LG Electronics Air Conditioner AS H076PB D M WL1 User Manual

website http://www.lgservice.com

LG Room

Air Conditioner

SERVICE MANUAL

MODELS: AS-H076PB/D/M/WL1

AS-H096PB/D/M/WL1

A-12AH series

CAUTION

• BEFORE SERVICING THE UNIT, READ THE SAFETY

PRECAUTIONS IN THIS MANUAL.

• ONLY FOR AUTHORIZED SERVICE PERSONNEL.

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LG Model Name

2003

Code

Type

Code of Model

Meaning

L: Chang-won R22

A: Chang-won R410A

C: Chang-won R407C

T: China

Producing Center,

Refrigerant

A~Z

N: India

Z: Brazil

D: Indonesia

M: Mexico

V: Vietnam

S: Out Sourcing

K: Turkey R22

E: Turkey R410A

H: Thailand

Product Type

A~Z

S: Split Type Air Conditioner

Cooling/Heating/Inverter

C: Cooling only

H: Heat pump

V: AC Inverter C/O

N: AC Inverter H/P

Q: DC Inverter C/O

W: DC Inverter H/P

X: C/O + E/Heater

Z: H/P + E/Heater

4, 5

Capacity

0~9

Cooling/Heating Capacity

Ex. "09" ¡ 9,000 Btu/h

Electric Range

1~9

A~Z

1: 115V/60Hz,

2: 220V/60Hz

A: 220V, 50Hz, 3Phase

B: 208~230V, 60Hz, 3Phase

C: 575V, 50Hz, 3Phase

D: 440~460, 60Hz, 3Phase

E: 265V, 60Hz

3: 208-230V/60Hz

5: 200-220V/50Hz

6: 220-240V/50Hz

7: 110V, 50/60Hz

8: 380-415V/50Hz

9: 380-415V/60Hz

F: 200V, 50/60Hz

Chassis

A~Z

Name of Chassis of Unit

Ex. LSP ¡ SP Chassis

Look

A~Z

Look,

Color (Artcool Model)

Function

Basic

Basic+4Way

Plasma Filter

Plasma Filter+4 Way

Tele+LCD

Tele+LCD+Nano plasma+4Way

Nano Plasma F+(A/changeove)+A/clean+Low A

Nano Plasma F+(A/changeove)+A/clean+4way+Low A

Tele+LED+4way

Internet

Plasma F+4Way+Oxy generator

Nano Plasma F+(A/changeove)+A/clean

Nano Plasma F+(A/changeove)+A/clean+4way

Nano Plasma F+(A/changeove)+A/clean+PTC

Nano Plasma F+(A/changeove)+Autoclean+4way+PTC

Nano Plasma F+(A/changeove)+A/clean+4way+Low A+PTC

Negative ION+A/Clean

(Nano)Plasma+Negative ION+A/Clean

4way+(Nano)Plasma F+Negative ION+Healthy dehumidification+A/Clean

Nano Plasma F+4Way+(A/changeove)+A/clean+

Serial No.

1~9

LG Model Development Serial No.

* ARTCOOL COLOR

Mirror

White

Blue

Wood

Metal

Cherry

Service Manual 3

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Safety Precautions

To prevent injury to the user or other people and property damage, the following instructions must

be followed.

I Incorrect operation due to ignoring instruction will cause harm or damage. The seriousness is

classified by the following indications.

This symbol indicates the possibility of death or serious injury.

This symbol indicates the possibility of injury or damage to properties only.

I Meanings of symbols used in this manual are as shown below.

Be sure not to do.

Be sure to follow the instruction.

I Installation

Always perform grounding.

Don’t use a power cord, a plug For installation of the product,

or a loose socket which is

damaged.

always contact the service center or

a professional installation agency.

• Otherwise, it may cause electrical

shock.

• Otherwise, it may cause a fire or

electrical shock.

• Otherwise, it may cause a fire, elec-

trical shock, explosion or injury.

Securely attach the electrical

part cover to the indoor unit

and the service panel to the

outdoor unit.

Always install an air leakage

breaker and a dedicated

switching board.

Do not keep or use flammable

gases or combustibles near

the air conditioner.

• If the electrical part cover of the

indoor unit and the service panel of

the outdoor unit are not attached

securely, it could result in a fire or

electric shock due to dust, water, etc.

• No installation may cause a fire and

electrical shock.

• Otherwise, it may cause a fire or the

failure of product.

Thinner

4 Room Air Conditioner

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Safety Precautions

Ensure that an installation

frame of the outdoor unit is

not damaged due to use for a

long time.

Do not disassemble or repair

the product randomly.

Do not install the product at a

place that ther is concern of

falling down.

• It may cause injury or an accident.

• It will cause a fire or electrical shock. • Otherwise, it may result in personal

injury.

I Operation

Use caution when unpacking

and installing.

Do not share the outlet with

other appliances.

Do not use the damaged

power cord.

• Sharp edges may cause injury.

• It will cause an electric shock or a

fire due to heat generation.

• Otherwise, it may cause a fire or

electrical shock.

Do not modify or extend the

power cord randomly.

Take care so that the power

cord may not be pulled during

operation.

Unplug the unit if strange

sounds, smell, or smoke

comes from it.

• Otherwise, it may cause a fire or

electrical shock.

• Otherwise, it may cause a fire or

electrical shock.

• Otherwise, it may cause electrical

shock or a fire.

Service Manual 5

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Safety Precautions

Keep the flames away.

Take the power plug out if neces-

sary, holding the head of the plug

and do not touch it with wet hands.

Do not use the power cord

near the heating tools.

• Otherwise, it may cause a fire.

• Otherwise, it may cause a fire or

electrical shock.

• Otherwise, it may cause a fire and

electrical shock.

Do not open the suction inlet

of the indoor/outdoor unit dur- electrical parts.

ing operation.

Do not allow water to run into

Never touch the metal parts of

the unit when removing the fil-

ter.

• Otherwise, it may electrical shock

and failure.

• Otherwise, it may cause the failure of • They are sharp and may cause

machine or electrical shock.

injury.

Do not step on the indoor/outdoor unit and do

not put anything on it.

Do not place a heavy object on the power cord.

• It may cause an injury through dropping of the unit or

falling down.

• Otherwise, it may cause a fire or electrical shock.

When the product is submerged into water,

always contact the service center.

Take care so that children may not step on the

outdoor unit.

• Otherwise, it may cause a fire or electrical shock.

• Otherwise, children may be seriously injured due to

falling down.

6 Room Air Conditioner

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Safety Precautions

I Installation

Install the drain hose to

ensure that drain can be

securely done.

Install the product so that the

noise or hot wind from the

outdoor unit may not cause

any damage to the neighbors.

Always inspect gas leakage

after the installation and repair

of product.

• Otherwise, it may cause water leak-

age.

• Otherwise, it may cause dispute with

the neighbors.

• Otherwise, it may cause the failure of

product.

I Operation

Keep level parallel in installing the product.

Avoid excessive cooling and perform ventila-

tion sometimes.

• Otherwise, it may cause vibration or water leakage.

• Otherwise, it may do harm to your health.

Use a soft cloth to clean. Do not use wax, thin-

ner, or a strong detergent.

When gas leaks, open the window for ventila-

tion before operating the unit.

• The appearance of the air conditioner may deteriorate,

change color, or develop surface flaws.

• Otherwise, it may cause explosion, and a fire.

Thinner

Service Manual 7

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Dimensions

Symbols used in this Manual

This symbol alerts you to the risk of electric shock.

This symbol alerts you to hazards that may cause harm to the

air conditioner.

NOTICE

This symbol indicates special notes.

Indoor Unit

Hanger Hole

Fix Hole

Pipe Hole

Model

INDOOR UNIT

Dimension

570

568

137

8 Room Air Conditioner

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Dimensions

Outdoor Unit

Gas side

(3-way valve)

Liquid side

(2-way valve)

MODEL

unit

AS-H076PB/D/M/WL1

DIM

575

525

260

301

392

100

Service Manual 9

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Dimensions

Gas side

(3-way valve)

Liquid side

(2-way valve)

MODEL

unit

AS-H096PB/D/M/WL1, AS-H126PB/D/M/WL1

DIM

770

540

245

285

518

100

10 Room Air Conditioner

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Product Specifications

Table-1

Model Name

AS-H076PB/D/M/WL1 AS-H096PB/D/M/W/L1

A-12AH series

Item

Unit

Btu/h

7500

9200

12000

Cooling Capacity

Heating Capacity

Moisture Removal

Power Source

7700

9400

12200

1.2

1.5

l/h

1Ø, 220-240V, 50Hz

Ø, V, Hz

Indoor

Outdoor

Indoor

5.5

6.8

8.3

m³/min

dB (A) 3

Air Circulation

Noise Level

Input

Outdoor

Cooling

Heating

Cooling

Heating

Cooling

685

840

1099

705

860

1200

3.8

4.9

Running

Current

E.E.R.

C.O.P

3.1

3.85

5.3

10.95

10.92

Btu/hW

3.2

2.98

Heating

Indoor

Motor Output

Outdoor

Indoor

25.5

Dimensions

(W x H x D)

570 x 568 x 137

Outdoor

Indoor

575 x 525 x 260

770 x 540 x 245

Net. Weight

Refrigerant

Outdoor

750(R410A)

870(R410A)

880(R410A)

Airflow Direction Control (Up & Down)

L.C.D Wireless

1/4 (6.35)

3/8 (9.52)

L.C.D Wireless

1/4 (6.35)

3/8 (9.52)

L.C.D Wireless

1/4 (6.35)

1/2 (12.7)

Remocon Type

Liquid

inch(mm)

Service Valve

Gas

Sleeping Operation

Drain Hose

Connecting Cable(p*mm²)

Power Cord(p*mm²)

3*1.0mm²+ 2*0.75mm²3*1.0mm²+ 2*0.75mm²3*1.0mm²+ 2*0.75mm²

3*1.0mm²

Service Manual 11

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Installation

Selection of the Best Location

Indoor unit

More than 60cm

More than 10cm

• Do not have any heat or steam near the unit.

• Select a place where there are no obstacles in

front of the unit.

More than 10cm

More than 70cm

• Make sure that condensation drainage can be con-

veniently routed away.

Do not install near a doorway.

than 60cm

• Ensure that the space around the left and right of

the unit is more than 50cm. The unit should be

installed as high on the wall as possible, allowing a

minimum of 10cm from ceiling.

Piping Length and Elevation

• Use a stud finder to locate studs to prevent unnec-

essary damage to the wall.

Standard Max.

Max.

Additional

Pipe Size

Capacity

(Btu/h)

Length Elevation Length Refrigerant

GAS

LIQUID

(m)

B (m)

A (m)

(g/m)

More than 10cm

7k, 8k, 9k

3/8"

1/2"

1/4"

7.5

than 50cm

12k, 18k~28k

Indoor unit

Outdoor unit

than 50cm

More than 2m

Indoor unit

Outdoor unit

CAUTION: Install the indoor unit on the wall

where the height from the floor is more than 2

meter.

Outdoor unit

Oil trap

Indoor unit

• If an awning is built over the unit to prevent direct

sunlight or rain exposure, make sure that heat

radiation from the condenser is not restricted.

• Ensure that the space around the back and sides

is more than 10cm. The front of the unit should

have more than 70cm of space.

If the piping length is more than 5m

• Do not place animals and plants in the path of the

warm air.

• Take the air conditioner weight into account and

select a place where noise and vibration are mini-

mum.

CAUTION:

• Capacity is based on standard length and maximum

• ^aO^li^ll^ot^wra^ap^ncs^eho^leuⁿld^gtb^he^isin^osⁿta^tl^hle^ed^be^av^se^isry^o5^f~^r7^elm^iabet^ile^itr^ys^..

• Select a place so that the warm air and noise from

the air conditioner do not disturb neighbors.

12 Room Air Conditioner

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Installation

Preparing Work for Installation

Open front panel

1. Push the front panel backward and lift it up to remove the two screws.

2. As soon as you lift the both lower parts of panel front, you can hear the sound from panel front. At this moment

panel front is separated

3. After pulling down this panel a bit, separate connecting wire from the product.

Panel Front

Connector

Remove pipe cover and side cover

1. Remove two screws(for fixing pipe cover)

2. Pull up the side cover of desired connecting direction,

and then side cover is separated.

3. Pick the pipe hole of the side cover.

CAUTION: After removing the pipe

Pipe hole

hole, cut the burr for safety.

Side cover

NOTICE

When making pipe path through rear

wall, you don’t need to pick the pipe hole.

Drain hose junction

1. Remove the rubber stopple in the desired drain direc-

tion.

2. Insert drain hose into the handle of drain pan, and

join drain hose and connecting hose according to the

figure by.

Adhesive

Only the

desired direction

Connecting

part

Drain

hose

rubber cap

Service Manual 13

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Installation

Fixing the Indoor Unit

1. Attach an Installation guide map on the

desired surface.

6. Look at suited horizon by horizontal

meter on the horizontal setting line, and

fix lightly the map by adhesive tape.

INSTALLATION GUIDE MAP

NST

ALLA

TION GUIDE MAP

Horizontality

2. Make a hole with a diameter of 6mm and

depth of 30-35mm by piercing a screw

7. Drill the pierted part as a diameter of 50mm

for connecting piping. (In case of piercing

rear surface)

point.

INST

AIIA

TION GUIDE MAP

8. First, Drive the two points of the upper

parts by screws. (Leave 10mm for hanging

the product)

3. Drive the fore plastic anchors into drilled

points.

INST

ALLA

TION GUIDE MAP

INST

ALLA

TION GU

Plastic anchors

9. Drive the lower parts after facing the hole

of product with plastic anchors, and fix

completely the upper screws.

4. Hang the hole of product at the upper

screws, and remove the map. (Falling

INST

attention)

ALLA

TION GUIDE MAP

Plastic anchors

Hanger hole

(Rear side of

the product)

5. Check the fixed product with light power.

10. In case of nothing wrong, connect the

pipe and the wire. (Refer to installation

manual)

Drill a Hole in the Wall

• Drill the piping hole with a ø50mm hole core drill.

Drill the piping hole at either the right or the left with

the hole slightly slanted to the outdoor side.

WALL

Indoor

Outdoor

14 Room Air Conditioner

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Installation

Flaring Work

Main cause for gas leakage is due to defect in flaring work. Carry out correct flaring work in the following procedure.

Cutting the pipes and the cable.

1. Use the piping kit accessory or the pipes purchased

Copper

pipe

locally.

Slanted Uneven Rough

90°

2. Measure the distance between the indoor and the out-

door unit.

3. Cut the pipes a little longer than measured distance.

4. Cut the cable 1.5m longer than the pipe length.

Removing burrs

Pipe

1. Completely remove all burrs from the cut cross section of

pipe/tube.

Reamer

2. Put the end of the copper tube/pipe in a downward direc-

tion as you remove burrs in order to avoid dropping burrs

into the tubing.

Point down

Flare nut

Putting nut on

• Remove flare nuts attached to indoor and outdoor unit,

then put them on pipe/tube having completed burr

removal.

Copper tube

(not possible to put them on after flaring work)

Flaring work

1. Firmly hold copper pipe in a die in the dimension shown

in the table below.

Handle

Bar

2. Carry out flaring work with the flaring tool.

Yoke

Cone

Outside diameter

Ø6.35

Ø9.52

Ø12.7

Ø15.88

Ø19.05

inch

1/4

3/8

1/2

5/8

3/4

0~0.5

0~1.0

1.0~1.3

Copper pipe

Clamp handle

Red arrow mark

Service Manual 15

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Installation

Check

Smooth all round

Inside is shiny without scratches

1. Compare the flared work with the figure by.

2. If a flared section is defective, cut it off and do flaring

work again.

= Improper flaring =

Inclined Surface Cracked Uneven

damaged

thickness

Even length

all round

Connecting the Pipings

Indoor

Preparing the indoor unit's piping and drain hose for installation through the wall.

Route the indoor tubing and the drain hose in the

direction of rear left or right

Drain hose

Tape the tubing, drain hose and the connecting

cable. Be sure that the drain hose is located at the

lowest side of the bundle. Locating at the upper

side can cause drain pan to overflow inside the unit.

Loop

Gas side piping

Connecting

cable

Liquid side piping

Drain hose

NOTICE

If the drain hose is routed inside the room, insulate the hose with an insulation

material* so that dripping from "sweating"(condensation) will not damage furniture

or floors.

*Foamed polyethylene or equivalent is recommended.

16 Room Air Conditioner

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Installation

Connecting the pipings with the indoor unit

and drain hose with drain pipe

1. Align the center of the pipings and sufficiently tighten

the flare nut by hand.

Indoor unit tubing

Flare nut Pipes

2. Tighten the flare nut with a wrench.

Outside diameter

Torque

Open-end wrench (fixed)

Flare nut

inch

1/4

3/8

1/2

5/8

3/4

kg.m

1.8

4.2

5.5

6.6

Ø6.35

Ø9.52

Ø12.7

Connection pipe

Wrench

Ø15.88

Ø19.05

Indoor unit tubing

3. When extending the drain hose at the indoor unit,

install the drain pipe.

Drain hose

Indoor unit drain hose

Vinyl tape (narrow)

Adhesive

Wrap the insulation material around the

connecting portion.

1. Overlap the connection pipe insulation material and

the indoor unit pipe insulation material. Bind them

together with vinyl tape so that there may be no gap.

Plastic bands

Insulation material

2. Wrap the area which accommodates the rear piping

housing section with vinyl tape.

Indoor

unit pipe

Connection

pipe

Vinyl tape

(wide)

Wrap with vinyl tape

Connecting cable

Pipe

3. Bundle the piping and drain hose together by wrap-

ping them with vinyl tape over the range within which

they fit into the rear piping housing section.

Vinyl tape(narrow)

Wrap with vinyl tape

Pipe

Vinyl tape(wide)

Drain hose

Service Manual 17

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Installation

Outdoor

Align the center of the pipings and sufficiently tighten

the flare nut by hand.

Finally, tighten the flare nut with torque wrench until the

wrench clicks.

Outdoor unit

Gas side piping

(Bigger diameter)

• When tightening the flare nut with torque wrench,

ensure the direction for tightening follows the arrow on

the wrench.

Liquid side

piping

(Smaller

diameter)

Outside diameter

Torque

Ø6.35

Ø9.52

Ø12.7

Ø15.88

Ø19.05

inch

1/4

3/8

1/2

5/8

3/4

kg.m

1.8

4.2

5.5

6.6

Torque wrench

18 Room Air Conditioner

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Installation

Connecting the Cables to the Indoor Unit.

• Connect the cables to the indoor unit by connecting the wires to the terminals on the control board

dividually according to the outdoor unit connection. (Ensure that the color of the wires of the outdoor unit and the

terminal No. are the same as those of the indoor unit.)

• Before connecting the cables to the terminal block, remove the cables in the holder of the control cover and

do it.

CAUTION:

• The above circuit diagram is subject to change without notice.

• The earth wire should be longer than the common wires.

• When installing, refer to the circuit diagram behind the panel front of the indoor unit.

• Connect the wires firmly so that they may not be pulled out easily.

• Connect the wires according to color codes, referring to the wiring diagram.

Main power source

CAUTION: If a power plug is not

used, provide a circuit breaker

between power source and the unit

as shown by.

Air

Circuit Breaker

Use a circuit breake

or time delay fuse.

Conditioner

CAUTION: The power cord connected to the "A" unit should be selected according to

the following specifications(Type "B" approved by HAR or SAA).

(mm²)

Grade

NORMAL CROSS

-SECTIONAL AREA

5k~9k 12k~14k

0.75 1.0

Indoor Indoor

18k

1.5

24k~28k 30k, 32k 36k, 38k

2.5 2.5 5.5

Indoor Outdoor Outdoor

Unit(A)

Indoor

Cable Type(B) H05VV-F H05VV-F H05VV-F H05VV-F H05RN-FH05RN-F

The power connecting cable connecting the indoor and outdoor unit should be selected

according to the following specifications (Type "B" approved by HAR or SAA).

NORMAL

(mm²)

CROSS-SECTIONAL

AREA 0.75mm²

NORMAL

CROSS

-SECTIONAL

AREA

Grade

NORMAL CROSS

-SECTIONAL AREA

5k~9K

0.75

12k~14k

18k

1.5

24k~28k

2.5

30k, 32k

0.75

36k, 38k

0.75

1.0

Cable Type(B) H07RN-F H07RN-F H07RN-F H07RN-F

Cable Type(B) H07RN-F H07RN-F

Service Manual 19

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Installation

Connecting the Cables to the Outdoor Unit

1. Remove the control cover from the unit by loos-

ening the screw.

Outdoor Unit

Connect the wires to the terminals on the control

board individually.

Terminal block

2. Secure the cable onto the control board with the

cord clamp.

Over 5mm

Connecting cable

3. Refix the control cover to the original position

with the screw.

Connecting cable

4. Use a recognized circuit breaker "A"

between the power source and the unit.

A disconnecting device to adequately disconnect

all supply lines must be fitted.

Cover control

Grade

Circuit

Breaker

(A)

7K~18K

~26K

~30K

~38K

CAUTION: After the confirmation of the above conditions, prepare the wiring as

follows:

1) Never fail to have an individual power circuit specifically for the air conditioner. As for the method of wiring,

be guided by the circuit diagram posted on the inside of control cover.

2) The screw which fasten the wiring in the casing of electrical fittings are liable to come loose from vibrations

to which the unit is subjected during the course of transportation. Check them and make sure that they are

all tightly fastened. (If they are loose, it could cause burn-out of the wires.)

3) Specification of power source.

4) Confirm that electrical capacity is sufficient.

5) See to that the starting voltage is maintained at more than 90 percent of the rated voltage marked on the

name plate.

6) Confirm that the cable thickness is as specified in the power source specification.

(Particularly note the relation between cable length and thickness. (Refer to page 19)

7) Always install an earth leakage circuit breaker in a wet or moist area.

8) The following would be caused by voltage drop.

• Vibration of a magnetic switch, which will damage the contact point, fuse breaking, disturbance of the normal func-

tion of the overload.

9) The means for disconnection from a power supply shall be incorporated in the fixed wiring and have an air

gap contact separation of at least 3mm in each active(phase) conductors.

20 Room Air Conditioner

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Installation

Checking the Drainage

Forming the Piping

1. Checking the drainage.

1. Form the piping by wrapping the connecting

portion of the indoor unit with insulation materi-

al and secure it with two kinds of vinyl tapes.

• Pour a glass of water on the evaporator.

• Ensure the water flows through the drain hose of

the indoor unit without any leakage and goes out

the drain exit.

• If you want to connect an additional drain hose,

the end of the drain outlet should be routed above

the ground. Secure the drain hose appropriately.

2. In cases where the outdoor unit is installed

below the indoor unit perform the following.

• Tape the piping, drain hose and connecting cable

from down to up.

• Secure the tapped piping along the exterior wall

using saddle or equivalent.

Seal small openings

around pipings with a

gum type sealer.

Taping

Drain

hose

Pipings

Connecting

cable

2. Drain piping

• The drain hose should point downward for easy

drain flow.

Trap is required to prevent water

from entering into electrical parts.

Downward slope

3. In cases where the Outdoor unit is installed

above the Indoor unit perform the following.

• Tape the piping and connecting cable from down

to up.

• Secure the taped piping along the exterior wall.

Form a trap to prevent water entering the room.

• Do not make drain piping like the following.

Accumulated

Do not raise

drain water

• Fix the piping onto the wall by saddle or equiva-

lent.

Air

Seal a small opening

around the pipings

with gum type sealer.

Water

leakage

Water

leakage

Waving

Trap

Less than

50mm gap

Tip of drain hose

dipped in water

Trap

Water

leakage

Ditch

Service Manual 21

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Installation

Air Purging

Air and moisture remaining in the refrigerant system

have undesirable effects as indicated below.

• Do a leak test of all joints of the tubing(both indoor

and outdoor) and both gas and liquid side service

valves.

Bubbles indicate a leak. Be sure to wipe off the

soap with a clean cloth.

• Pressure in the system rises.

• Operating current rises.

• Cooling(or heating) efficiency drops.

• After the system is found to be free of leaks,

relieve the nitrogen pressure by loosening the

charge hose connector at the nitrogen cylinder.

When the system pressure is reduced to normal,

disconnect the hose from the cylinder.

• Moisture in the refrigerant circuit may freeze and

block capillary tubing.

• Water may lead to corrosion of parts in the refrig-

eration system.

Therefore, the refrigerant system must be leak test-

ed and evacuated to remove any noncondensables

and moisture from the system.

Air Purging with Vacuum Pump

Indoor unit

1. Preparation

• Check that each tube(both liquid and gas side

tubes) between the indoor and outdoor units have

been properly connected and all wiring for the test

run has been completed. Remove the service

valve caps from both the gas and the liquid side on

the outdoor unit. Note that both the liquid and the

gas side service valves on the outdoor unit are

kept closed at this stage.

Outdoor unit

2. Leak test

• Connect the manifold valve(with pressure gauges)

and dry nitrogen gas cylinder to this service port

with charge hoses.

Manifold valve

Pressure

gauge

CAUTION: Be sure to use a manifold valve

for air purging. If it is not available, use a stop

valve for this purpose. The "Hi" knob of the manifold

valve must always be kept close.

Charge hose

• Pressurize the system to no more than 150

P.S.I.G. with dry nitrogen gas and close the cylin-

der valve when the gauge reading reached 150

P.S.I.G. Next, test for leaks with liquid soap.

Nitrogen gas

cylinder(in vertical

standing position)

CAUTION: To avoid nitrogen entering the

refrigerant system in a liquid state, the top of

the cylinder must be higher than its bottom when you

pressurize the system. Usually, the cylinder is used

in a vertical standing position.

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Installation

Soap water method

Gas side

(1) Remove the caps from the 2-way and 3-way

valves.

(2) Remove the service-port cap from the 3-way valve.

(3) To open the 2-way valve turn the valve stem coun-

terclockwise approximately 90°, wait for about 2~3

sec, and close it.

(4) Apply a soap water or a liquid neutral detergent on

the indoor unit connection or outdoor unit connec-

tions by a soft brush to check for leakage of the

connecting points of the piping.

Liquid side

3-way valve

(Close)

2-wayy valve

(Open)

(5) If bubbles come out, the pipes have leakage.

Cap

Hexagonal wrench

3. Evacuation

• Connect the charge hose end described in the pre-

ceding steps to the vacuum pump to evacuate the

tubing and indoor unit.

Confirm the "Lo" knob of the manifold valve is

open. Then, run the vacuum pump.

The operation time for evacuation varies with tub-

ing length and capacity of the pump. The following

table shows the time required for evacuation.

Indoor unit

Required time for evacuation when 30 gal/h vacuum pump is

used

Outdoor unit

if tubing length is longer than 10m

(33 ft)

If tubing length is less than 10m

(33 ft)

10 min. or more

15 min. or more

• When the desired vacuum is reached, close the

"Lo" knob of the manifold valve and stop the vacu-

um pump.

4. Finishing the job

Manifold valve

• With a service valve wrench, turn the valve stem of

liquid side valve counter-clockwise to fully open

the valve.

Pressure

gauge

• Turn the valve stem of gas side valve counter-

clockwise to fully open the valve.

Open

• Loosen the charge hose connected to the gas side

service port slightly to release the pressure, then

remove the hose.

• Replace the flare nut and its bonnet on the gas

side service port and fasten the flare nut securely

with an adjustable wrench. This process is very

important to prevent leakage from the system.

• Replace the valve caps at both gas and liquid side

service valves and fasten them tight.

Vacuum pump

This completes air purging with a vacuum pump.

The air conditioner is now ready to test run.

Service Manual 23

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Installation

Front Panel Assembly

1. First, Check the side cover assembly exactly,

and fix the power cord in the bottom groove of

cover side left.

2. Assemble connecting lead wire with controller,

fix the upper part of the front panel, and match

the lower part of the front panel.

Panel Front

Connector

3. Screw up the front panel, and suspend the hook

of the front panel in the groove.

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Test Running

Intake temperature

1. Check that all tubing and wiring have been properly

Discharge air

connected.

2. Check that the gas and liquid side service valves are

fully open.

Prepare remote controller

1. Remove the battery cover

by pulling it according to the

arrow direction.

Discharge

temperature

2. Insert new batteries making

sure that the (+) and (–) of

battery are installed correctly.

3. Reattach the cover by

pushing it back into position.

4. For reference; the gas side pressure of optimum

condition is as below.(Cooling)

Outside ambient

TEMP.

The pressure of the gas side

service valve.

Refrigerant

R-22

35°C (95°F)

4~5kg/cm²G(56.8~71.0 P.S.I.G.)

8.5~9.5kg/cm²G(120~135 P.S.I.G.)

NOTICE

• Use 2 AAA(1.5volt) batteries. Do not use

rechargeable batteries.

R-410A

35°C (95°F)

NOTICE

If the actual pressure is higher than shown,

the system is most likely over-charged, and

charge should be removed. If the actual pres-

sure are lower than shown, the system is

most likely undercharged, and charge should

be added.

• Remove the batteries from the remote

control if the system is not going to be

used for a long time.

Settlement of outdoor unit

• Anchor the outdoor unit with a bolt and

nut(ø10mm) tightly and horizontally on a concrete

or rigid mount.

The air conditioner is now ready for use.

• When installing on the wall, roof or rooftop, anchor

the mounting base securely with a nail or wire

assuming the influence of wind and earthquake.

PUMP DOWN

This is performed when the unit is to be relocated

or the refrigerant circuit is serviced.

• In the case when the vibration of the unit is con-

veyed to the hose, secure the unit with an anti-

vibration bushing.

Pump Down means collecting all refrigerant in the

outdoor unit without loss in refrigerant gas.

CAUTION:

Be sure to perform Pump Down procedure with the

unit cooling mode.

Bolt

Pump Down Procedure

1. Connect a low-pressure gauge manifold hose to

the charge port on the gas side service valve.

2. Open the gas side service valve halfway and purge

the air from the manifold hose using the refrigerant

gas.

3. Close the liquid side service valve(all the way in).

4. Turn on the unit's operating switch and start the

cooling operation.

Tubing connection

Evaluation of the performance

Operate unit for 15~20 minutes, then check the system

refrigerant charge:

1. Measure the pressure of the gas side service valve.

2. Measure the temperature of the intake and discharge

of air.

3. Ensure the difference between the intake tempera-

ture and the discharge is more than 8°C(46°F)

(Cooling) or (Heating).

5. When the low-pressure gauge reading becomes 1

to 0.5kg/cm2 G(14.2 to 7.1 P.S.I.G.), fully close the

gas side valve stem and then quickly turn off the

unit. At that time, Pump Down has been completed

and all refrigerant gas will have been collected in

the outdoor unit.

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Operation

Function of Controls

DISPLAY

1) C/O Model (high quality LCD remote controller supplied)

Operation Indicator

• On while in appliance operation, off while in appliance pause

Timer Indicator

• On while in timer mode (on/off) and in sleep timer mode, off when timer mode is completed or canceled.

Comp. Running Indicator

• While in appliance operation, on while in outdoor unit compressor running, off while in compressor off

Plasma Indicator

• On while in plasma mode, off while plasma mode is canceled.

Auto restart Indicator

• On while auto restart mode, off while auto restart mode is canceled.

Auto restart

• In case the power comes on again after a power failure, Auto Restarting Operation is the function to operate

procedures automatically to the previous operating conditions.

If your want to use this operation, press the Auto Restart Button.

Power(Forced Operation)

• Operation starts, when this button is pressed and stops when you press the button again.

2) H/P Model (high quality LCD remote controller supplied)

Operation Indicator

• On while in appliance operation, off while in appliance pause

Timer Indicator

• On while in timer mode (on/off) and in sleep timer mode, off when timer mode is completed or canceled

Defrost Indicator

• Off except when hot start during heating mode operation or while in defrost control.

Plasma Indicator

• On while in plasma mode, off while plasma mode is canceled.

Auto restart Indicator

• On while auto restart mode, off while auto restart mode is canceled.

Auto restart

• In case the power comes on again after a power failure, Auto Restarting Operation is the function to operate

procedures automatically to the previous operating conditions.

If your want to use this operation, press the Auto Restart Button.

Power(Forced Operation)

• Operation starts, when this button is pressed and stops when you press the button again.

I Cooling Mode Operation

•

When the intake air temperature reaches 0.5°C below the setting temp, the compressor and the outdoor fan stop.

• When it reaches 0.5°C above the setting temp, they start to operate again.

Compressor ON Temp=> Setting Temp+0.5°C

Compressor OFF Temp => Setting Temp-0.5°C

• While in compressor running, operating with the airflow speed set by the remote controller. While in compressor

not running, operating with the low airflow speed regardless of the setting.

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Operation

I Healthy Dehumidification Mode

• When the dehumidification operation input by the remote controller is received, the intake air temperature is

detected and the setting temp is automatically set according to the intake air temperature.

26°C ≤ Intake Air Temp

=> 25°C

24°C ≤ Intake Air Temp < 26°C => Intake Air Temp-1°C

18°C ≤ Intake Air Temp < 24°C => Intake Air Temp-0.5°C

Intake Air Temp < 18°C

=> 18°C

• While in compressor off, the indoor fan repeats low airflow speed and pause.

• While the intake air temp is between compressor on temp. and compressor off temp., 10-min dehumidification

operation and 4-min compressor off repeat

Compressor ON Temp. => Setting Temp+0.5°C

Compressor OFF Temp. => Setting Temp-0.5°C

• In 10-min dehumidification operation, the indoor fan operates with the low airflow speed.

I Heating Mode Operation

• When the intake air temp reaches +3°Cabove the setting temp, the compressor is turned off. When below the

setting temp, the compressor is turned on.

Compressor ON Temp. => Setting Temp.

Compressor OFF Temp. => Setting Temp.+3°C

• While in compressor on, the indoor fan is off when the indoor pipe temp. is below 26®¨C , when above 28°C , it

operates with the low or setting airflow speed (while in sleep mode, with the medium airflow speed).

• While in compressor off, the indoor fan is off when the indoor pipe temp is below 33°C , when above 35°C , it

operates with the low airflow speed.

• If overloaded while in heating mode operation, in order to prevent the compressor from OLP operation, the out-

door fan is turned on/off according to the indoor pipe temp.

• While in defrost control, both of the indoor and outdoor fans are turned off.

I Defrost Control

• While in heating mode operation in order to protect the evaporator pipe of outdoor unit from freezing, reversed

to cooling cycle to defrost the evaporator pipe of the outdoor unit.

• Defrost control is available 30 minutes later since heating mode operation started, and it will not prolong over 6

minutes.

•

Deicing starts only when the outdoor pipe temperature falls below -6°C after 30 minutes passed from starting of

heating operating and more than 10 minutes operation of compressor.

• Deicing ends after 6 minutes passed from starting of deice operation or when the outdoor pipe temperature rises

over 12°C even if before 6 minutes.

I Fuzzy Operation (C/O Model)

• According to the temperature set by Fuzzy rule, when the intake air temp is 0.5°C or more below the setting

temp, the compressor is turned off. When 0.5°C or more above the setting temp, the compressor is turned on.

Compressor ON Temp => Setting Temp+0.5°C

Compressor OFF Temp => Setting Temp+0.5°C

• At the beginning of Fuzzy mode operation, the setting temperature is automatically selected according to the

intake air temp at that time.

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Operation

26°C ≤ Intake Air Temp

=> 25°C

24°C ≤ Intake Air Temp<26°C => Intake Air Temp+1°C

22°C ≤ Intake Air Temp<24°C => Intake Air Temp+0.5°C

18°C ≤ Intake Air Temp<22°C => Intake Air Temp

Intake Air Temp<18°C

=> 18°C

• When the Fuzzy key (Temperature Control key) is input after the initial setting temperature is selected, the

Fuzzy key value and the intake air temperature at that time are compared to select the setting temperature

automatically according to the Fuzzy rule.

• While in Fuzzy operation, the airflow speed of the indoor fan is automatically selected according to the temper-

ature

I Fuzzy Operation (H/P Model)

• When any of operation mode is not selected like the moment of the power on or when 3 hrs has passed since

the operation off, the operation mode is selected.

• When determining the operation mode, the compressor, the outdoor fan, and the 4 way valve are off and only

the indoor fan is operated for 15 seconds. Then an operation mode is selected according to the intake air

temp at that moment as follows.

24°C ≤ Inatake Air Temp

21°C ≤ Inatake Air Temp<24°C => Fuzzy Operation for Dehumidification

Inatake Air Temp<21°C => Fuzzy Operation for Heating

=> Fuzzy Operation for Cooling

• If any of the operation modes among cooling / dehumidification / heating mode operations is carried out for 10

sec or longer before Fuzzy operation, the mode before Fuzzy operation is operated.

1) Fuzzy Operation for Cooling

• According to the setting temperature selected by Fuzzy rule, when the intake air temp is 0.5°C or more below

the setting temp, the compressor is turned off. When 0.5°C or more above the setting temp, the compressor is

turned on.

Compressor ON Temp => Setting Temp+0.5°C

Compressor OFF Temp => Setting Temp+0.5°C

• At the beginning of Fuzzy mode operation, the setting temperature is automatically selected according to the

intake air temp at that time.

26°C ≤ Intake Air Temp

=> 25°C

24°C ≤ Intake Air Temp<26°C => Intake Air Temp+1°C

22°C ≤ Intake Air Temp<24°C => Intake Air Temp+0.5°C

18°C ≤ Intake Air Temp<22°C => Intake Air Temp

Intake Air Temp < 18°C

=> 18°C

• When the Fuzzy key (Temperature Control key) is input after the initial setting temperature is selected, the

Fuzzy key value and the intake air temperature at that time are compared to select the setting temperature

automatically according to the Fuzzy rule.

• While in Fuzzy operation, the airflow speed of the indoor fan is automatically selected according to the temperature.

2) Fuzzy Operation for Dehumidification

• According to the setting temperature selected by Fuzzy rule, when the intake air temp is 0.5°C or more below

the setting temp, the compressor is turned off. When 0.5°C or more above the setting temp, the compressor is

turned on.

Compressor ON Temp => Setting Temp+0.5°C

Compressor OFF Temp => Setting Temp+0.5°C

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Operation

• At the beginning of Fuzzy mode operation, the setting temperature is automatically selected according to the

intake air temp at that time.

26°C ≤ Intake Air Temp

=> 25°C

24°C ≤ Intake Air Temp<26°C => Intake Air Temp+1°C

22°C ≤ Intake Air Temp<24°C => Intake Air Temp+0.5°C

18°C ≤ Intake Air Temp<22°C => Intake Air Temp

Intake Air Temp < 18°C

=> 18°C

• When the Fuzzy key (Temperature Control key) is input after the initial setting temperature is selected, the

Fuzzy key value and the intake air temperature at that time are compared to select the setting temperature

automatically according to the Fuzzy rule.

• While in Fuzzy operation, the airflow speed of the indoor fan repeats the low airflow speed or pause as in dehu-

midification operation.

3) Fuzzy Operation for Heating

• According to the setting temperature selected by Fuzzy rule, when the intake air temp is 3°C or more above the

setting temp, the compressor is turned off. When below the setting temp, the compressor is turned on.

Compressor ON Temp => Setting Temp

Compressor OFF Temp => Setting Temp + 3°C

• At the beginning of Fuzzy mode operation, the setting temperature is automatically selected according to the

intake air temp at that time.

20°C ≤ Intake Air Temp => Intake Air Temp + 0.5°C

Intake Air Temp < 20°C => 20°C

• When the Fuzzy key (Temperature Control key) is input after the initial setting temperature is selected, the

Fuzzy key value and the intake air temperature at that time are compared to select the setting temperature

automatically according to the Fuzzy rule.

• While in Fuzzy operation, the airflow speed of the indoor fan is set to the high or the medium according to the

intake air temperature and the setting temperature.

I Airflow Speed Selection

• The airflow speed of the indoor fan is set to high, medium, low, or chaos by the input of the airflow speed selec-

tion key on the remote controller.

I On-Timer Operation

• When the set time is reached after the time is input by the remote controller, the appliance starts to operate.

• The timer LED is on when the on-timer is input. It is off when the time set by the timer is reached.

• If the appliance is operating at the time set by the timer, the operation continues.

I Off-Timer Operation

• When the set time is reached after the time is input by the remote controller, the appliance stops operating.

• The timer LED is on when the off-timer is input. It is off when the time set by the timer is reached.

• If the appliance is on pause at the time set by the timer, the pause continues.

Service Manual 29

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Operation

I Off-Timer <=> On-Timer Operation

• When the set time is reached after the on/off time is input by the remote controller, the on/off-timer operation is

carried out according to the set time.

I Sleep Timer Operation

• When the sleep time is reached after <1,2,3,4,5,6,7,0(cancel) hr> is input by the remote controller while in

appliance operation, the operation of the appliance stops.

• While the appliance is on pause, the sleep timer mode cannot be input.

• While in cooling mode operation, 30 min later since the start of the sleep timer, the setting temperature

increases by 1°C After another 30 min elapse, it increases by 1°C again.

• When the sleep timer mode is input while in cooling cycle mode, the airflow speed of the indoor fan is set to

the low.

• When the sleep timer mode is input while in heating cycle mode, the airflow speed of the indoor fan is set to

the medium.

I Chaos Swing Mode

• By the Chaos Swing key input, the vane automatically operates with the Chaos Swing or they are fixed to the

desired direction.

I Chaos Natural Wind Mode

• When the Chaos Natural Wind mode is selected and then operated, the high, medium, or low speed of the air-

flow mode is operated for 2~15 sec randomly by the Chaos Simulation.”

I Jet Cool Mode Operation (C/O Model)

• If the Jet Cool key is input at any operation mode while in appliance operation, the Jet Cool mode operates.

• In the Jet Cool mode, the indoor fan is operated at super-high speed for 30 min at cooling mode operation.

• In the Jet Cool mode operation, the room temperature is controlled to the setting temperature, 18°C

• When the sleep timer mode is input while in the Jet Cool mode operation, the Jet Cool mode has the priority.

• During the JET COOL function at any moment, the A/C starts to blow the cool air with side louvers closed at

extremely high speed for 30 minutes setting the room temp. automatically to 18°C.

I Jet Cool Mode Operation (H/P Model)

• While in heating mode or Fuzzy operation, the Jet Cool key cannot be input. When it is input while in the other

mode operation (cooling, dehumidification, ventilation), the Jet Cool mode is operated.”

• In the Jet Cool mode, the indoor fan is operated at super-high speed for 30 min at cooling mode operation.

• In the Jet Cool mode operation, the room temperature is controlled to the setting temperature, 18°C

• When the sleep timer mode is input while in the Jet Cool mode operation, the Jet Cool mode has the priority.

• During the JET HEAT function at any moment, the A/C starts to blow the hot air with side louvers closed at

extremely high speed for 60 minutes setting the room temp. automatically to 30°C.

I Auto Restarting Operation

• When the power is restored after a sudden power failure while in appliance operation, the mode before the

power failure is kept on the memory and the appliance automatically operates in the mode on the memory.

• Operation Mode that is kept on the memory

- State of Operation ON/OFF

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Operation

- Operation Mode/Setting Temp/Selected Airflow Speed

- Sleep Timer Mode/Remaining Time of Sleep Timer (unit of hour)

I Forced Operation

• Operation procedures when the remote control can't be used.

• The operation will be started if the power button is pressed.

• If you want to stop operation, re-press the button.

Heat pump Model

Cooling Model

Room Temp. ≥ 24°C 21°C ≤ Room Temp. < 24°C Room Temp. < 21°C

Operating mode

Indoor Fan Speed

Setting Temperature

Cooling

High

Cooling

High

Healthy Dehumidification

Heating

High

22°C

23°C

24°C

• While in forced operation, the key input by the remote control has no effect and the buzzer sounds 10 times to

indicate the forced operation.

I Test operation

•

During the TEST OPERATION, the unit operates in cooling mode at high speed fan, regardless of room tem-

perature and resets in 18 1 minutes.

•

During test operation, if remote controller signal is received, the unit operates as remote controller sets.

If you want to use this operation, open the front panel upward and Press the power button let it be pressed for

about 3 seconds.

•

If you want to stop the operation, re-press the button.

I Protection of the evaporator pipe from frosting

• If the indoor pipe temp is below 0°C in 7 min. after the compressor operates without any pause while in cooling

cycle operation mode, the compressor and the outdoor fan are turned off in order to protect the indoor evapo-

rator pipe from frosting.

• When the indoor pipe temp is 7°C or higher after 3 min. pause of the compressor, the compressor and the out-

door fan is turned on according to the condition of the room temperature.

I Buzzer Sounding Operation

• When the appliance-operation key is input by the remote control, the short "beep-beep-" sounds.

• When the appliance-pause key is input by the remote control, the long "beep—" sounds.

• When a key is input by the remote control while the slide switch on the main unit of the appliance is on the

forced operation position, the error sound "beep-beep-beep-beep-beep-" is made 10 times to indicate that the

remote control signal cannot be received.

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Operation

I Air Cleaner Operation

• When an air cleaner function is selected during Air Conditioner operation

- Plasma air cleaner function will be operated while in any operation mode with selecting the function.

- The function is to be stopped while it is operating with selecting the function.

• When an air cleaner function is selected during operation off

- The function will be only operated.

• When inlet grille of air conditioner is opened during plasma operation, High Voltage Generator(H.V.B) is to be

stopped. When inlet grille of air conditioner is closed during plasma operation, High Voltage Generator(H.V.B)

will be operated again.

32 Room Air Conditioner

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Operation

Display Function

1. Heating Model

2. Cooling Model

Operation Indicator

• Cooling, Soft Dry, Fan

Operation Indicator

• Cooling, Soft Dry, Fan, Heating

Sleep Timer Indicator

• Sleep Mode

Timer Indicator

• Timer Mode

Outdoor Unit Operation

Defrost Indicator

• Hot-start, Defrost

PLASMA Indicator

• PLASMA Mode

Service Manual 33

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Operation

Self-diagnosis Function

Error

Code

Error Display LED

(Indoor body operation LED)

Error contents

SVC check point

• Indoor room temperature

thermistor open/short

• Indoor pipe temperature

thermistor open/short.

(once)

3sec

• Indoor Thermistor

assembly check

3sec

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Operation

Remote Control Operations

The controls will look like the following.

1. START/STOP BUTTON

Operation starts when this button is pressed and

stops when the button is pressed again.

Controls

2. OPERATION MODE SELECTION BUTTON

Used to select the operation mode.

3. ROOM TEMPERATURE SETTING BUTTONS

Used to select the room temperature.

Signal transmitter

4. INDOOR FAN SPEED SELECTOR

Used to select fan speed in four steps

low, medium, high and CHAOS.

5. JET COOL/HEATING(OPTIONAL)

Used to start or stop the speed

cooling. (Speed cooling/heating operates at super

high fan speed in cooling/heating mode.)

6. CHAOS SWING BUTTON

Used to stop or start louver movement and set the

desired up/down airflow direction.

7. ON/OFF TIMER BUTTONS

Used to set the time of starting and stopping opera-

tion.

CANCEL

8. TIME SETTING BUTTONS

Used to adjust the time.

SET

OFF

AUTO CLEAN

9. TIMER SET/CANCEL BUTTON

Used to set the timer when the desired time is

obtained and to cancel the Timer operation.

10. SLEEP MODE AUTO BUTTON

Used to set Sleep Mode Auto operation.

11. AIR CIRCULATION BUTTON

Used to circulate the room air without cooling or

heating.

Flip-up door

(opened)

12. ROOM TEMPERATURE CHECKING BUTTON

Operation Mode

Used to check the room temperature.

13. NANO PLASMA(OPTIONAL)

Used to start or stop the plasma-purification

function.

Cooling Operation

Auto Operation or Auto Changeover

Healthy Dehumidification Operation

14. HORIZONTAL AIRFLOW DIRECTION CONTROL

BUTTON

(OPTIONAL)

Used to set the desired horizontal airflow direction.

Heating Operation

15. RESET BUTTON

•

Cooling Model( ), Heat Pump Model(

)

Used prior to resetting time or after replacing bat-

teries.

16. 2nd F Button

Used prior to using modes printed in blue at the

bottom of buttons.

17. AUTO CLEAN(OPTIONAL)

Used to set Auto Clean mode.

Service Manual 35

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Disassembly

Indoor Unit

WARNING: Disconnect the unit from

power supply before making any

checks. Be sure the power switch is set

to "OFF"

1. To remove the Grille from the Chassis.

- Pull the grille bottom, the remove 2 securing screws.

- Lift the both lower parts of panel front.

- After pull down this panel a bit, separate connecting

wire with product.

Panel Front

Connector

2. To remove the Control Box.

- Before removing the control box, be sure to

disconnect the wires from PWB.

Step Motor Connectors

Sensor Connector

- Pull the cover control out from the control box

and disconnect other wires.

- Remove securing screws.

- Pull the control box out from the chassis carefully.

4Way/Fan Connector

Motor

Comp Connector

Power Connector

Comp Connector

Connector

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Disassembly

3. To remove the Evaporator.

- Remove 4 screws securing the evaporator.

- Pull the evaporator out from the chassis carefully.

4. Before removing the Turbo Fan.

- Remove the securing screws from the chassis.

- Pull the pipe cover, top cover and the air guide.

Air Guide

Top Cover

Pipe Cover

5. To remove the Motor.

- Remove the securing bolt from the motor shaft.

- Pull the fan out from the motor shaft.

Bracket

- Remove 4 screws securing motor mount from the

chassis and lift up the motor mount and the bracket.

Turbo Fan

Bolt

Motor Mount

Service Manual 37

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Schematic Diagram

Electric Control Device

• Heat Pump Model

BL PK YL OR

A V s s

A V d d 1

5 V

T X D

R X D

YL PK BL

RD OR

38 Room Air Conditioner

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Schematic Diagram

Wiring Diagram

Indoor Unit

Outdoor Unit

AS-H076PB/D/M/WL1

AS-H096PB/D/M/WL1

AS-H126PB/D/M/WL1

Service Manual 39

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Schematic Diagram

Components Location

MAIN P.W.B ASSEMBLY (AC PART)

• HEAT PUMP MODEL

CN-GND1

IC03D

CN-MOTOR2

D01D

T/BLOCK

CN-MOTOR1

NTC

CY4

CN-ACDC1

C01D

D05D

CY1

1(L)

Q01G

C12D

R08D

R09D

D06D

C11D

SMPS

CN-COMP

CN-OUT

ZD02D

R05D

C03D

RY-COMP

2(N)

GND

250V-T3.15A

250V-T3.0A

125V-T3.15A

Q02G

R16D

FUSE

C10D

C02D

CY5

D02D

D03D

CN-POW1

C02N

RY-4WAY

IC07D IC08D

C01N

IC05DIC06D

C04D

R13D

ZD01D

R07D R06D

IC02D

IC01D

NF01N

PWB ASM : 6871A10121

RY-O2

PWB : 6870A90161D

MAIN P.W.B ASSEMBLY (DC PART)

• TOP VIEW

• BOTTOM VIEW

40 Room Air Conditioner

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Schematic Diagram

DISPLAY ASSEMBLY

– 6871A20462

TOP VIEW

BOTTOM VIEW

SUB P.W.B ASSEMBLY

CN-D4

PWB ASM:6871A20363

PWB:6870A90126B

CN-D3

CN-D2

CN-D1

CN-CON(WH)

CN-12V(WH)

CN-D5

CN-SW(BL)

CN-D7

CN-D6

CN-D8

Service Manual 41

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Troubleshooting Guide

Refrigeration Cycle Diagram

(1) Cooling Only Models

INDOOR UNIT

OUTDOOR UNIT

LIQUID SIDE

CAPILLARY TUBE

HEAT

EXCHANGE

(EVAPORATOR)

EXCHANGE

(CONDENSER)

GAS SIDE

COMPRESSOR

(2) Cooling & Heating Models

INDOOR UNIT

OUTDOOR UNIT

CHECK VALVE

(Heating Model only)

LIQUID SIDE

3-WAY VALVE

CAPILLARY TUBE

HEAT

EXCHANGE

(EVAPORATOR)

EXCHANGE

(CONDENSER)

GAS SIDE

REVERSING

VALVE

(Heating Model Only)

3-WAY VALVE

ACCUMU

LATOR

COOLING

HEATING

COMPRESSOR

42 Room Air Conditioner

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Troubleshooting Guide

2-way, 3-way Valve

2-way Valve (Liquid Side)

3-way Valve (Gas Side)

Valve cap

Open position

Hexagonal wrench (4mm)

Flare nut

Closed position

Open position

Closed position

piping

Service

port cap

Service

port

connection

To outdoor unit

Works

Shaft position

Service port

Closed

(with valve cap)

Closed

(with valve cap)

Closed

(with cap)

Shipping

Air purging

Open

Closed

Open

(Installation)

(counter-clockwise)

(clockwise)

(push-pin or with

vacumm pump)

Open

(with valve cap)

Open

(with valve cap)

Closed

(with cap)

Operation

Closed

(clockwise)

Open

Pumping down

(Transfering)

(counter-clockwise) (connected manifold

gauge)

Open

(with charging

cylinder)

Evacuation

(Servicing)

Open

(with charging

cylinder)

Gas charging

(Servicing)

Open

Pressure check

(Servicing)

(with charging cylinder)

Open

Gas releasing

(Servicing)

(with charging cylinder)

Service Manual 43

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Troubleshooting Guide

Pumping Down

Liquid side

2-Way

Indoor unit

Outdoor unit

Open

valve

Gas side

Closed

3-Way

valve

Purge the air

• Procedure

(6) Operate the air conditioner at the cooling

cycle and stop it when the gauge indicates

(1) Confirm that both the 2-way and 3-way valves

are set to the open position.

1kg/cm g.

– Remove the valve stem caps and confirm that

the valve stems are in the raised position.

– Be sure to use a hexagonal wrench to operate

the valve stems.

(7) Immediately set the 3-way valve to the closed

position.

– Do this quickly so that the gauge ends up indi-

cating 3 to 5kg/cm²g.

(2) Operate the unit for 10 to 15 minutes.

(8) Disconnect the charge set, and mount the 2-

way and 3-way valve’s stem nuts and the ser-

vice port nut.

(3) Stop operation and wait for 3 minutes, then

connect the charge set to the service port of

the 3-way valve.

– Use torque wrench to tighten the service port

nut to a torque of 1.8 kg.m.

– Connect the charge hose with the push pin to

the service port.

– Be sure to check for gas leakage.

(4) Air purging of the charge hose.

– Open the low-pressure valve on the charge set

slightly to air purge from the charge hose.

(5) Set the 2-way valve to the closed position.

44 Room Air Conditioner

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Troubleshooting Guide

Balance Refrigerant of the 3-way Valve

(Gas leakage)

Liquid side

Indoor unit

Outdoor unit

3-Way

valve

Open

Gas side

3-Way

valve

Open

OPEN

• Procedure

(1) Confirm that both the 2-way and 3-way valves

are set to the back seat.

(3) Open the valve (Lo side) on the charge set and

discharge the refrigerant until the gauge indi-

cates 0 kg/cm G.

(2) Connect the charge set to the 3-way valve’s

port.

– If there is no air in the refrigerant cycle (the

pressure when the air conditioner is not running

is higher than 1 kg/cm²G), discharge the refrig-

erant until the gauge indicates 0.5 to 1

kg/cm²G. if this is the case, it will not be neces-

sary to apply a evacuatin.

– Leave the valve on the charge set closed.

– Connect the charge hose to the service port.

– Discharge the refrigerant gradually; if it is dis-

charged too suddenly, the refrigeration oil will

also be discharged.

Service Manual 45

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Troubleshooting Guide

Evacuation

(All amount of refrigerant leaked)

Liquid side

Indoor unit

Outdoor unit

3-Way

valve

Open

Gas side

3-Way

valve

Open

Vacuum pump

OPEN

• Procedure

(1) Connect the vacuum pump to the center hose

of charge set center hose

(3) Close the valve (Lo side) on the charge set,

turn off the vacuum pump, and confirm that

the gauge needle does not move (approxima-

tely 5 minutes after turning off the vacuum

pump).

(2) Evacuation for approximately one hour.

– Confirm that the gauge needle has moved

toward -76 cmHg (vacuum of 4 mmHg or less).

(4) Disconnect the charge hose from the vacuum

pump.

– Vacuum pump oil.

If the vacuum pump oil becomes dirty or

depleted, replenish as needed.

46 Room Air Conditioner

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Troubleshooting Guide

Gas Charging

(After Evacuation)

Liquid side

3-Way

Indoor unit

Outdoor unit

Open

valve

Gas side

Open

3-Way

valve

Check valve

Charging

cylinder

(1)

OPEN

• Procedure

(1) Connect the charge hose to the charging

cylinder.

This is different from previous procedures.

Because you are charging with liquid refrigerant

from the gas side, absolutely do not attempt to

charge with larger amounts of liquid refrigerant

while operating the air conditioner.

– Connect the charge hose which you dis-con-

nected from the vacuum pump to the valve at

the bottom of the cylinder.

– If you are using a gas cylinder, also use a

scale and reverse the cylinder so that the sys-

tem can be charged with liquid.

(4) Immediately disconnect the charge hose from

the 3-way valve’s service port.

– Stopping partway will allow the gas to be dis-

charged.

– If the system has been charged with liquid

refrigerant while operating the air conditioner

turn off the air conditioner before disconnecting

the hose.

(2) Purge the air from the charge hose.

– Open the valve at the bottom of the cylinder

and press the check valve on the charge set to

purge the air. (Be careful of the liquid refriger-

ant). The procedure is the same if using a gas

cylinder.

(3) Open the valve (Lo side on the charge set and

charge the system with liquid refrigerant.

– If the system can not be charged with the spec-

ified amount of refrigerant, it can be charged

with a little at a time (approximately 150g each

time) while operating the air conditioner in the

cooling cycle; however, one time is not suffi-

cient, wait approximately 1 minute and then

repeat the procedure (pumping down-pin).

(5) Mount the valve stem nuts and the service

port nut.

– Use torque wrench to tighten the service port

nut to a torque of 1.8 kg.m.

– Be sure to check for gas leakage.

Service Manual 47

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Troubleshooting Guide

Cycle Parts

Trouble analysis

1. Check temperature difference between intake and discharge air and operating current.

Temp. difference : approx. 0°C

• All amount of refrigerant leaked

out. Check refrigeration cycle.

Current

: less than 80% of

rated current

Temp. Difference

Operating Current

• Refrigerant leakege

Clog of refrigeration cycle

Defective compressor

Temp. difference : approx. 8°C

Current

: less than 80% of

rated current

Temp. difference : less than 8°C

• Excessive amount of refrigerant

Current

: over the reated

current

• Normal

Temp. difference : over 8°C

NOTICE

Temperature difference between intake and discharge air depends on room air humidity. When the room air

humidity is relativery higher, temperature difference is smaller. When the room air humidity is relatively lower tem-

perature difference is larger.

2. Check temperature and pressure of refrigeration cycle.

Suction pressure

(Compared with

the normal value)

Temperature

(Compared with

the normal valve)

Cause of Trouble

Description

Defective compressor

Defective 4-way reverse valve

Current is low.

High

Higher

Excessive amount of

refrigerant

High pressure does not quickly

rise at the beginning of

operation.

Normal

Insufficient amount of

refrigerant (Leakage)

Clogging

Current is low.

Lower

Higher

NOTICE

1. The suction pressure is usually 4.5~6.0 kg/cm²G(Cooling) at normal condition.

2. The temperature can be measured by attaching the thermometer to the low pressure tubing and wrap it with

putty.

48 Room Air Conditioner

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Troubleshooting Guide

Electronic Parts

Product does not operate at all.

(* Refer to Electronic Control Device drawing and Schematic diagram.)

Turn off Main Power

(After 10 seconds)

Turn on Main Power

Does "beeping" sound is made from the Indoor Unit?

YES

Primarily, the operating condition of Micom is OK.

Check the voltage of power(About AC 220V, 60Hz)

(About AC 220/240V, 50Hz)

• Main power's voltage

• Voltage applied to the unit

• Connecting method of Indoor/Outdoor connecting

cable

• Check PWB Assembly

- Fuse

Check each load(Indoor/Outdoor Fan Motor,

Compressor, Stepping Motor) and contacting

condition of related connector

- Pattern damage

- Varistor(ZNR01N)

Check the connection housing for contacting

• Connector related to CN-POWER1, 2

• Connector related to CN-MOTOR

• Connector contacting of Outdoor Fan/Compressor

• Display PWB Assembly Check

Main PCB Board Operation Check

Content

Remedy

Items

• SMPS Transformer

(Indoor unit)

- Input Voltage

- Output Voltage

- About AC220V/240V 10% - Check the power voltage

- About DC12V

• Replace Trans

• IC04D(7805) Output

• DC 5V

• Replace IC04D

• Replace faulty parts

• IC01A(Reset IC)

OSC01B(8MHz)

• Voltage of Micom No. 36,

(DC +4.5V over) and Soldering condition.

Service Manual 49

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Troubleshooting Guide

The product does not operate with the remote controller.

Turn on Main Power

While the compressor has been stopped, the compressor does not

operate owing to the delaying function for 3 minutes after stopped.

When the compressor stopped Indoor Fan is driven by a low speed.

At this point the wind speed is not controlled by the remote controller.

(When operated in the Sleeping Mode, the wind speed is set to the

low speed by force.)

Caused by other parts except the remote control

Cause by the remote control

When the mark(

battery.

) is displayed in LCD screen, replace

Check the contact of CN-D1, 2 connector.

Check the connecting circuit between the remote controller

MICOM (No. 30 ) - R17(2Ω) - IR LED - TR - R16(2.2KΩ).

Check Display PWB Assembly

- Voltage between CN-D2

Check point

: DC 5V

• Check the connecting circuit between PIN -

R02L(1K) - C01L(680PF) - MICOM PIN 43

• Check Receiver Assembly

50 Room Air Conditioner

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Troubleshooting Guide

Compressor/Outdoor Fan are unable to drive.

Turn on Main Power

Operate "Cooling Mode( )" by setting the desired temperature of the

remote controller is less than one of the indoor temperature by 1°C at least.

When in Air Circulation Mode, Compressor/Outdoor Fan is stopped.

Check the sensor for indoor temperature is attached as close as to be

effected by the temperature of Heat Exchanger(EVA).

When the sensor circuit for indoor temperature and connector are in bad

connection or are not engaged, Compressor/Outdoor Fan is stopped.

• Check R02H(12.1k), R04H(6.2k), Micom Pin 26, 27

• Check the indoor temperature sensor is disconnected or not(About 10kΩ / at 25°C).

Check Relay(RY - COMP) for driving compressor.

• When the power(About AC220V/240V) is applied to the connecting wire

terminal support transferred to compressor, PWB Assembly is normal.

• Check the circuit related to the relay.

Check point

Between Micom(No.

63) and GND

COMP ON

COMP OFF

DC5V

DC0V

Between IC02M(No. 14)

and GND

Below DC 1V

(app)

About DC12V

Turn off Main Power

• Check the electrical wiring diagram of outdoor side.

• Check the abnormal condition for the component of

Compressor/Outdoor Fan Motor.

• Check the "open" or "short" of conmecting wires between indoor and

outdoor.

Service Manual 51

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Troubleshooting Guide

When Indoor Fan does not operate.

Turn off Main power

Check the connection of CN-MOTOR1, 2

Check the Fan Motor

Check the Fuse(AC250V/3.15A)

- Check PWM signal from Micom Pin 50

- Check On/Off signal from micom pin14.

- Check Voltage of CN-Motor 1, 2

(pin

is about 15V)

Turn ON Main Power

Fan can't operate for dehumidifying mode.

- Change operation for cooling mode.

52 Room Air Conditioner

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Troubleshooting Guide

When Louvers do not operate.

• Confirm that the Louver is normally geared with the shaft of Stepping

Motor.

• If the regular torque is detected when rotating the Louver with hands

Normal

• Check the connecting condition of CN-UD, LR1, LR2 Connector.

• Check the soldering condition(on PWB) of CN-UD LR1, LR2 Connector.

Check the operating circuit of the Louvers.

• Confirm that there is DC 12V between pin of CN-UD and GND.

• Confirm that there is a soldering short at following terminals.

45 46 47

56 57 59

61 62

Between

of MICOM

- Between

of IC02M

of IC03M

of IC04M

of CN-UD/LR1/LR2

If there are no problems after above checks

• Confirm the assembly conditions that are catching and interfering parts

in the rotation radial of the Louvers.

Service Manual 53

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Troubleshooting Guide

When Heating does not operate

Turn ON Main Power

Operate “Heating Mode( )” by setting the desired temperature of the

remote control is higher than one of the indoor temperature by 2°C at

least.

In heating Mode, the indoor fan operates in case the pipe temperature

is higher than 28°C.

Check the connector of intake and pipe sensor(thermistors)

• Check the related circuit of RY-4WAY

• Check the indoor room temperature is disconnected or not (about

10KΩ/at 25°C).

• Check the indoor pipe temperature is disconnected or not (about

5KΩ/at 25°C).

Check the DC voltage on the PWB ASSEMBLY

• The details of check are as followings

• Comp Relay.

• Outdoor fan Relay

Check point

Comp ON

DC 5V

Comp OFF

DC 0V

Check point

Fan ON

DC 5V

Fan OFF

DC 0V

Between Micom

(NO.63) and GND

Between Micom

(NO.53) and GND

Between IC02M

(NO.14) and GND

Between IC03M

(NO.11) and GND

Below DC 1V

About DC

12V

Below DC 1V About DC 12V

• 4 way Relay

Check point

4 way ON

DC 5V

4 way OFF

DC 0V

Between Micom

(NO.51) and GND

Between IC03M

(No.9) and GND

About 12V

Below DC1V

54 Room Air Conditioner

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Troubleshooting Guide

Turn off Main Power

• Check the electrical wiring diagram of outdoor side.

• Check the abnormal condition for the component of

Compressor/Outdoor Fan Motor, 4 way.

• Check the "open" or "short" of connecting wires between indoor and

outdoor.

Service Manual 55

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Exploded View

Indoor Unit

56 Room Air Conditioner

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Exploded View

Outdoor Unit (AS-H076PB/D/M/WL1)

437210

437212

554031

435301

435511

546810

552102-2

559010

649950

552201

552111

552116

552102-1

W0CZZ

552202

567502

561410

554160

447910

550140

552203-1

430410

552203-2

Service Manual 57

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Exploded View

Outdoor Unit (AS-H096PB/D/M/WL1, A-12AH..

437210

437212

554031

435301

435511

546810

552102

559010

649950

552201

552111

552116

W0CZZ

552202

567502

561410

554160

447910

550140

552203-1

430410

552203-2

58 Room Air Conditioner

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Replacement Parts List

Indoor Unit

PART No.

LOCATION

No.

DESCRIPTION

REMARKS

AS-H076PB/D/M/WL1 AS-H096PB/D/M/WL1

A-12AH series

3141A20004N

3530A20077F

3531A20069G

3531A20069H

3531A20069J

3531A20213E

3531A20212E

3550A20123A

3550A20124A

3550A20060A

3551A20031B

4681A20055A

4758A20014B

5230A20032A

5983A20007F

4995A20372A

6323A20004N

6411A20014S

6711A20073Z

6871A20462A

6871A10121A

6871A20439C

6871A20363D

3087A30004A

4681A20091A

5211A20302B

5211A20301B

5211AR7066D

5251AR1222R

5238A20020A

5421A20072A

5900A00003A

131410 CHASSIS ASSEMBLY

3141A20004N

3530A20077F

3531A20069G

3531A20069H

3531A20069J

3531A20213E

3531A20212E

3550A20123A

3141A20004D

3530A20077F

3531A20069G

3531A20069H

3531A20069J

3531A20213E

3531A20212E

3550A20123A

135303 GRILLE,INLET

135311-1 GRILLE ASSEMBLY,DISCHARGE(INDOOR)

135311-2 GRILLE ASSEMBLY,DISCHARGE(INDOOR)

135311-3 GRILLE ASSEMBLY,DISCHARGE(INDOOR)

135312 GRILLE ASSEMBLY,FRONT(INDOOR)

135314 GRILLE ASSEMBLY,INLET

135500-1 COVER

135500-2 COVER

135500-3 COVER

3550A20060A

3551A20031B

4681A20055A

4758A20014B

5230A20032A

5983A20007F

4995A20372Q

6323A20004N

6411A20014S

6711A20073Z

6871A20462A

6871A10121A

6871A20439J

6871A20363D

3087A30004A

4681A20091A

3550A20060A

3551A20031B

4681A20055A

4758A20014B

5230A20032A

5983A20007F

4995A20372E

6323A20004N

6411A20014S

6711A20073Z

6871A20462A

6871A10121A

6871A20439D

6871A20363D

3087A30004A

4681A20091A

135515 COVER ASSEMBLY,TOP(INDOOR)

146811 MOTOR ASSEMBLY,STEP

147581 LOUVER,HORIZONTAL

152302 FILTER(MECH),A/C

159830 AIR CLEANER ASSEMBLY

249951 CONTROL BOX ASSEMBLY,INDOOR

263230 THERMISTOR ASSEMBLY

264110 POWER CORD ASSEMBLY

267110 REMOTE CONTROLLER ASSEMBLY

268712 PWB(PCB) ASSEMBLY,DISPLAY

268714-1 PWB(PCB) ASSEMBLY,MAIN

268714-2 PWB(PCB) ASSEMBLY,MAIN(DC)

268717 PWB(PCB) ASSEMBLY,SUB

330870 DRAIN PAN ASSEMBLY

346810 MOTOR ASSEMBLY,INDOOR

352115 TUBE ASSEMBLY,EVAPORATOR IN

352116 TUBE ASSEMBLY,EVAPORATOR OUT

35211B TUBE ASSY,TUBING

5211AR7066F

5251AR1222R

5238A20020A

5421A20072A

5900A00003A

5211AR7066F

5251AR1222R

5238A20020A

5421A20072A

5900A00003A

352150 HOSE ASSEMBLY,DRAIN

352380 AIR GUIDE

354210 EVAPORATOR ASSEMBLY,FIRST

359012 FAN,TURBO

NOTE) Please ensure GCSC since these parts may be changed depending upon the buyer's request.

(GCSC WEBSITE http://[email protected])

Service Manual 59

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Replacement Parts List

Outdoor Unit

PART No.

LOCATION

DESCRIPTION

REMARKS

No.

AS-H076PB/D/M/WL1 AS-H096PB/D/M/WL1

A-12AH series

3041A20008K

3530A20006B

3551A30023E

3721A20027B

3721A20026A

4791A30002A

4681A20004S

4H00982E

430410 BASE ASSY,OUTDOOR

435301 GRILLE,DISCHARGE

3041A20016A

3041A20008K

3530A20006B

3551A30023E

3721A20027B

3721A20026B

4791A30002A

4681A20004S

435511 COVER ASSEMBLY,CONTROL(OUTDOOR)

437210 PANEL ASSEMBLY,FRONT(OUTDOOR)

437212 PANEL ASSY,REAR(OUTDOOR)

447910 BARRIER ASSEMBLY,OUTDOOR

546810 MOTOR ASSEMBLY,OUTDOOR

550140 ISOLATOR,COMP

3551A30023Q

3720A10171A

3720A10172A

4790A10025B

4681A20121A

4H00982E

552111 TUBE ASSEMBLY,CAPILLARY

552116 TUBE ASSEMBLY,REVERSING

552201 VALVE,CHECK

5211A21121B

5211A20188U

5220AR7182A

5220AR3228D

2H02479P

5211A30331Q

5211A20160E

5220AR7182A

5220AR3228B

2H02479H

5211A20117J

5211A20140X

5220AR7182A

5220AR3228D

2H02479H

552202 VALVE,REVERSING

552203-1 VALVE,SERVICE

552203-2 VALVE,SERVICE

5220A20001B

5403A20045M

2520UGDP2CA

5900AR1266A

6141A20017A

4995A10032B

6120AR2194H

5220A20001B

5403A20019F

2520UGAP2GA

5901A10004A

3A02028Y

5220A20006B

5403A20019V

2520UGHP2AA

5901A10004A

6141AR3733R

4995A20083Y

2H01451T

554031 CONDENSER ASSEMBLY,BENT

554160 COMPRESSOR SET

559010 FAN ASSEMBLY,PROPELLER

561410 COIL ASSEMBLY,REVERSING VALVE

649950 CONTROL BOX ASSEMBLY,OUTDOOR

W0CZZ CAPACITOR,DRAWING

4995A20083B

6120AR2194N

NOTE) Please ensure GCSC since these parts may be changed depending upon the buyer's request.

(GCSC WEBSITE http://biz.LGservice.com)

60 Room Air Conditioner

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Memo

Service Manual 61

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Memo

62 Room Air Conditioner

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February, 2004

Printed in Korea

P/No.: 3828A20135S

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