Lg L1204r Service Manual

Internal Use Only

http://biz.lgservice.com

Room Air Conditioner

SVC MANUAL(Exploded View)

MODEL : WR-8030 WM-8031
WM-1031 WR-1230
WM-1231 WR-1030
HBLG8003R HBLG1003R
R1200M L1204R
R1200E

CAUTION

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

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

2.

DISASSEMBLY INSTRUCTIONS

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

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

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

2.1.3 CONTROL BOX .....................................6

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

2.2.1 AIR GUIDE AND TURBO FAN...............7

2.2.2 FAN ........................................................7

2.2.3 SHROUD ................................................8

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

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

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

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

2.3.4 POWER CORD ......................................9

2.3.5 MOTOR ................................................10

2.4 REFRIGERATION CYCLE ............................10

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

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

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

3.

INSTALLATION

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

3.2 CHECK OF INSTALLATION..........................13

3.3 HOW TO DRAIN............................................13

3.4 HOW TO INSTALL ........................................14

3.4.1 WHEN USING GASKET.......................14

3.4.2 WHEN USING INSTALLATION KITS...14

4.

TROUBLESHOOTING GUIDE

4.1 OUTSIDE DIMENSIONS ...............................17

4.2 PIPING SYSTEM...........................................18

4.3 TROUBLESHOOTING GUIDE ......................19

5. SCHEMATIC DIAGRAM

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

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

5.3

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

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

5.4

..29

...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.

Copyright ©2008 LG Electronics. Inc. All right reserved.
Only for training and service purposes

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 WR-8030, WM-8031, WM-1031, WR-1230, WM-1231, HBLG8003R, HBLG1003R,
WR-1030, R1200M, L1204R, R1200E

MODELS

ITEMS

POWER SUPPLY

COOLING CAPACITY (Btu/h)

INPUT (W)

RUNNING CURRENT (A)

E.E.R (BTU/W.h)

OPERATING INDOOR (°C)

CONDITION OUTDOOR (°C)

REFRIGERANT (R-22) CHARGE

EVAPORATOR

CONDENSER

FAN, INDOOR

FAN, OUTDOOR

FAN SPEEDS, FAN/COOLING

FAN MOTOR

WR-8030

300g(10.6oz)

2 ROW 11STACKS

WM-8031

HBLG8003R

8,000 10,000 12,000 10,000

800 1,020 1,220 1,020

7.3 9.2 11.0 9.2

10 9.8

2 ROW 16STACKS

PROPELLER TYPE FAN WITH SLINGER RING

2/3 3/3 2/3 3/3 2/3

WM-1031

HBLG1003R

1ø, 115, 60Hz

26.7(DB)* 19.4(WB)**

35(DB)* 23.9(WB)**

520g(18.3oz)

3 ROW 11STACKS

TURBO FAN

WR-1230
R-1200M

470g(16.6oz)

2 ROW 12STACKS

2 ROW 17STACKS

6 POLES

WM-1231

L1204R
R1200E

WR1030

520g(18.3oz)

3 ROW 11STACKS

2 ROW 16STACKS

OPERATION CONTROL

ROOM TEMP. CONTROL

AIR DIRECTION CONTROL

CONSTRUCTION

PROTECTOR

POWER CORD

DRAIN SYSTEM

NET WEIGHT (lbs/kg)

OUTSIDE DIMENSION (inch)

(W xH xD) (mm)

* DB:Dry Bulb
**

WB:Wet Bulb

COMPRESSOR

FAN MOTOR

ROTARY SWITCH

THERMOSTAT THERMISTOR THERMOSTAT THERMISTOR THERMOSTAT

REMOTE CONTROLLER

VERTICAL LOUVER (RIGHT & LEFT)

HORIZONTAL LOUVER (UP & DOWN)

SLIDE IN-OUT CHASSIS

OVERLOAD PROTECTOR

INTERNAL THERMAL PROTECTOR

(3 WIRE WITH GROUDING)

ATTACHMENT PLUG (CORD-CONNECTED TYPE)

DRAIN PIPE OR SPLASHED BY FAN SLINGER

203/32 x 1329/32 x 193/8

510 x 354 x 490

ROTARY SWITCH

62/28

REMOTE CONTROLLER

ROTARY SWITCH

Copyright ©2008 LG Electronics. Inc. All right reserved.
Only for training and service purposes

- 3 -

LGE Internal Use Only

1.4 FEATURES

OPERATIONTHERMOSTAT

OFF

HIGH

COOL

MED

COOL

LOW COOL

MED

FAN

LOW

FAN

Air

Purifier

Power

Temp

Sleep Mode

Timer

Auto

Swing

Fan Speed

AIR

PURIFIER

7 1

2

3

4

8

5

Powe r

Temp

Fan Speed

Timer Mode

˚C

TIMER POWERMODE

TEMP

FAN

SPEED

F1 LOW
F2 MED
F3 HIGH

Dry Timer

Fan

Energy

Saver

Cool

1

2

6

3 45

1

2

3

4

5

• Designed for COOLING ONLY.

• Powerful and whispering cooling.

• Slide-in and slide-out chassis for the simple
installation and service.

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

1.5 CONTROL LOCATIONS

• THERMOSTAT

Thermostat will automatically control the temperature of
the room. Select a higher number (the right side of arc)
for a cooler temperature in the room. The temperature is
selected by positioning the knob to the desired position.
The 5 or 6 position is a normal setting for average
conditions.

• OPERATION

OFF : Turns the air conditioner to off.

MED FAN : Permits the medium fan speed operation

without cooling.

• Built-in adjustable Thermistor

• Washable one-touch filter

• Compact size

• Reliable and efficient rotary compressor is equipped.

LOW FAN : Permits the low fan speed operation

without cooling.

HIGH COOL : Permits cooling with the high fan speed

operation.

MED COOL : Permits cooling with the medium fan

speed operation.

LOW COOL : Permits cooling with the low fan speed

operation.

DISPLAY

Copyright ©2008 LG Electronics. Inc. All right reserved.
Only for training and service purposes

- 4 -

REMOTE CONTROL

LGE Internal Use Only

6

6

7

7

8

8

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

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

POWER BUTTON

To turn the air conditioner ON, push the button. To turn the air conditioner OFF, push the button again.
This button takes priority over any other buttons.

ROOM TEMPERATURE SETTING BUTTON

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

OPERATION MODE SELECTION BUTTON

Every time you push this button, it will shift among COOL, ENERGY SAVER, FAN and DRY.

-

Energy Saver: If Energy Save mode is selected, 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 SELECTOR

Every time you push this button, it is set as follows.
(Hi ➔ Low ➔ Med ➔ Hi ➔ Low ➔...)

ON/OFF TIMER BUTTON

You can set the time when the unit will turn on or turn off automatically by pressing the timer button. If the unit is operating,
this button controls the time it will be turned off. If the unit is off state, this button controls the time it will start. Every time
you push this button, the remaining time will be set as follows.

- Stopping operation
(1Hour ➔ 2Hours ➔ 3Hours ➔ 4Hours ➔ 5Hours ➔ 6Hours ➔ 7Hours ➔ 8Hours ➔ 9Hours ➔ 10Hours ➔ 11Hours ➔

12Hours ➔ 0Hour ➔ 1Hour ➔ 2Hours ➔... )

- Starting operation
(1Hour ➔ 2Hours ➔ 3Hours ➔ 4Hours ➔ 5Hours ➔ 6Hours ➔ 7Hours ➔ 8Hours ➔ 9Hours ➔ 10Hours ➔ 11Hours ➔

12Hours ➔ off ➔ 1Hour ➔ 2Hours ➔ ... )

REMOCON SIGNAL RECEIVER

AIR PURIFIER

• Press the Air Purifier button.
Operation will start when the button is pressed and stop when the button is pressed again.

• Set the fan speed with the remote control. You can select the fan speed in three steps high, low or medium.
Each time the button is pressed, the fan speed mode is shifted.

• If you press the only Air Purifier button, only air purifying operates.
Then, fan speed is low. You can select the fan speed in three steps high, low or medium.
Each time the button is pressed, the fan speed mode is shifed.

SLEEP MODE

• Press the sleep mode button to set the time you want the unit to turn off automatically.

• Every time you push this button, the remaining time will be set as follows.

(1Hour ➔ 2Hours ➔ 3Hours ➔ 4Hours ➔ 5Hours ➔ 6Hours ➔ 7Hours ➔ 0Hour ➔ 1Hour ➔ 2Hours ➔

...

)

• The temperature setting will be raised by 2˚F in 30 minutes and by 4˚F in 1 hour to prevent overcooling during sleep.

Copyright ©2008 LG Electronics. Inc. All right reserved.
Only for training and service purposes

- 5 -

LGE Internal Use Only

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2. DISASSEMBLY INSTRUCTIONS

— Before the following disassembly, POWER SWITCH set to OFF and disconnect the power cord.

2.1 MECHANICAL PARTS

2.1.1 FRONT GRILLE

1. Open the lnlet grille downward and remove the air
filter.

2. Remove the screw which fastens the front
grille.(See Figure 1)

3. Pull the front grille from the right side.

4. Remove the front grille.(There are 4 hooks.)

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

2.1.2 CABINET

1. After disassembling the FRONT GRILLE, remove
the 2 screws which fasten the cabinet at both
sides.

2. Remove the 2 screws which fasten the cabinet at
back.

3. Pull the base pan forward. (See Figure 2)

4. Remove the cabinet.

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

Figure 1

2.1.3 CONTROL BOX

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

2. Remove the cabinet. (Refer to section 2.1.2)

3. Remove the 2 screws which fasten the power
cord.

4. Disconnect the grounding screw from the
evaporator channel.

5. Remove the 1 screw which fasten the control box
cover.

6. Remove the housing which connects PCB and
motor wire in the control box.

7. Disconnect the housing which connects Plazma
Air Purifier.(Optional)

8. Remove the screw at left cover of filter case and
open the cover to remove inner screw. (Optional)

9. Remove the nut which fastens the terminal cover.

10. Remove the terminal cover.

11. Remove all the leads from the overload protector.

12. Discharge the capacitor by placing a 20,000
ohmresistor across the capacitor terminals.

13. Raise the control box upward completely.
(See Figure 3)

14. Re-install the components by referring to the
removal procedure, above.
(Refer to the circuit diagram found on page 27 in
this manual and on the control box.)

Copyright ©2008 LG Electronics. Inc. All right reserved.
Only for training and service purposes

- 6 -

Figure 2

Figure 3

LGE Internal Use Only

2.2 AIR HANDLING PARTS

2.2.1 AIR GUIDE AND TURBO FAN

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

2. Remove the cabinet. (Refer to section 2.1.2)

3. Remove the control box. (Refer to section 2.1.3)

4. Remove the 4 screws which fasten the brace.

5. Remove the brace.

6. Remove the 2 screws which fasten the air guide
upper.

7. Remove the air guide upper.(See figure 4)

8. Remove the 2 screws which fasten the evaporator.

9. Move the evaporator forward and pulling it upward
slightly. (See Figure 5)

10. Pull out the hook of orifice by pushing the tabs

and remove it. (See Figure 6)

11. Remove the clamp with a hand plier which

secures the turbo fan.

12. Remove the turbo fan.

13. Remove the 2 screws which fasten the air guide

from the base pan.

14. Move the air guide backward, and pull out from

the base pan.(Move the air giude lower carefully.)

15. Re-install the components by referring to the

removal procedure, above.

Figure 4

2.2.2 FAN

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

2. Remove the brace (Refer to section 2.2.1)

3. Remove the 5 screws which fasten the condenser.

4. Move the condenser to the left carefully.

5. Remove the clamp which secures the fan.

6. Remove the fan. (See Figure 7)

7. Re-install by referring to the removal procedure.

Figure 5

Figure 6

Copyright ©2008 LG Electronics. Inc. All right reserved.
Only for training and service purposes

- 7 -

Figure 7

LGE Internal Use Only

2.2.3 SHROUD

1. Remove the fan. (Refer to section 2.2.2)

2. Remove the shroud. (See Figure 8)

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

2.3 ELECTRICAL PARTS

2.3.1 OVERLOAD PROTECTOR

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

2. Remove the nut which fastens the terminal cover.

3. Remove the terminal cover. (See Figure 9)

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.

Figure 8

Figure 9

2.3.2 COMPRESSOR

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

2. 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.

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 which
fasten the compressor.

6. Remove the compressor. (See Figure 10)

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

Copyright ©2008 LG Electronics. Inc. All right reserved.
Only for training and service purposes

TM

Figure 10

- 8 -

LGE Internal Use Only

2.3.3 CAPACITOR

DEFROST

HEAT

CO

OL

IND

OO

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DE

SIRED

EN

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SA

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P

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TART

FAN

FAN

DRY

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1. Remove the control box. (Refer to section 2.1.3)

2. Open the top cover from the control box.
(See Figure 11)

3. Pull out the capacitor from the control box.

4. Disconnect all the leads of capacitor terminals.

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

2.3.4 POWER CORD

1. Remove the control box. (Refer to section 2.1.3)

2. Open the top cover from the control box.
(Refer to section 2.3.3)

3. Disconnect the front panel from the control box.
(See Figure 12)

4. Disconnect two leads from the capacitor and relay.

5. Pull out the power cord.

6. Re-install the component by referring to the above
removal procedure, 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 which has the
same specification marked on the supply cord
attached at the unit.)

Figure 11

Copyright ©2008 LG Electronics. Inc. All right reserved.
Only for training and service purposes

- 9 -

Figure 12

LGE Internal Use Only

2.3.5 MOTOR

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

2. Remove the turbo fan. (Refer to section 2.2.1)

3. Remove the fan. (Refer to section 2.2.2)

4. Remove the 4 screws which fasten the motor from
the air guide. (See Figure 13)

5. Remove the motor.

6. Re-install the components by referring to the
removal procedure, above.(See Figure 13)

2.4 REFRIGERATING 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.

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

2. Remove the 5 screws which fasten the
brace.(Refer to section 2.2.1)

3. Remove the 5 screws which fasten the condenser
and shroud.

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

5. Remove the condenser.

6. Re-install the components by referring to notes.
(See Figure 14)

2.4.2 EVAPORATOR

1. Remove the control box.(Refer to section 2.1.3)

2. Remove the air guide upper. (Refer to section

2.2.1)

3. Remove the 2 screws which fasten the evaporator.

4. Move the evaporator sideways carefully.
(Refer to section 2.2.1)

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

6. Remove the evaporator.

7. Re-install the components by referring to notes.
(See Figure 15)

Figure 13

Figure 14

Copyright ©2008 LG Electronics. Inc. All right reserved.
Only for training and service purposes

- 10 -

Figure 15

LGE Internal Use Only