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Dry Fan
Cool
website: http://www.lgservice.com
e-mail: http://www.lgeservice.com/techsup.html
ROOM AIR CONDITIONER
SERVICE MANUAL
CAUTION
BEFORE SERVICING THE UNIT,
READ THE SAFETY PRECAUTIONS IN THIS MANUAL.
MODEL : M5403R, M5203R, M5203L, M6003R, WM-6011,
LWJ0611PCG, LWC061JGMK1
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CONTENTS 2.4 REFRIGERANT CYCLE ........................................... 10 1. PREFACE ................................................................ 2 2.4.1 CONDENSER .................................................. 10 1.1 FEATURES.................................................................. 2 2.4.2 EVAPORATOR ................................................. 10 1.2 SPECIFICATIONS ...................................................... 3 2.4.3 CAPILLARY TUBE ........................
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1.2 SPECIFICATIONS M6003R LWJ0611PCG MODELS M5403R M5203R M5203L WM-6011 LWC061JGMK1 ITEMS COOLING CAPACITY (BTU/h) 5,300 5,200 5,200 6,000 6,000 POWER SUPPLY (Phase, V, Hz) 1ø, 115V, 60HZ INPUT (W) 530 470 610 620 OPERATING CURRENT (AMP.) 4.8 4.3 5.6 5.8 REFRIGERANT CONTROL CAPILLARY TUBE REFRIGERANT CHARGE (R-22) 230g (8.1 Oz ) 330g(11.6 Oz) 335g (11.8 Oz) 235g (8.3 Oz) INSIDE FAN TURBO OUTSIDE FAN PROPELLER FAN WITH SLINGER RING AIR DISCHARGE 2-WAY (RIGHT AND LEFT) CHASSIS TOP-DOWN • OVE
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1.5 LOCATIONS OF CONTROLS 1.5.1 CONTROLS 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. 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/COOL/DRY • Everytime you push this button
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1.5.2 REMOTE CONTROLLER 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). 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 Power 86°F(30°C) by 1°F(1°C). Select the lower number for lower temperature of the room. FAN
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2. DISASSEMBLY INSTRUCTIONS 2.1 MECHANICAL PARTS 2.1.1 FRONT GRILLE Figure 1 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. Figure 2 2.
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Figure 6 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 air guide upper to air guide lower. (See Figure 6) 6. Lift air guide upper upward. 7. Re-install by referring to the procedures above. Figure 7 2.2.2 ORIFICE, TURBO FAN AND FAN 1. Disconnect the unit fro
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2.2.3 MOTOR Figure 10 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 ab
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2.3.2 COMPRESSOR Figure 14 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
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Figure 18 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 orifice. 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 Figure19 2.4.1 CONDENSER
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6-4. Remove the hose from the vacuum pump and 2.4.3 CAPILLARY TUBE place it on the charging cylinder. See figure 1. Remove the cabinet. 23B. Open valve C. 2. Discharge the refrigerant by using a refrigerant Discharge the line at the manifold connection. recovery system. 6-5. The system is now ready for final charging. 3. Remove the air guide upper. (Refer to Section 7. Recharge as follows: 2.2.1) 7-1. Rotary compressor systems are charged from 4. After discharging the refrigerant completely,
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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. COMPOUND GAUGE MANIFOLD GAUGE B A CONDENSER SEE INSETS (HIGH PRESSURE SIDE) BELOW COMPRESSOR EVAPORATOR (LOW PRESSURE SIDE) CAPILLARY TUBE LO HI CHARGING CYLINDER A A B B EXTERNAL VACUUM PUMP C Figure 20A-Pulling Vacuum Figure 20B-Charging —12—
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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 INSIDE OUTSIDE on the unit. FENCE AWNING 3. The outside of the cabinet must extend outward for at least 10" and there should be no obstacles, such as a COOLED AIR fence or wall, within 20" from the back
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CENTER LINE ROOM SIDE Installation HARDWARE TYPE A: 11EA TYPE B: 4EA TYPE C: 3EA DRAIN PIPE (SHORT SCREW) (WOOD SCREW) (L BACKET) TYPE D: 1EA TYPE E: 1EA TYPE F: 2EA (SEAL STRIP) (SASH SEAL) (GUIDE PANEL) (Adhesive backed) (Not adhesive backed) 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 TYPE A A) as shown Figure. 24. 2. Cut the adhesive-backed seal strip (TYPE D) to the window width. Remove the
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3. INSTALL THE AIR CONDITIONER IN THE WINDOW INNER SILL a. Carefully lift the air conditioner and slide it into the TYPE A OUTER SILL INSIDE open window. Make sure the bottom guide of the air CENTER LINE conditioner drops into the notches of the L bracket. See Figure. 27. 8" SHORT SIDE 8" OUTSIDE Figure 27 L BRACKET 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,
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REMOVAL FROM WINDOW Turn the air conditioner off, disconnect the power cord, remove the L bracket and the screws installed through the top and bot- tom 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 water. Lift the air conditioner from the window and remove the sash seal from between the windows. 3.3 ELECTRICAL DATA Line Cord Plug U
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4.2 PIPING SYSTEM CONDENSER COILS FAN MOTOR CAPILLARY TUBE TURBO FAN EVAPORATOR COILS Following is a brief description of the important components and their function in what is called the refrigeration system. Reference should be made to Figure 32 to follow the refrigerating cycle and the flow of the refrigerant in the cooling cycle. ROOM AIR CONDITIONER CYCLE OF REFRIGERATION EVAPORATOR COILS CONDENSER COILS VAPOR INLET SUCTION LINE HOT COMPLETE LIQUID COOL LOW PRESSURE VAPOR DISCHARGED BOIL
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4.3 TROUBLESHOOTING GUIDE In general, possible trouble is classified in two kinds. The one is called Starting Failure which is caused by an electrical defect. The other is Ineffective Air Con- ditioning caused by a defect in the refrigeration circuit and improper application. Unit is running but cooling is ineffective. Ineffective Cooling Check cold air Check outdoor coil Check heat load circulation for smooth (heat exchanger) and increase. flow. fan operation. Clean condenser. Dirty i
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Fails to Start Check of circuit breaker Check of power source. and fuse. Check of control panel Check control panel. setting. Compressor fails only to Fan only fails to start. start. Improper wiring. Improper thermistor Drop of power voltage. setting Defect of fan motor capacitor. Defect of compressor Loose terminal capacitor. connection Irregular motor resistance (Ω ) Capacitor check. Improper wiring Irregular motor insulation (Ω ) Replacement. Replacement of fan motor. I
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ELECTRIC PARTS TROUBLESHOOTING GUIDE: • The unit does not operate. Possible Trouble 1 NO • Check the Fuse. Is the Trans output power • Check the wiring diagram. AC 115V? YES NO NO • Check the Main Is the Trans output power Is shorted the Trans. output? P.W.B pattern. about AC 14V? YES YES • Exchange the Trans. • Exchange D02D~D05D. NO Is output Voltage of IC01D • Exchange IC01D. DC 12V? YES NO • Exchange IC02D. Is output Voltage of IC02D DC 5V? YES NO Is the reset circuit all right? • Exchan
