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Room Air Conditioner
SERVICE MANUAL
MODEL: LWJ0561ACG
LWJ0561ACP/AAG
CAUTION
- BEFORE SERVICING THE UNIT, READ THE "SAFETY
PRECAUTIONS" IN THIS MANUAL.
- ONLY FOR AUTHORIZED SERVICE PERSONNEL.
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CONTENTS 1. PREFACE .................................................................................................................................................. 3 1.1 FEATURES ................................................................................................................................................... 3 1.2 SPECIFICATIONS ........................................................................................................................................ 3 1.3 LOCATI
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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 • BUILT-IN ADJUSTABLE THERMOSTAT • WAS
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L O O R C E L 1.3 LOCATIONS OF CONTROLS Off ( ) : Turns air conditioner off. 0 Operation Operation Off High Fan ( ) : High speed fan operation with- 0 High High out cooling. Fan Cool Low Fan ( ) : Low speed fan operation with- Low Low out cooling. Fan Cool High Cool ( ) : Cooling with high speed fan operation. Low Cool ( ) : Cooling with low speed fan operation. Thermostat Thermostat 5 This automatically controls the temperature of the 5 4 6 6 4 indoor air. Turn the knob so that the arrow points
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2. DISASSEMBLY INSTRUCTIONS 2.1 MECHANICAL PARTS 2.1.1 FRONT GRILLE Figure 1 1. Disconnect the unit from the power source. 2. Remove the two knobs by pulling them off. 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) Figure 2 4. Replace the grille by placing the tabs in the slots and push th
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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 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 proced
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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 above.
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2.3.3 CAPACITOR 1. Remove the cabinet. (Refer to Section 2.1.2) Figure 15 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. Remove the screw which fastens the capacitor clamp. 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 THERMOSTAT 1. Remove the cabinet. (Refer to Section 2.1.2) 2. Remove the control board
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wise. This will keep oil from foaming and being 2.4.2 EVAPORATOR drawn into the vacuum pump. 1. Remove the cabinet. (Refer to section 2.1.2) 2. Discharge the refrigerant by using a refrigerant 6-3. Operate the vacuum pump for 20 to 30 min- recovery system. utes, until 600 micron vacuum is obtained. 3. Remove the air guide upper. (Refer to Section Close valves A and B and observe vacuum 2.2.1) gauge for a few minutes. 4. After discharging the refrigerant completely, A rise in pressure would indic
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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 —10—
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3. INSTALLATION This air conditioner is designed with a button- down chassis so that it can be installed simply 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 sunlight does not shine directly on the unit. 3. The outside of the cabinet must extend outward for FENCE AWNING at least 10" and there should be no obstacles, such as a fence or wall, within 20" from the back of COOLED AIR the
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3.4 HOW TO INSTALL • WHEN USING GASKET A 1 2 2 RIGHT SIDE HORIZONTAL 3 G LINE C D E Figure 24 Figure 25 1. WINDOW (A - WIDTH,B-HEIGHT) 2. GASKET 3. WALL AB C D E F G 487mm 324mm 30mm 0~25mm OVER 240mm 5~10mm -5~5mm 3 3 1 15 3 3 3 3 (19 / ) (12 /)(1 / ) (0~1") (9 /)( / ~ /)(- / ~ / ) 16" 4" 16" 32" 16" 8" 16" 16" 4. TROUBLE SHOOTING GUIDE 4.1 OUTSIDE DIMENSION (unit : mm) 370 472 —12— 312 F B
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4.2 PIPING SYSTEM CONDENSER COILS FAN MOTOR CAPILLARY TUBE BLOWER 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 26 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 OFF
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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 from an electrical defect. The other is Ineffective Air Conditioning caused from 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 indoor co
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Fails to Start Check of circuit breaker Check of power source. and fuse. Check of control switch Gas leakage of feeler setting. bulb of thermostat. Check control switch. Compressor fails only to Fan only fails to start. start. Improper wiring. Improper thermostat 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. Replac
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ROOM AIR CONDITIONER VOLTAGE LIMITS NAME PLATE RATING MINIMUM MAXIMUM 220V~240V 198V 264V 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
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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 e
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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 t
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5. SCHEMATIC DIAGRAM 5-1. CIRCUIT DIAGRAM • MODEL : LWJ0561ACG POWER INPUT 1 BK(BR) WH(BL) (Plain) (Ribbed) ROTARY SWITCH GN(GN/YL) 1 2 BK BK H 3 L RD RD 4 4 OR(BR) 2 5 6 M MOTOR 7 YL 8 CAPACITOR YL F OR(BR) R 6 BK C 3 S RD BR H COMP. BR BL C OLP 7 THERMOSTAT 5 WIRING DIAGRAM REF. NO DESCRIPTION & NAME Q'TY 1 POWERCORDASSY 1 2 FAN MOTOR 1 3 COMPRESSOR 1 4 ROTARY SWITCH 1 5 THERMOSTAT 1 6 CAPACITOR 1 7 OVERLOAD PROTECTOR 1 —19—
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• MODEL : LWJ0561ACP/AAG 1 4 2 6 3 7 5 REF. NO DESCRIPTION & NAME Q'TY 1 POWERCORDASSY 1 2 FAN MOTOR 1 3 COMPRESSOR 1 4 ROTARY SWITCH 1 5 THERMOSTAT 1 6 CAPACITOR 1 7 OVERLOAD PROTECTOR 1 —20—
