ROOM AIR CONDITIONER
SERVICE MANUAL
CAUTION
BEFORE SERVICING THE UNIT,
READ THE SAFETY PRECAUTIONS IN THIS MANUAL.
Dr
y
Fa
n
C
o
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l
MODEL: BG5200ER, WG6000RH4, L6004R,HBLG6000R,
HBLG5200E,
—2—
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
3.3
ELECTRICAL DATA
..................................................................................................................................................... 16
4. TROUBLESHOOTING GUIDE ........................................................................................................................
16
4.1 OUTSIDE DIMENSIONS ................................................................................................................................................. 16
4.2 PIPING SYSTEM ............................................................................................................................................................ 17
4.3 TROUBLESHOOTING GUIDE ........................................................................................................................................ 18
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)
............................................................................................................... 28
5.4
COMPONENTS LOCATION(FOR DISPLAY P.W.B ASM)
......................................................................................................... 28
6. EXPLODED VIEW ................................................................................................................................................... 29
7. SERVICE PARTS LIST ......................................................................................................................................... 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 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
¥NOTE: Specifications are subject to minor change without notice for further improvement.
3
MODELS
ITEMS
COOLING CAPACITY (BTU/h)
5,200 6,000
POWER SUPPLY (Phase, V, Hz)
1f, 115V, 60HZ
INPUT (W)
480 620
OPERATING CURRENT (AMP.)
4.4 5.8
REFRIGERANT CONTROL
CAPILLARY TUBE
REFRIGERANT CHARGE (R-22)
325g (11.5 Oz) 350g (12.3 Oz)
INSIDE FAN
TURBO
OUTSIDE FAN
PROPELLER FAN WITH SLINGER RING
AIR DISCHARGE
2-WAY (RIGHT AND LEFT)
CHASSIS
TOP-DOWN
PROTECTOR
TEMPERATURE CONTROL
THERMISTOR
ROTARY SWITCH
5 POSITIONS (LOW FAN, HIGH FAN, OFF, HIGH COOL, LOW COOL)
FAN MOTOR
6 POLES, 21W 6 POLES, 21W
¥OVERLOAD PROTECTOR FOR COMPRESSOR
¥INTERNAL PROTECTOR FOR FAN MOTOR
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 MW.
HBLG5200E
BG5200ER WG6000RH4 L6004R
HBLG6000R
_ _
—4—
1.5 LOCATIONS OF CONTROLS
1.5.1 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.
—5—
1.5.2 REMOTE CONTROLLER
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.
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.
—6—
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.
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.
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 1
Figure 2
Figure 3
Figure 4
Figure 5
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.
—7—
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
—8—
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
Section
2.2.2)
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.
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
Section
2.2.2)
7.
Remove the motor. (Refer to
Section
2.2.3)
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.
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 10
Figure 12
Figure 13
Figure 11
—9—
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)
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 14
Figure 15
Figure 16
Figure 17
—10—
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.
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.
Figure 18
Figure19
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.
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.
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.
—11—
—12—
Equipment needed: Vacuum pump, charging cylinder, manifold gauge, brazing equipment, pinch-off tool capable
of making a vapor proof seal, leak detector, tubing cutter, hand tools to remove components and service valve.
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
Figure 20A-Pulling Vacuum Figure 20B-Charging
—13—
3. INSTALLATION
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.
4. Install the unit slanted slightly so the back is slightly lower than the front (about1/
4"). This will force
condensed water to the outside.
5.Install the unit with the bottom about 30"~60"
above the floor level.
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 approximately3/4" higher than the
storm window frame (STORM WINDOW FRAME) or
wood strip (OUTDOORS) to help condensation to
drain properly to the outside.
3.
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.
4. If the distance between STORM WINDOW FRAME
and WOOD STRIP MOUNTED ON TOP OF INNER
SILL is more than 1", two of wood strip are not necessary.
ABOUT / "
Over 20"
HEAT
RADIATION
FENCE
AWNING
OUTSIDE
INSIDE
COOLED AIR
30"-60"
1
4
Figure 21
Figure 22
Figure 23
All side louvers of the cabinet must remain
exposed on the outdside of the structure.
CAUTION
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
—14—
Installation Kit (Some models)
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
the short side of bracket as shown.
Use the 2 screws (TYPE A) provided.
b. The bracket helps to hold unit securely in place. Be
sure to place bracket edge flush against back of inner
sill. See Figure. 27.
3. INST ALLTHE AIR CONDITIONER IN THE WINDOW
a. Carefully lift the air conditioner and slide it into the
open window. Make sure the bottom guide of the air
conditioner drops into the notches of the
L bracket. See Figure. 27.
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
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.
CAUTION
ROOM SIDE
CENTER LINE
INNER SILL
SEAL STRIP
(TYPE D)
TYPE A
TYPE C
Figure 24
Figure 25
Figure 26
OUTSIDE
INSIDE
L
BRACKET
OUTER SILL
INNER SILL
TYPE A
8"
8"
CENTER LINE
Figure 27
IMPORTANT :
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
showninFigure.30.
5. INSTALL THE SASH SEAL AND SASH LOCK
a. Cut the sash seal (TYPE E) to the window width. Stuff
thesashsealbetweentheglassandthewindowto
prevent air and insects from getting into the room, as
showninFigure.30.
b. Fasten the L bracket using a (TYPE A) screw, as
shown in 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—
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
Figure 28
Figure 29
Figure 30
Figure 32
Figure 31
TYPE B
—16—
REMOVAL FROM WINDOW
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.
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.
4. TROUBLESHOOTING GUIDE
4.1 OUTSIDE DIMENSIONS (unit: mm [in])
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")
42 (1 21/32")
155(6
3
/
32
")
12
(0.4
1
/
16
")
472 (18 9/16")
22.5(0.8
3
/
32
")
—17—
4.2 PIPING SYSTEM
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.
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
Figure 33
CONDENSER COILS
FAN
CAPILLARY
MOTOR
TUBE
TURBO FAN
EVAPORATOR
COILS
—18—
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
Satisfactory operation
with temperature
difference of inlet & outlet
air; 44~50°F (7~10°C)
Replacement of unit if
the unit is beyond repair.
Check outdoor coil
(heat exchanger) and
fan operation.
Check heat load
increase.
Check cold air
circulation for smooth
flow.
Check gas leakage.
Clean condenser.
Not on separate circuit
Check inside gas
pressure.
Adjust refrigerant
charge.
Malfunction of
compressor.
Replacement of
compressor.
Check clogging in refrigeration circuit.
Repair clogging in
refrigeration circuit.
Dirty indoor coil
(heat exchanger)
Repair gas leak.
Malfunction of fan.
Clogging of air filter.
Obstruction at air outlet.
Remove obstruction.
—19—
Fails to Start
Improper thermistor
setting
Loose terminal
connection
Improper wiring
Check of power source.
Drop of power voltage.
Capacitor check.
Replacement.
Check of control panel
setting.
Compressor fails only to
start.
Defect of compressor
capacitor.
Replacement of compressor
(Motor damaged).
Irregular motor insulation (Ω)
Irregular motor resistance (Ω)
Check of circuit breaker
and fuse.
Check control panel.
Fan only fails to start.
Improper wiring.
Defect of fan motor
capacitor.
Replacement of fan motor.
Regular but fails to start.
Replacement of compressor.
(Locking of piston, metal.)
Irregular motor
resistance (Ω)
Irregular motor
insulation (Ω)
—20—
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
NO
NO
NO
NO
NO
NO
YES
YES
YES
YES
YES
YES
YES
NO
YES
ELECTRIC PARTS TROUBLESHOOTING GUIDE:
Possible Trouble 1
• The unit does not operate.
—21—
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 NO
YES
YES
YES
YES
Possible Trouble 2
• The compressor does not operate.
Is the wire connection of
RY-COMP all right?
• Check the RY-COMP.
• Connect LEAD Wire to
RY-COMP again.
NO
YES
Possible Trouble 3
• The compressor always operate.
• Exchange IC01M.
• 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
NO
YES
YES
Possible Trouble 4
• Fan does not operate.
—22—
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
NO
NO
YES
YES
YES
Possible Trouble 5
• Romote controller does not operate.
NO
NO
NO
NO
YES
YES
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?
Possible Trouble 6
• It displays abnormally on Display P.W.B Ass'y.
—23—
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.
Pay attention to any change from high speed to
low speed. If the speed does not change,
replace the motor.
—24—
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 discon-
nected, 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
Check the compressor overload if externally mounted.
Replace if open. (If the compressor temperature is
high, remove the overload, cool, and retest.)
Compressor cycles on Voltage Check the voltage. See the limits on the
overload. preceding page. If voltage is not within these limits,
call an electrician.
Overload Check overload, if externally mounted.
Replace if open. (If the compressor temperature
is high, remove the overload, cool, and retest.)
—25—
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.
—26—
5. SCHEMATIC DIAGRAM
5.1 CIRCUIT DIAGRAM
Q'TY
PER SET
1
1
1
1
1
1
1
1
LOCATION
NO.
1
2
3
4
5
6
7
8
DESCRIPTION
POWER CORD ASSEMBLY
FAN MOTOR
COMPRESSOR
DISPLAY P.W.B ASSEMBLY
MAIN P.W.B ASSEMBLY
THERMISTOR
CAPACITOR
OWERLOAD PROTECTOR
1
6
4
5
8
3
7
2
—27—
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
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
4
3
2
OR1H
RY-SYNC
RY-LOW
RY-4WAY
RY-COMP
111213
654107
OR2H
5V
12.1K
R21H
R03H
0K
12.1K
1%
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
1
2
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
220
220
220
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
5V
17
1
17
1
D03F
5V
ENERGY
SAVER
SW3
D07F
TEMP UP
SW7
1K
R04P
6
5
20K
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
—28—
5.3 COMPONENTS LOCATION
(FOR MAIN P.W.B ASM)
5.4 COMPONENTS LOCATION
(FOR DISPLAY P.W.B ASM)
—29—
6. EXPLODED VIEW
135313
135303
352390-1
267110
152302
130410
359012
W48602
135312
354210
349480
352390-2
149980
559010
346811
554030
W48602
130910
264110
238310
W0CZZ
249950
268714
263230
550140
554160
567502
352115
552111
552102
352113
35211A
137215
268712
159900-2
145200
159900-1
148000
132111-1
132111-2
_
30
7. SERVICE PARTS LIST
NOTE)*Please ensure GCSC since these parts may be changed depending upon the buyer's request. (GCSC WEBSITE http://biz.lgservice.com)
130410 BASE ASSEMBLY,SINGLE 3041A10011E 3041A10011E 3041A10011E 3041A10011E 3 041A10011E R
130910 CABINET ASSEMBLY,SINGLE 3091A10020D 3091A10020D 3091A10020D 3091A10020D 3 091A10020D R
132111-1 FRAME ASSEMBLY 3211AR3239A 3211AR3239A 3211AR3239A 3211AR3239A 3211AR3239A R
132111-2 FRAME ASSEMBLY 3211AR3239B 3211AR3239B 3211AR3239B 3211AR3239B 3211AR3239B R
135312 GRILLE ASSEMBLY, FRONT(SINGLE) 3531AR1644H 3531A10130B 3531AR1644H 3531AR1644T
3531A10130B
R
135313 GRILLE ASSEMBLY, INLET 3530A10039A 3530A10039A 3530A10039A 3530A10039A 3 530A10039A R
145200 LINK 4520AR3191A 4520AR3191A 4520AR3191A 4520AR3191A 4520AR3191A R
148000 BRACE 4800A30003A 4800A30003A 4800A30003A 4800A30003A 4800A30003A R
149980 SHROUD 4998A10008A 4998A10008A 4998A10008A 4998A10008A 4998A10008A R
152302 FILTER(MECH),A/C 5231AR2148G 5231AR2148G 5231AR2148G 5231AR2148G 5231AR2148G R
159900-1 VANE,VERTICAL 5990AR3190C 5990AR3190C 5990AR3190A 5990AR3190C 5990AR3190C R
159900-2 VANE,VERTICAL 5990AR3190D 5990AR3190D 5990AR3190B 5990AR3190D 5990AR3190D R
238310 ESCUTCHEON 3831A10001F 3831A10001F 3831A10001F 3 831A10001F 3 831A10001F R
249950 CONTROL BOX ASSEMBLY 4995A20127H 4995A20127H 4995A20127H 4995A20127H 4995A20127H R
263230 THERMISTOR ASSEMBLY 6323A20003D 6323A20003D 6323A20003D 6323A20003D 6323A20003D R
264110 POWER CORD ASSEMBLY 2H00677P 2H00677P 2H00677P 2H00677P 2H00677P R
267110 REMOTE CONTROLLER ASSEMBLY 6711A90019A 6711A90019B 6711A90019A 6711A20034E
6711A90019B
R
268712 PWB(PCB) ASSEMBLY, DISPLAY 6871A20193B 6871A20193B 6871A20193B 6871A20193B 6871A20193B R
268714 PWB(PCB) ASSEMBLY, MAIN 6871A20188L 6871A20188L 6871A20188L 6871A20188L 6871A20188L R
346811 MOTOR ASSEMBLY,SINGLE 4681A10002P 4681A10002P 4681A10002S 4681A10002S 4681A10002S R
349480 ORIFICE 4948A10007A 4948A10007A 4948A10007A 4948A10007A 4948A10007A R
352113 TUBE,DISCHARGE 5210A21100A 5210A21100A 5210A21100A 5210A21100A 5210A21100A R
352115 TUBE ASSEMBLY, EVAPORATOR IN 5211A10063C 5211A10063C 5211A10063C 5211A10063C 5211A10063C R
35211A TUBE ASSEMBLY, SUCTION SINGLE 5211A10062B 5211A10062B 5211A10062B 5211A10062B 5211A10062B R
352390-2 AIR GUIDE ASSEMBLY 5239A10005B 5239A10005B 5239A10005B 5239A10005B 5239A10005B R
352390-1 AIR GUIDE ASSEMBLY 5239A30003A 5239A30003A 5239A30003A 5239A30003A 5239A30003A R
354210 EVAPORATOR ASSEMBLY, FIRST 5421A20016G 5421A20016G 5421A20016G 5421A20016G 5421A20016G R
359012 FAN, TURBO 5900A10005A 5900A10005A 5900A10005A 5900A10005A 5900A20005A R
550140 ISOLATOR,COMPRESSOR 5040AR4195A 5040AR4195A 5040AR4195A 5040AR4195A 5040AR4195A R
552111 TUBE ASSEMBLY, CAPILLARY 5211AR3332R 5211AR3332R 5211AR3332R 5211AR3332R 5211AR3332R R
554030 CONDENSER ASSEMBLY, FIRST 5403A20009E 5403A20009E 5403A20009E 5403A20009E 5403A20009E R
554160 COMPRESSOR
5416A20014D 5416A20014D
5416A20014T 5416A20014T 5416A20014T R
559010 FAN, AXIAL 5900A20017A 5900A20017A 5900A20017A 5900A20017A 5900A20017A R
567502 O.L.P
6750A30001U
6750A30001U 6750UL0604A 6750UL060A 6750UL060A R
W0CZZ CAPACITOR, DRAWING 6120AR2359V 6120AR2359V 6750A90001E 6750A90001E 6750A90001E R
W48602 CLAMP, SPRING 3H02932B 3H02932B 3H02932B 3H02932B 3H02932B R
REMARKS
DESCRIPTION
LOCATION
NO
BG5200ER HBLG6000R WG6000RH4
L6004R
HBLG5200E
PART NO
_
P/No.: 3828A20295X
December, 2003
Printed inThailand
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