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
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
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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
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LGE Internal Use Only
T
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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
R
DE
SIRED
EN
ER
GY
SA
VE
R
A
IR
P
URY
F
IER
AU
T
O
RE
S TART
FAN
FAN
DRY
T I M
E
M O
D E
T
E M
P
P O
W
E R
F A
N
S P
E E D
COO
L
I N
D O O
R
D E S
I R E
D
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E R G
Y
S A
V E
R
A
I R
P U R
Y F I
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A
U T O
R E S
T A
R T
FA
N
FA
N
D RY
H
EA
T
D EF
R O
S T
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
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