GRILLE ....................................................................................................................................................... 6

2.1.2 CABINET................................................................................................................................................................... 6

2.1.3 CONTROL BOARD ................................................................................................................................................... 6

2.2 AIR HANDLING PARTS .................................................................................................................................................... 7

2.2.1 AIR GUIDE UPPER................................................................................................................................................... 7

2.2.2 ORIFICE, TURBO FAN AND FAN............................................................................................................................. 7

2.2.3 MOTOR .................................................................................................................................................................... 8

2.2.4 AIR GUIDE ................................................................................................................................................................ 8

2.3 ELECTRICAL PARTS ....................................................................................................................................................... 8

2.3.1 OVERLOAD PROTECTOR ...................................................................................................................................... 8

2.3.2 COMPRESSOR ........................................................................................................................................................ 9

2.3.3 CAPACITOR ............................................................................................................................................................. 9

2.3.4 THERMISTOR........................................................................................................................................................... 9

2.3.5 CONTROL PANEL..................................................................................................................................................... 9

2.3.6 POWER CORD ...................................................................................................................................................... 10

2.4 REFRIGERANT CYCLE ............................................................................................................................................ 10

2.4.1 CONDENSER ........................................................................................................................................................ 10

2.4.2 EVAPORATOR ....................................................................................................................................................... 10

2.4.3 CAPILLARY TUBE ................................................................................................................................................. 11

3. INSTALLATION ......................................................................................................................................................... 13

3.1 SELECT THE BEST LOCATION ..................................................................................................................................... 13

3.2 HOW TO INSTALL .......................................................................................................................................................... 13

ELECTRICAL DATA

3.3

4. TROUBLESHOOTING GUIDE ........................................................................................................................

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

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

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

..................................................................................................................................................... 16

16

5. SCHEMATIC DIAGRAM ...................................................................................................................................... 26

5.1 CIRCUIT DIAGRAM......................................................................................................................................................... 26

5.2 ELECTRONIC CONTROL DEVICE ................................................................................................................................. 27

5.3

COMPONENTS LOCATION(FOR MAIN P.W.B ASM)

5.4

COMPONENTS LOCATION(FOR DISPLAY P.W.B ASM)

............................................................................................................... 28

......................................................................................................... 28

6. EXPLODED VIEW ................................................................................................................................................... 29

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LGE Internal Use Only

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 FEATURES

• DESIGNED FOR COOLING ONLY

• POWERFUL AND INCREDIBLE COOLING

• TOP-DOWN CHASSIS FOR THE SIMPLE INSTALLATION AND SERVICE

• WASHABLE ONE-TOUCH FILTER

• COMPACT SIZE

1.2 SPECIFICATIONS

ITEMS

MODELS

WG5200ER

LW5200ER

HBLG5200E

LWC051JGMK2

KG5200ER ACQ058PL

LW050CE

WG5200R

ACQ052PK

M5404R

WM5031

LWJ0515PAG

LW5200R

WG6000R

M6004R

KG6000R

HBLG6000R

LW7000R

COOLING CAPACITY (BTU/h)

POWER SUPPLY (Phase, V, Hz)

INPUT (W)

OPERATING CURRENT (AMP.)

REFRIGERANT CONTROL

REFRIGERANT CHARGE (R-22)

INSIDE FAN

OUTSIDE FAN

AIR DISCHARGE

CHASSIS

PROTECTOR

TEMPERATURE CONTROL

ROTARY SWITCH

FAN MOTOR

5,200 5,050 5,250 6,000 76,000

1ø, 115V, 60HZ

470/480 520 540 620 720

4.3/4.4 4.8 5.0 5.8 6.7

CAPILLARY TUBE

330g (11.6 Oz) 220g(7.8 Oz) 235g (8.3 Oz) 315g (11.1 Oz)

TURBO

PROPELLER FAN WITH SLINGER RING

2-WAY (RIGHT AND LEFT)

TOP-DOWN

• OVERLOAD PROTECTOR FOR COMPRESSOR

• INTERNAL PROTECTOR FOR FAN MOTOR

THERMISTOR

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

6 POLES, 21W 6 POLES, 19W 6 POLES, 21W 6 POLES, 27W

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

1.3 SAFETY PRECAUTIONS

1. When servicing, set the POWER of CONTROL BOARD 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, make an insulation resistance test to prevent the customer's exposure to shock hazards.

1.4

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 Mode [except POWER OFF].

4. The value should be over 1 MΩ.

- 3 -

LGE Internal Use Only

1.5 LOCATIONS OF CONTROLS

Dry Fan

Cool

ON/OFF TIMER

- STOPPING OPERATION

• Everytime you push this button, when the unit is operating, timer is set as follows.

(1Hour 2Hours 3Hours 4Hours 5Hours 6Hours

7Hours 8Hours 9Hours 10Hours 11Hours 12Hours Cancel)

• The Setting Temperature will be raised by 2°F(1°C) 30min. later and by 2°F(1°C) after another 30 min.

- STARTING OPERATION

• Everytime you push this button, when the unit is not operating, timer is set as follow.

(1Hour 2Hours 3Hours 4Hours 5Hours 6Hours

7Hours 8Hours 9Hours 10Hours 11Hours 12Hours Cancel)

MODE

• Everytime you push this button, it will toggle between COOL, FAN, DRY or FAN, COOL.

POWER

• To turn the unit ON, push the button. To turn the unit OFF, push the button again.

• This button takes priority over any other buttons.

• When you first turn it on, the unit is on the High cool mode

and the temp. at 72°F(22°C).

TEMPERATURE SETTING

• This button can automatically control the temperature of the room. The temperature can be set within a range of 60°F(16°C) to 86°F(30°C) by 1°F(1°C). Select the lower number for lower temperature of the room.

FAN SPEED

• Everytime you push this button it is set as follows. {High(F2) Low(F1) High(F2)...} or {High(F3) Mid(F2) Low(F1) High(F3)...}.

ENERGY SAVER

The fan stops when the compressor stops cooling.

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

1.5.1

CONTROLS

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LGE Internal Use Only

1.5.2 REMOTE CONTROLLER

Auto

Swing

Power

Temp

Fan Speed

Timer Mode

Energy

Saver

TEMPERATURE SETTING

ENERGY SAVER

The fan stops when the compressor stops cooling.

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

FAN SPEED

• Everytime you push this button it is set as follows. {High(F2) Low(F1) High(F2) or {High(F3) Mid(F2) Low(F1) High(F3)...}

POWER

• To turn the Set ON, push the button. To turn the Set OFF, push the button again.

• This button takes priority over any other buttons.

• When you first turn it on, the Set is on the High cool mode and the temp. at 72°F(22°C).

COOL/FAN/DRY or COOL/FAN

• Everytime you push this button, it will toggle between COOL, FAN and DRY.

ON/OFF TIMER

- STOPPING OPERATION

• Everytime you push this button, when the set is operating, timer is set as follows.

(1Hour 2Hours 3Hours 4Hours 5Hours 6Hours

7Hours 8Hours 9Hours 10Hours 11Hours 12Hours Cancel)

• The Setting Temperature will be raised by 2°F(1°C) 30min. later and by 2°F(1°C) after another 30 min.

- STARTING OPERATION

• Everytime you push this button, when the set is not operating, timer is set as follow.

(1Hour 2Hours 3Hours 4Hours 5Hours 6Hours

7Hours 8Hours 9Hours 10Hours 11Hours 12Hours Cancel)

• This button can automatically control the temperature of the room. The temperature can be set within a range of

60°F(16°C) to 86°F(30°C) by 1°F(1°C). Select the lower number for lower temperature of the room.

How to Insert Batteries

1. Remove the cover from the back of the

remote controller

2. Insert two batteries.

• Be sure that the (+) and (-) directions are correct.

• Be sure that both batteries are new.

3. Re-attach the cover.

• Do not use rechargeable batteries. Such batteries differ from standard dry cells in shape, dimensions, and performance.

• Remove the batteries from the remote controller if the air conditioner is not going to be used for an extended length of time.

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LGE Internal Use Only

2. DISASSEMBLY INSTRUCTIONS

2.1 MECHANICAL PARTS

2.1.1 FRONT GRILLE

1. Disconnect the unit from source of power.

2. Using a screwdriver, remove the screw that secures the front grille to control board. (See Figure 1)

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 2)

4. Replace the grille by placing the tabs in the slots and push the grille until it snaps into place.

2.1.2 CABINET

1. Disconnect the unit from the power source.

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

3. Remove 9 screws that secure the cabinet to the base pan and condenser. (See Figure 3)

4. Lift the cabinet from the unit.

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

Figure 1

Figure 2

Figure 3

2.1.3 CONTROL BOARD

1. Disconnect the unit from the power source.

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

3. Remove the cabinet. (Refer to Section 2.1.2)

4. Remove 2 screws that secure the control board to base pan and air guide. (See Figure 4)

5. Pull the control board toward yourself.

NOTE : Controls, wires, and capacitor are now

accessible for servicing. Discharge the capacitor before servicing. See step

2.3.3 on page 9 for procedures.

6. Disconnect one housing terminal and 3 wires for the fan motor and compressor. (See Figure 5)

7. Re-install components by referring to procedures above. (Refer to circuit diagram on page 26 in this manual or inside control board.)

Figure 4

Figure 5

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LGE Internal Use Only

2.2 AIR HANDLING PARTS

2.2.1 AIR GUIDE UPPER

1. Disconnect the unit from the power source.

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

3. Remove the cabinet. (Refer to Section 2.1.2)

4. Remove the control board. (Refer to Section 2.1.3)

5. Remove 2 screws that secure the brace to air guide upper and shroud. (See Figure 6)

6. Remove 2 screws that secure the air guide upper to air guide lower. (See Figure 6)

7. Lift air guide upper upward.

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

2.2.2 ORIFICE, TURBO FAN AND FAN

1. Disconnect the unit from the power source.

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

3. Remove the cabinet. (Refer to Section 2.1.2)

4. Remove the control board. (Refer to Section 2.1.3)

5. Remove the air guide upper. (Refer to Section 2.2.1)

6. Remove 2 screws that secure the base pan to condenser. (See Figure 7)

7. Remove 2 screws 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. Lift the compressor upward with the evaporator and condenser. (See Figure 7)

10. Remove the orfice by pushing the snap area of the air guide blower. (See Figure 8)

11. Remove the clamp springs which are clamped to the boss of fan and turbo fan by hand plier. (See Figure 9)

12. Pull the fan and turbo fan outward.

13. Remove the shroud.

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

Figure 6

Figure 7

Figure 8

Figure 9

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LGE Internal Use Only

2.2.3 MOTOR

1. Disconnect the unit from the power source.

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

3. Remove the cabinet. (Refer to Section 2.1.2)

4. Remove the control board. (Refer to Section 2.1.3)

5. Remove the air guide upper. (Refer to Section 2.2.1)

6.

Remove the compressor, turbo fan, fan and shroud. (Refer to

7.

Remove 2 screws that secure the motor to the motor. (See Figure 10)

8. Remove the motor.

9.

Re-install by referring to the procedures above.

Section

2.2.2)

Figure 10

2.2.4 AIR GUIDE

1. Disconnect the unit from the power source.

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

3. Remove the cabinet. (Refer to Section 2.1.2)

4. Remove the control board. (Refer to Section 2.1.3)

5. Remove the air guide upper. (Refer to Section 2.2.1)

6.

Remove the compressor, turbo fan, fan and shroud. (Refer to

7.

Remove the motor. (Refer to

8. Remove 2 screws that secure the air guide to the base pan. (See Figure 11)

9. Push the air guide backward and lift it upward. (See Figure 11)

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

Section

2.2.2) Section

2.2.3)

2.3 ELECTRICAL PARTS

2.3.1 OVERLOAD PROTECTOR

1. Remove the front grille 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 12 and 13)

Figure 11

Figure 12

Figure 13

- 8 -

LGE Internal Use Only

2.3.2 COMPRESSOR

1. Remove the front grille and cabinet. (Refer to Section 2.1.2)

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

3. Remove the overload protector. (Refer to Section 2.3.1)

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 14)

2.3.3 CAPACITOR

1. Remove the cabinet. (Refer to Section 2.1.2)

2. Remove the control board. (Refer to Section 2.1.3)

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

4. Pull the capacitor upward.

5. Remove all the leads of capacitor terminals.

6. Re-install the components by referring to the removal procedure above. (See Figure 15)

Figure 14

Figure 15

2.3.4 THERMISTOR

1. Remove the cabinet. (Refer to Section 2.1.2)

2. Remove the control board. (Refer to Section 2.1.3)

3. Disconnect the thermistor terminals from main P.W.B assembly.

4. Remove the thermistor.

5. Re-install the components by referring to the removal procedure above. (See Figure 16)

2.3.5 CONTROL PANEL

1. Remove the cabinet. (Refer to Section 2.1.2)

2. Remove the control board. (Refer to Section 2.1.3)

3. Pull the control panel forward and pull out it.

4. Remove 2 lead wire terminals.

5. Re-install the components by referring to the removal procedure above. (See Figure 17)

Figure 16

Figure 17

- 9 -

LGE Internal Use Only

2.3.6 POWER CORD

1. Disconnect the unit from source of power.

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

3. Remove the cabinet. (Refer to Section 2.1.2)

4. Remove 2 screws that secure control board to base pan and air guide. (Refer to Section 2.1.3)

5. Pulls the control board toward you.

6. Remove the grounding screw.

7. Remove a screw securing the clip with cord to the control board.

8. Pull the power cord.

9. Re-install by referring to procedures above.

Figure 18

2.4 REFRIGERANT CYCLE

2.4.1 CONDENSER

1. Remove the cabinet. (Refer to Section 2.1.2)

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

3. Remove 2 screws which fasten the condenser. (See Figure 19)

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

5. Remove the condenser.

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

2.4.2 EVAPORATOR

1. Remove the cabinet. (Refer to Section 2.1.2)

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

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

2.2.1)

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.

Figure19

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LGE Internal Use Only

2.4.3 CAPILLARY TUBE

1. Remove the cabinet. (Refer to Section 2.1.2)

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

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

2.2.1)

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.

NOTES

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 20A.

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.

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 20B. 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.

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.

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 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 min-

utes, 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.

- 11 -

LGE Internal Use Only

Equipment needed: Vacuum pump, charging cylinder, manifold gauge, brazing equipment, pinch-off tool capable

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

of making a vapor proof seal, leak detector, tubing cutter, hand tools to remove components and service valve.

Figure 20A-Pulling Vacuum Figure 20B-Charging

- 12 -

LGE Internal Use Only

3. INSTALLATION

ABOUT / "

Over 20"

HEAT

RADIATION

FENCE

AWNING

OUTSIDE

INSIDE

COOLED AIR

30"-60"

1

4

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

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

3.1 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.

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

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

4"). This will force

Figure 21

3.2 HOW TO INSTALL

3.2.1 WINDOW REQUIREMENTS

NOTE: 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 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.

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. 23. 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

3.

4. If the distance between STORM WINDOW FRAME

drain properly to the outside.

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. 23.

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

- 13 -

Figure 22

Figure 23

LGE Internal Use Only

Installation Kit (Some models)

HARDWARE

TYPE E: 1EA

(SASH SEAL)

(Not adhesive backed)

TYPE D: 1EA

(SEAL STRIP)

(Adhesive backed)

TYPE F: 2EA

(GUIDE PANEL)

TYPE C: 3EA

(L BACKET)

TYPE A: 11EA

(SHORT SCREW)

10mm

TYPE B: 5EA

(WOOD SCREW)

16mm

TYPE G: 1EA

(SUPPORT BACKET)

DRAIN PIPE

ROOM SIDE

CENTER LINE

INNER SILL

SEAL STRIP (TYPE D)

TYPE A

TYPE C

OUTSIDE

INSIDE

L

BRACKET

OUTER SILL

INNER SILL

TYPE A

8"

CENTER LINE

3.2.2 BEFORE INSTALLATION

1. Insert the guide panels into the guides of the air condi-

tioner. Fasten the curtains to the unit with screws (TYPE A), as shown Figure. 24.

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

. 25)

3.2.3 NOW START INSTALLATION

1. LOCATING UNIT IN WINDOW

Open the window and mark center line on the center of the inner sill, as shown in Figure. 26.

2. ATTACH L BRACKET

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

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

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

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

sure to place bracket edge flush against back of inner sill. See Figure. 27.

CAUTION

open window. Make sure the bottom guide of the air conditioner drops into the notches of the

L bracket. See Figure. 27.

Figure 24

Figure 25

Figure 26

Figure 27

- 14 -

LGE Internal Use Only

IMPORTANT :

CENTER LINE

SEAL

WINDOW FRAME

BOTTOM GUIDE

ABOUT

1/4"

L

BRACKET

UPPER GUIDE

DRAIN PIPE

DRAIN CAP

hang push

SASH SEAL

(TYPE E)

L BRACKET

TYPE A

TYPE B

Support Bracket (TYPE G)

1 2

When the air conditioner drops into the L bracket, the air conditioner will be centered in window opening as shown in Figure. 28.

b. While steadying the air conditioner, carefully bring the

window sash down behind the upper guide of the air conditioner, as shown in Figure. 29.

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. 30.

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. 30.

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

shown in Figure. 30.

Figure 28

Figure 29

TYPE B

Figure 30

6. a. Remove the screws that secure the cabinet and base

pan in the right side.

b. Fasten the suport bracket (TYPE G) using a removed

screw. Attach the suport bracket (TYPE G) in the inner window sill with a screw (TYPE B), as shown Figure.

31.

7. Window installation of room air conditioner is now

completed. See ELECTRICAL DATA for attaching power cord to electrical outlet.

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

- 15 -

Figure 31

Figure 32

LGE Internal Use Only

REMOVAL FROM WINDOW

Do not under any circumstances cut or remove the grounding prong from the plug.

Line Cord Plug Use Wall Receptacle Power Supply

Power supply cord with 3-prong grounding plug

Standard 125V, 3-wire grounding receptacle rated 15A, 125V AC

Use 15 AMP, time delay fuse or circuit breaker.

370 (14 9/16")

312 (12 1/4")

370 (14 9/16")

312 (12

1

/4")

29 (1

5

/32")

120 (4 3/4")

27.5 (1

3

/32")

346 (13

5

/8")

472 (18 9/16")

42 (1 21/32")

155(6

3

/

32

")

12

(0.4

1

/

16

")

472 (18 9/16")

22.5(0.8

3

/

32

")

Turn the air conditioner off, disconnect the power cord, remove the L bracket, the screws and support bracket installed through the top and bottom of the guide panels, and save for reinstallation later. Close the guide panels. Keeping a firm grip on the air conditioner, raise the sash, and carefully tilt the air conditioner backward, draining any condensate. Lift the air conditioner from the window and remove the sash seal from between the windows.

3.3 ELECTRICAL DATA

USE OF EXTENSION CORDS

Because of potential safety hazards, we strongly discourage the use of an extension cord. However, if you wish to use an extension cord, use a CSA certified/UL-listed 3-wire (grounding) extension cord, rated 15A, 125V.

4. TROUBLESHOOTING GUIDE

4.1 OUTSIDE DIMENSIONS (unit: mm [in])

- 16 -

LGE Internal Use Only

4.2 PIPING SYSTEM

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

CONDENSER COILS

FAN

CAPILLARY

MOTOR

TUBE

TURBO FAN

EVAPORATOR COILS

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 33 to follow the refrigerating cycle and the flow of the refrigerant in the cooling cycle.

Figure 33

- 17 -

LGE Internal Use Only

4.3 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 Con-

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

Unit is running but cooling is ineffective.

Ineffective Cooling

Check cold air circulation for smooth flow.

Dirty indoor coil (heat exchanger)

Malfunction of fan.

Clogging of air filter.

Obstruction at air outlet.

Check outdoor coil (heat exchanger) and fan operation.

Check gas leakage.

Repair gas leak.

Replacement of unit if the unit is beyond repair.

Check heat load increase.

Clean condenser.

Not on separate circuit

Check inside gas pressure.

Adjust refrigerant charge.

Remove obstruction.

Check clogging in refrigeration circuit.

Repair clogging in refrigeration circuit.

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

- 18 -

Malfunction of compressor.

Replacement of compressor.

LGE Internal Use Only

Fails to Start

Check of power source.

Check of control panel setting.

Compressor fails only to start.

Drop of power voltage.

Defect of compressor capacitor.

Improper thermistor setting

Loose terminal connection

Check of circuit breaker and fuse.

Check control panel.

Fan only fails to start.

Improper wiring.

Defect of fan motor capacitor.

Capacitor check.

Replacement.

Irregular motor resistance (Ω)

Irregular motor insulation (Ω)

Replacement of compressor (Motor damaged).

Improper wiring

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

Replacement of fan motor.

Regular but fails to start.

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

- 19 -

LGE Internal Use Only

Is the Trans output 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

ELECTRIC PARTS TROUBLESHOOTING GUIDE:

Possible Trouble 1

• The unit does not operate.

- 20 -

LGE Internal Use Only

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 higher 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

Is the wire connection of

RY-COMP all right?

• Check the RY-COMP.

• Connect LEAD Wire to

RY-COMP again.

NO

YES

• 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

• The compressor does not operate.

Possible Trouble 3

Possible Trouble 4

• The compressor always operate.

• Fan does not operate.

- 21 -

LGE Internal Use Only

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

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?

• Romote controller does not operate.

Possible Trouble 6

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

- 22 -

LGE Internal Use Only

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.

Rotary 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.

- 23 -

Pay attention to any change from high speed to low speed. If the speed does not change, replace the motor.

LGE Internal Use Only

COMPLAINT CAUSE REMEDY

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

replace it.

Blower 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 disconnected, refer to wiring diagram for identification, and replace the wires. Check the wire connections; If not according to the wiring diagram, correct the connections.

Thermistor Check the TEMP control. If not at the lowest

number, set TEMP control to this setting and restart the unit.

Check the continuity of the thermistor. Replace the thermistor 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

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

Overload Check overload, if externally mounted.

Check the compressor overload if externally mounted. Replace if open. (If the compressor temperature is high, remove the overload, cool, and retest.)

call an electrician.

Replace if open. (If the compressor temperature is high, remove the overload, cool, and retest.)

- 24 -

LGE Internal Use Only

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. Blower or fan Check the set screw, or clamp. If loose or miss-

ing, correct. If the blower or 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.

- 25 -

LGE Internal Use Only

5. SCHEMATIC DIAGRAM

1

6

4

5

8

3

7

2

5.1 CIRCUIT DIAGRAM

LOCATION

NO.

1

2

3

4

5

6

DESCRIPTION

POWER CORD ASSEMBLY

FAN MOTOR

COMPRESSOR

DISPLAY P.W.B ASSEMBLY

MAIN P.W.B ASSEMBLY

THERMISTOR

Q'TY

PER SET

1

7

8

CAPACITOR

OWERLOAD PROTECTOR

1

- 26 -

LGE Internal Use Only

5.2 ELECTRONIC CONTROL DEVICE

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

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

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

- 27 -

LGE Internal Use Only

5.3 COMPONENTS LOCATION (FOR MAIN P.W.B ASM)

5.4 COMPONENTS LOCATION (FOR DISPLAY P.W.B ASM)

- 28 -

LGE Internal Use Only

6. EXPLODED VIEW

352390A

267110

152302

130410

359012

135312

354210

349480

352390B

559010

346811

554030

130910

264110

W0CZZ

249950

268711B

567480

550140

554160

567502

352115

552111

552102

35211A

268711A

147582B

145200

147582A

Models : LWJ0515PCW/CG, LWJ0514PCF, LWJ0512PGG/CW/CG, LWC051JGMK1/JPMK2, LWJ0611PCG

- 29 -

LGE Internal Use Only

Models : *LWC071JGMK0 / LWC061JPMK0

352390A

267110

152302

130410

359012

135312

354210

349480

352390B

559010

346811

554030

130910

264110

W0CZZ

249950

268711B

567480

550140

554160

567502

352115

552111

352113

552102

35211A

268711A

147582B

145200

147582A

- 30 -

LGE Internal Use Only

P/NO : 3828A20038L

FEBRUARY, 2008

Lg Kp05a10 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual