LG L1204R Schematic

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Room Air Conditioner

SERVICE MANUAL

CAUTION

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

- ONLY FOR AUTHORIZED SERVICE.

MODEL: WR-8030 WM-8031

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

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 ....................................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

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

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

7. REPLACEMENT PARTS LIST........31

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.

—2—

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

—3—

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

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

3 45

• 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

—4—

REMOTE CONTROL

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.

—5—

T IM E

M O

D E

T E M

P O

W E

F A

S P

C O

O L

I N

D O

O R

D E S

I R E

E N E

R G

S A

V E R

I R

P U R

Y F I

E R

A U

T O

R E S

T A R

F A

D R Y

E A

T DE

S T

T I M

M O

D E

T E

M P

P O W

E R

F A

S P E

E D

C O O

IN D

O O

D E S

I R E

E N

E R

G Y

A V

R A IR

P U

R Y

A U T

R E

S T

A N

F A

D R YH

E A

T D E

F R

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.)

Figure 2

Figure 3

—6—

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

—7—

Figure 7

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.

Figure 10

—8—

2.3.3 CAPACITOR

DEFROST

HEAT

IND

SIRED

URY

IER

S TART

FAN

DRY

T I M

M O

D E

E M

P O

E R

F A

S P

E E D

COO

I N

D O O

D E S

I R E

E N

E R G

S A

V E

I R

P U R

Y F I

E R

U T O

R E S

T A

R T

D RY

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

—9—

Figure 12

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

—10—

Figure 15

2.4.3 CAPILLARY TUBE

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

2. After discharging the refrigerant completely, unbraze the interconnecting tube at the capillary tube.(See caution above)

NOTES

— Replacement of the refrigeration cycle.

1. When replacing the refrigeration cycle, 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. Solder service valves into the pinch-off tube ports, leaving the valves open.

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

5. Evacuate as follows.

1) Connect the vacuum pump, as illustrated figure

16A.

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 16B. Open valve C. Discharge the line at the manifold connection.

5) The system is now ready for final charging.

3. Remove the capillary tube.

4. Re-install the components by referring to notes.

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 16B. 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.

—11—

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